532 SM Collahuasi Rev000 Jan 30 2011 PDF

en Service Manual
Haul Truck
T282C-532-Y06435 to 06436
Document ID
Order number: 10880897

Issued: January 30, 2011
Version: Revision Preliminary Issue
Author: LME / Technical Publications and
Documentation Department
Product ID
Manufacturer: Liebherr Mining Equipment Newport News Co.

Model: T282C
Serial no. from: 532-Y06435 to 06436
Contact
Address Liebherr Mining Equipment Newport News Co.

4100 Chestnut Avenue
Newport News, Virginia 23607 USA
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Service Manual Contents
Contents
1 Foreword 19
1.1 Foreword 20
1.1.1 General Overview 20
1.1.2 Languages 20
1.2 Service Manual Organization 21
1.2.1 Audience 21
1.2.2 Task Analysis 21
1.2.3 Manual Organization 21
1.2.4 Chapters 21
1.2.5 Procedures 21
1.2.6 Required Tools and Materials 22
1.2.7 Illustrations 22
1.2.8 Serviceable Parts 22
2 Introduction 23
2.1 Introduction 26
2.2 Safety 27
2.2.1 Visual Safety Alert Devices 27
2.2.3 Health and Safety Information 28
2.2.4 First Aid Kit 28
2.2.5 Protective Equipment 28
2.2.6 Fire and Explosion Hazards 28
2.2.7 Fire Blanket 29
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2.2.8 Fire Extinguisher 29

2.2.9 Burn Prevention 29
2.2.10 Oils 29
2.2.11 Coolant 29
2.2.12 Batteries 30
2.2.13 Chemicals 30
2.2.14 Visual Safety Alerts on the haul truck 31
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Contents Service Manual
2.2.15 Safety Alert Signs and Label Maintenance 33

2.2.16 Maintenance Preparation 33
2.2.17 Maintenance Parking 34
2.2.18 Brake Safety 34
2.2.19 Anchor Tie-Off Points 35
2.2.20 Safety Harness 36
2.2.21 Jack and Lift Devices 37
2.2.22 Tire Safety 37
2.2.23 Hydraulic Safety 38
2.2.24 Dump Body Safety 39
2.2.25 General Maintenance Safety 39
2.2.26 Work Area Safety 40
2.2.27 Component Preparation 40
2.3 Torque Charts 41
2.3.1 Torque Chart for Unified Threaded Fasteners 41
2.3.2 Torque Chart for Metric Threaded Fasteners 42
2.4 Welding Guidelines 43
2.4.1 Welding Precautions 43
2.4.2 Moisture 43
2.4.3 Buttering Method 43
2.4.4 Ni-Cr-Mo Steel Plate Repair Welding Procedure 45
2.4.5 Reference Specification 45
2.4.6 Base Metals 45
2.4.7 Filler Metal 45
2.4.8 Preparation of Base Metal 45
2.4.9 Pre-heating 46
2.4.10 Welding Position 46
2.4.11 Electrical Properties 46
2.4.12 Welding Instructions 46
2.4.13 Post-weld Heat Treatment: 46
2.4.14 Inspection Criteria 46
2.4.15 Flux-Cored Arc Welding (FCAW) Welding
Procedures 47
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2.4.16 Shielded Metal Arc Welding (SMAW) Welding

Procedures 48
2.5 Jacking Points Guidance 49
2.5.1 Jacking Guide 49
2.6 Towing or Recovery of a Disabled haul truck 50
2.6.1 Rating for Optional Towing and Recovery Devices 51
2.6.2 51288AH (2 per bumper) 51
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2.6.3 51288AM (2 per bumper) 51

2.6.4 51091-K (2 per bumper) 51
2.6.5 Vertical Drag Link Pin Axle Box 52
2.6.6 Vertical Drag Link Pin Axle Box - shown with part
number 51288AN (includes hook and fasteners) 52
2.6.7 Horizontal Drag Link Pin Axle Box 52
2.7 Service Tools 54
2.7.1 Fixture Dump Cylinder Extend Tool - 10025660 54
2.7.2 Barring Gear Tool - 10339053 54
2.7.3 Adaptor Hanging Forklift Load 10469271 55
2.7.4 Endplay Measuring Tool 10880099 55
2.7.5 Straight Edge Parallel Tool 11002203 55
2.7.6 Electrical System Repair Kit SVC-200 55
2.7.7 Pin Puller T-075-B 56
2.7.8 Axle Box Stand T-099-A 56
2.7.9 Front Wheel Lifting Bracket T-103-E 56
2.7.10 Gas Tank Nipple T-107-A 57
2.7.11 Gas Tank Nipple T-107-B 57
2.7.12 Nitrogen Charge Kit T-107-T 57
2.7.13 Pin Puller T-124-C 58
2.7.14 Power Module Lifting Beam T-128-F 58
2.7.15 Rear Wheel Assembly Lifting Beam T-128-K 58
2.7.16 Dump Cylinder Shipping Brackets T-193-A 59
2.7.17 Frame Stand T-367-B 59
2.7.18 Frame Stand T-367-G 59
2.7.19 Engine Endplay Measuring Tool T-481 59
2.7.20 Hydraulic Pressure Test Kit T-493 60
2.7.21 Power Module Shipping Stand T-500-J 60
2.7.22 Rear Brake Disc Hub Puller T-504-A 60
2.7.23 O-ring Seal Kit T-528-A 61
2.8 Useful Information 62
2.8.1 Information Tables 62
2.8.2 Unit of Measure Conversions 63
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3 Technical Description 67
3.1 Component Weights and Dimensions 68
3.1.1 Frame with Power Module 68
3.1.2 Frame 68
3.1.3 Superstructure Assembly 68
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3.1.4 Front Wheel Assembly 68

3.1.5 Lower Control Arm 68
3.1.6 Upper Control Arm 69
3.1.7 Front Suspension 69
3.1.8 Rear Suspension 69
3.1.9 Rim 69
3.1.10 Tire and Rim 70
3.1.11 Traction Motor 70
3.1.12 Planetary Gear Box 70
3.1.13 Planetary Gear Box Assembly 70
3.1.14 Fuel Tank Assembly 70
3.1.15 Fuel and Hydraulic Tank Assembly 71
3.1.16 Dump Cylinder 71
3.1.17 Power Module Assembly 71
3.1.18 Traction Alternator 71
3.1.19 Air Cleaner 72
3.1.20 Cab with Air Conditioning 72
3.1.21 Additional Component Weights 72
4 Maintenance 75
4.1 Maintenance Plan 78
4.1.1 Preventive Maintenance Program 78
4.2 Oil and Lubricant Specifications 79
4.3 Major Component Replacement Guidance 86
4.4 Preventive Maintenance Daily Inspections and Checks 87
4.5 Preventive Maintenance Master Schedule 89
4.5.1 Preventive Maintenance Reference Structure 95
4.6 500-Hour Preventive Maintenance References 96
4.7 LME-00-01-01 - Battery Maintenance 97
4.8 LME-20-01-00 - Oil Sampling Guideline 98
4.9 LME-20-08-01 - Air Intake System Inspection and Filter
Replacement Procedures 100
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4.10 LME-30-01-01 - Axle Box Inspection 102

4.11 LME-40-01-01 - Hydraulic Hoses Inspection 104
4.12 LME-40-02-00 - Pump Drive Service Procedure 105
4.13 LME-40-03-01 - Brake Accumulator Pre-Charge Check, Drain,
and Pre-Charge Procedures 106
4.13.1 Brake Accumulator Pre-charge Check 106
4.13.2 Brake Accumulator Drain 106
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4.13.3 Brake Accumulator Pre-Charge 107

4.14 LME-40-04-01 - Steering Accumulator Pre-Charge Check, Drain,
4.14.1 Steering Accumulator Pre-charge Check 110
4.14.2 Steering Accumulator Drain 110
4.14.3 Steering Accumulator Pre-Charge 111
4.15 LME-40-05-00 - Unloader Accumulator Pre-Charge Check,
Drain, and Pre-Charge Procedures 114
4.15.1 Unloader Accumulator Pre-charge Check
Procedure 114
4.15.2 Unloader Accumulator Drain Procedure 115
4.15.3 Unloader Accumulator Pre-Charge Procedure 115
4.16 LME-80-16-00 - Suspension Monitoring and Maintenance 118
4.16.1 Pre-Maintenance Fault Review 118
4.16.2 Visual Inspection 118
4.16.3 Suspension Charge Check 119
4.16.4 Additional Information (Guidance for Reviewing
Faults) 120
4.18 LME-20-02-02 - Brake and Steering Pressure Filter Replacement
Procedure 123
4.19 LME-20-03-02 - Dump System Filter Replacement Procedure 125
4.20 LME-110-01-00 - Grid Motor Inspection Guidelines 128
4.22 LME-10-01-01 - Exhaust Bellows and Blankets Inspection 130
4.23 LME-20-04-00 - Gear Oil Cooling System Filters Replacement
Procedure 131
4.24 LME-80-02-02 - Rear Brake Pad and Disc Check Procedure 132
4.25 LME-80-15-01 - Front Brake Pad and Disc Check Procedure 134
4.27 LME-20-06-00 - Front Wheel Oil Drain and Fill Procedures 137
4.27.1 Front Wheel Oil Drain 137
4.27.2 Front Wheel Oil Fill 137
4.28 LME-80-04-02 - Wear Limit Check Procedure 139
4.28.1 Drag Links and Rear Control Arm Bushing Check 139
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4.28.2 Steering Cylinder and Tie Rod Bushing Check 140

4.28.3 Idler Arm Bearing Check 141
4.30 LME-80-03-01 - Lower Kingpin Bushing Wear Check Procedure 145
4.30.2 Additional Information 145
4.31 5000-Hour Preventive Maintenance 149
4.32 LME-20-07-00 - Rear Wheel Oil Drain and Fill Procedures 150
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4.32.1 Rear Wheel Oil Drain Procedure 150

4.32.2 Rear Wheel Oil Fill Procedure 151
4.33 LME-30-02-01 - Rear Control Arm Fasteners Torque Procedure 152
4.34 LME-80-05-02 - Rear Brake Assembly Fasteners Torque
Procedure 155
4.35 LME-80-06-02 - Steering Cylinder Fasteners Torque Procedure 159
4.36 LME-80-09-01 - Tie Rod Fastener Torque Procedure 163
4.37 LME-80-11-00 - Lower Kingpin Fasteners Torque Procedure 167
4.38 LME-80-13-01 - Steering Arm Fasteners Torque Procedure 169
4.39 LME-80-14-00 - Upper Kingpin Fastener Torque Procedure 171
4.41 LME-80-10-00 - Replace Lower Kingpin Fasteners 174
4.42 LME-80-12-01 - Steering Arm Fasteners Replacement 176
4.43 Conditional-Hours Preventive Maintenance References 178
4.44 LME-80-07-02 - Front Brake Assembly Fasteners Torque
Procedure 179
4.45 LME-80-08-02 - Rear Wheel Assembly Fasteners Torque
Procedure 181
5 Power Module (Drive System) 185

5.1 Power Module 186
5.1.1 Power Module Assembly Removal 187
5.1.4 Power Module Assembly Installation 190
5.2 Engine 193
5.2.1 Engine Removal 195
5.2.4 Engine Installation 198
5.2.7 Engine Flywheel Runout Check 201
5.2.10 Engine Endplay Measurements 203
5.3 Exhaust System 205
5.3.1 Exhaust System Removal 206
5.3.4 Exhaust System Installation 213
5.4 Engine Air Cleaner 220
5.4.1 Engine Air Cleaner Ducts Removal 221
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5.4.4 Engine Air Cleaner Ducts Installation 223

5.5 Traction Alternator 225
5.5.1 Traction Alternator Removal 226
5.5.4 Traction Alternator Installation 229
5.5.7 Traction Alternator Measurements 233
5.6 Air Cleaner Restriction Check 235
5.7 Fuel System 236
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5.7.1 Fuel and Hydraulic Tank Drain 236
6 Cooling Systems 237

6.1 Radiator 238
6.1.1 Adding Coolant 238
6.1.2 Cleaning 239
6.1.3 Replacement Tubes 239
6.1.4 Cores with Center Tanks 239
6.1.5 Tank Gasket 239
6.1.6 Radiator Removal 241
6.1.9 Radiator Installation 247
6.1.12 Radiator Tubes Replacement 253
6.1.15 Radiator Coolant Fill 256
6.2 AC Drive Cooling System 257
6.2.1 Main Blower Housing 257
6.2.2 Auxiliary Inverter 258
6.2.3 Parameters 258
6.2.4 Auxiliary Inverter Field Test 259
6.2.5 AC Drive Cooling System Motor Removal 261
6.2.8 AC Drive Cooling System Motor Installation 263
6.2.11 Main Blower Troubleshooting 265
6.3 Alternator Cooling Duct 266
6.3.1 Alternator Cooling Duct Removal 266
6.3.4 Alternator Cooling Duct Installation 268
6.4 Axle Box Cooling Duct 270
6.4.1 Axle Box Cooling Duct Removal 270
6.4.4 Axle Box Cooling Duct Installation 271
6.5 Gear Oil Cooling Condenser 274
6.5.1 Gear Oil Cooling Condenser Removal 274
6.5.4 Gear Oil Cooling Condenser Installation 275
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7 Electrical Power and Distribution 277

7.1 AC Drive System 279
7.1.2 Field Regulator 283
7.1.3 Main Rectifier 284
7.1.4 DC-DC Converter Box 285
7.1.5 Auxiliary Inverters 286
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7.1.6 Inverters 287

7.1.7 Chopper 288
7.1.8 DC Link Capacitors 289
7.1.10 Grid Box 291
7.1.11 Main Blower Assembly 292
7.1.12 Cooling Pump 294
7.1.13 Pre-Heaters 295
7.1.14 Main Programmable I/O Module 296
7.1.15 Inverter Controller 297
7.1.16 Mini Programmable I/O Module 298
7.1.17 CAN Temperature Module 299
7.1.18 Independent Power Control 300
7.1.19 Touch Screen Display Panel 301
7.2 Main Rectifier Removal 302
7.3 Main Rectifier Installation 304
7.4 DC to DC Converter Box Removal 306
7.5 DC to DC Converter Box Installation 308
7.6 Inverters Removal 310
7.7 Inverters Installation 312
7.8 Chopper Removal 314
7.9 Chopper Installation 316
7.10 DC Link Capacitor Removal 318
7.11 DC Link Capacitor Installation 320
7.12 Battery Disconnect Switch Box 322
7.12.1 24 VDC Battery Isolator Switch 322
7.12.2 Starter Isolator Switch 322
7.12.3 Battery Charger Receptacle 322
7.12.4 Propulsion Lockout Switch 322
7.13 24 VDC Battery Bank 323
7.13.1 Batteries Removal 324
7.13.4 Batteries Installation 326
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8 Hydraulic Power and Distribution 329

8.1 Drive Shaft Assembly 330
8.1.1 Pump Drive Unit 331
8.1.2 Drive Shaft 333
8.1.3 Pump Drive Unit Removal 334
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8.1.5 Drive Shaft Removal 336

8.1.6 Drive Shaft Installation 338
8.1.7 Pump Drive Unit Installation 340
8.2 Hydraulic Tank 342
8.2.1 Dump System Hydraulic Tank 343
8.2.8 Brake and Steering Hydraulic Tank 347
8.2.16 Central Service Assembly 353
9 Dump System 355

9.1 Dump System 356
9.1.1 Dump System Schematic 357
9.2 Dump Pumps 358
9.2.1 Specifications 358
9.2.2 Dump Pumps Removal 360
9.2.5 Dump Pumps Installation 362
9.3 Dump Pumps 358
9.4 Pilot Control Valve and Manifold Assembly 370
9.4.1 Pilot Control Valve Removal 371
9.4.4 Pilot Control Valve Installation 372
9.5 Dump Body Control Lever 373
9.5.1 Dump Control Lever Adjustment (Factory-Set) 374
9.5.2 Dump Body Override Switch 374
9.6 Dump Body Cylinders 375
9.6.1 Dump Body Cylinders Removal 376
9.6.4 Dump Body Cylinders Installation 380
9.7 Dump System Pressure Filters 383
9.7.1 Dump System Pressure Filters Removal 384
9.7.4 Dump System Pressure Filters Installation 386
9.8 Dump System Troubleshooting 388
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9.8.2 Observation: Dump Body will not Rise 388

9.8.3 Observation: Dump Body will not Lower 397
9.8.4 Observation: Slow slew rate 401
9.8.5 Observation: System Overheat 403
10 Hydraulic Brake and Steering Systems 407

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10.1 Brake and Steering Pump 409

10.1.1 Pump Control 410
10.1.2 At Rest (No Rotation of Prime Mover) 411
10.1.3 Start-up (Prime Mover Running) 412
10.1.4 Pump Unloading 413
10.1.5 Loading 414
10.1.6 Brake and Steering Pump Removal 416
10.1.9 Brake and Steering Pump Installation 418
10.2 Brake and Steering Pressure Filter 420
10.2.1 Brake and Steering Pressure Filter Removal 421
10.2.4 Brake and Steering Pressure Filter Installation 423
10.3 Brake and Steering Manifold 425
10.3.1 Brake and Steering Manifold Removal 427
10.3.4 Brake and Steering Manifold Installation 429
10.4 Brake System 431
10.4.1 Brake Accumulators 434
10.4.2 Brake Accumulators Removal 435
10.4.5 Brake Accumulators Installation 437
10.4.8 Brake System Accumulator Bleed 439
10.5 Hand Brake Valve and Manifold 440
10.5.1 Hand Brake Valve and Manifold Removal 441
10.5.4 Hand Brake Valve and Manifold Installation 442
10.6 Steering System 443
10.6.1 Steering Accumulator 444
10.6.2 Steering Accumulator Removal 445
10.6.5 Steering Accumulator Installation 447
10.6.8 Steering System Accumulator Bleed 449
10.7 Flow Amplifier Valve 450
10.7.1 Flow Amplifier Valve Removal 451
10.7.4 Flow Amplifier Valve Installation 454
10.8 Steering Control Valve 457
10.8.1 Steering Control Valve Removal 458
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10.8.4 Steering Control Valve Installation 460

10.9 Steering Cylinders 462
10.9.1 Steering Cylinders Removal 463
10.9.4 Steering Cylinders Installation 465
10.10 Buddy Brake and Steering Components 468
10.11 Brake and Steering Pump Unloader Valve Accumulator 470
10.11.1 Brake and Steering Pump Unloader Valve
Accumulator Removal 471
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Accumulator Installation 473
10.11.7 Brake and Steering Unloader Valve Accumulator
Pressure Check 475
11 Hydraulic Auxiliary Systems 477

11.1 Auto Lube System 478
11.1.1 Auto Lube Components 480
11.1.2 Lubrication Pump 481
11.1.3 Grease Tank 481
11.1.4 Safety Unloader Valve 481
11.1.5 Vent Valve Assembly 481
11.1.6 Low Level Indicator 482
11.1.7 Pressure Switch 482
11.1.8 Injectors 483
11.1.9 Ecomat (LITES) Controller 483
11.1.10 Neutral Position Pause Function 483
11.1.11 SL-V Injector (Series B) 484
11.1.13 Stage 1 484
11.1.14 Stage 2 484
11.1.15 Stage 3 484
11.1.16 Stage 4 484
11.1.17 Spectrum Adjustment System 485
11.1.19 Hydraulic Pump 486
11.1.20 Hydraulic Pump Schematic 487
11.1.21 Hydraulic Pump Troubleshooting 488
11.2 Gear Oil Cooling System 489
11.2.1 Gear Oil Cooling Pump Removal 492
11.2.4 Gear Oil Cooling Pump Installation 494
11.3 Hoist Cooling System 496
11.3.1 Hoist Cooling System Schematic 497
11.4 Hydraulic A/C Pump 498
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11.4.1 Hydraulic A/C Pump Removal 498

11.4.4 Hydraulic A/C Pump Installation 499
12 Suspensions 501
12.1 Front Suspensions 502
12.1.1 Front Suspensions Removal 504
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12.1.4 Front Suspensions Installation 506

12.1.7 Front Suspension Oil Drain 508
12.1.10 Front Suspension Oil Fill 510
12.1.12 Front Suspension Gas Discharge 511
12.1.15 Front Suspension Gas Charge 513
12.1.17 Front Suspension Pressure Check 514
12.2 Rear Suspension 516
12.2.1 Rear Suspensions Removal 518
12.2.4 Rear Suspensions Installation 520
12.2.7 Rear Suspension Oil Drain 522
12.2.10 Rear Suspension Oil Fill 524
12.2.12 Rear Suspension Gas Discharge 525
12.2.15 Rear Suspension Gas Charge 527
12.2.17 Rear Suspension Pressure Check 528
13 Wheel Assemblies 531

13.1 Front Wheel Removal (Complete) 533
13.1.3 Front Wheel (Complete) Installation 537
13.2 Front Brakes 541
13.2.1 Front Brake Bleed 543
13.2.4 Front Brake Burnish 544
13.3 Front Brake Caliper 545
13.3.1 Front Brake Caliper Removal 547
13.3.4 Front Brake Caliper Installation 549
13.4 Front Brake Disc 551
13.5 Kingpins and Spindle 552
13.5.1 Kingpins Removal 553
13.5.4 Kingpins Installation 555
13.5.7 Toe-In Check 557
13.5.10 Toe-In Adjustment 559
13.6 Steering Encoder Test 561
13.7 Tie Rods 562
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13.7.1 Tie Rods Removal 562

13.7.4 Tie Rods Installation 563
13.8 Idler Arm Assembly 567
13.8.1 Idler Arm Assembly Removal 568
13.8.4 Idler Arm Assembly Installation 571
13.9 Steering Arm 574
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13.9.1 Steering Arm Removal 575

13.9.4 Steering Arm Installation 577
13.10 Steering Stop Pads 579
13.10.1 Steering Stop Pads Removal 580
13.10.4 Steering Stop Pads Installation 581
13.11 Upper and Lower Control Arms 583
13.11.1 System Description and Function 583
13.11.2 Control Arm Removal 584
13.11.4 Control Arm Installation 586
13.12 Rear Tire and Rim Assembly 589
13.12.1 Rear Tire and Rim Assembly Removal 590
13.12.4 Tire and Rim Assembly Installation 593
13.12.7 Rear Tire Studs Replacement 596
13.13 Rear Brakes 598
13.13.1 Rear Brakes Removal 600
13.13.4 Rear Brakes Installation 603
13.13.7 Rear Brake Bleed 608
13.13.10 Rear Brake Burnish 609
13.14 Rear Disc Brake Hub 610
13.14.1 Rear Disc Brake Hub Removal 611
13.14.4 Rear Brake Disc Hub Installation 614
13.15 Park Brake (Carlisle) 617
13.15.1 Park Brake (Carlisle) Removal 619
13.15.4 Park Brake (Carlisle) Installation 622
13.16 Mechanical Release of the Park Brake 625
14 Frame, Dump Body and Structures 629

14.1 Frame 631
14.1.1 Frame Welding and Repairs 631
14.2 Dump Body 632
14.2.1 Dump Body Welding and Repairs 632
14.2.2 Dump Body Removal 633
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14.2.5 Dump Body Installation and Alignment 635

14.2.9 Dump Body Guides Installation and Alignment 638
14.2.12 Dump Body Lift or Lower for Service (Hydraulically) 641
14.2.15 Dump Body Lift or Lower for Service (Manually) 642
14.3 Dump Body Pivot Pins 643
14.3.1 Dump Body Pivot Pins and Bearing Removal 644
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14.3.4 Dump Body Pivot Pins and Bearing Installation and

Alignment 646
14.4 Dump Body Pads 649
14.4.1 Dump Body Pads Removal 650
14.4.4 Dump Body Pads Installation 652
14.5 Rock Knocker 655
14.5.1 Rock Knocker Removal 656
14.5.4 Rock Knocker Installation 658
14.6 Superstructure 660
14.7 Hood and Grill 661
14.7.1 Hood Removal 661
14.7.4 Hood Installation 661
14.7.7 Grill Removal 665
14.7.10 Grill Installation 669
14.8 Battery Boxes 674
14.8.1 Battery Boxes Removal 674
14.8.4 Battery Boxes Installation 675
14.9 Axle Box 678
14.9.1 Axle Box: Rear Door Removal 679
14.9.4 Axle Box: Rear Door Installation 680
14.9.7 Axle Box: Front Door Removal 681
14.9.10 Axle Box: Front Door Installation 683
14.10 Drag Links 685
14.10.1 Drag Links Removal 686
14.10.4 Drag Links Installation 688
14.11 Rear Control A-Arm (Rear Control Arm Axle Box) 690
14.11.1 Rear Control A-Arm Removal 691
14.11.4 Rear Control A-Arm Installation 693
15 Operator Cab 695

15.1 Operator Cab Glass 696
15.1.1 Operator Cab Glass Replacement 697
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15.2 Foot Pedal Controls 701

15.2.2 (1) Service Brake Pedal 701
15.2.3 (2) Dynamic Braking Pedal 701
15.2.4 (3) Accelerator Pedal 702
15.3 Steering Column and Controls 703
15.3.1 Tilt and Telescopic Lever 703
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15.3.2 Left and Right Turn Signals Lever, and Dimmer

Switch 703
15.3.3 Hazard Flasher 704
15.3.4 Horn Button 704
15.3.5 Steering Column Turn Signal Replacement 705
15.3.16 Steering Column Trough Cover Replacement 709
15.3.21 Steering Column Wire Harness Replacement 711
15.3.26 Steering Column Knob Kit Replacement 713
15.4 Access Panels and Miscellaneous Items 714
16 Computers and Auxiliary Systems 717

16.1 Computer and Auxiliary Systems 718
17 Class Documents 719

17.1 Class Documents 720
17.1.1 Suspension Test and Charge Procedures 720
17.1.2 Diesel Engine 20 V 4000 Operating Manual 720
17.1.3 Truck Test Procedure 720
17.1.4 Hydraulic Test Points 720
17.1.5 Dump Body Proximity Wiring Assembly 720
List of Acronyms 721
Index 723
Illustration Index 727

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Service Manual Foreword
1 Foreword 19
1.1 Foreword 20
1.1.1 General Overview 20
1.1.2 Languages 20
1.2 Service Manual Organization 21
1.2.1 Audience 21
1.2.2 Task Analysis 21
1.2.3 Manual Organization 21
1.2.4 Chapters 21
1.2.5 Procedures 21
1.2.6 Required Tools and Materials 22
1.2.7 Illustrations 22
1.2.8 Serviceable Parts 22
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Foreword Service Manual
Foreword
1.1 Foreword
This publication provides the approved procedures for the repair, service,
and maintenance of the systems, and components for the T282B-531 haul
truck made by the Liebherr Mining Equipment Company (LME).
Completely read this publication before you do any repairs, service, or
maintenance work on the haul truck.
Continue to read this publication at intervals as the contents of this manual
can change without notice..
om0289.tif
1.1.1 General Overview

This manual is published only to give guidance information to service and
maintenance technicians approved to do service and maintenance work on
the haul truck.
This publication does not have all of the service and maintenance
information about specified Original Equipment Manufacturer (OEM)
components. Refer to the related OEM publications for information about
service and maintenance of specified OEM components and systems.
WARNING! Loss of life, injury to persons, or damage to the haul truck can
occur from incorrect repair, service and maintenance methods.
► Keep all repair, service, and maintenance methods within the limits
shown in this publication.
Adjustments to the haul truck can change its performance, impede safety
mechanisms, contravene site, and government regulations. Changes to the
haul truck are not allowed without the written approval from the
manufacturer.
The accuracy of the information in this publication is not part of any warranty.
This publication contains the information, illustrations, and specifications
available to the manufacturer at the time of its release. Continuous product
improvement can change the information in this service manual without
notice.
1.1.2 Languages
LME/10880897/January 30, 2011/en
If differences in interpretations between translated versions of this manual

occur, the English-language version prevails.
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Service Manual Foreword
Service Manual Organization
1.2 Service Manual Organization
Audience
The publication is written for the well-trained service technician approved to
do the maintenance and service work on the T282B-531 haul truck.
1.2.1 Task Analysis

This service manual contains procedures to do the service and maintenance
tasks on-site. Information on component breakdown and rebuild cannot be
found in this service manual.
1.2.2 Manual Organization

Each assembly is described in a separate chapter. The titled assembly has
a system and function description of the assembly or subassembly. The
normal, installation, removal, service and procedures follow the
maintenance procedures. The service manual is organized by the following
chapters:
1.2.3 Chapters
This publication is organized in the following chapters:
1. Introduction
2. Technical Description
3. Maintenance
4. Power Module (Drive System)
5. Cooling Systems
6. Electrical System
7. Hydraulic Power and Distribution
8. Dump System
9. Hydraulic Brake and Steering Systems
10. Hydraulic Auxiliary Systems
11. Suspensions
12. Wheel Assemblies
13. Frame, Dump Body and Structures
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14. Operator Cab

15. Computers and Auxiliary Systems
16. Class Documents
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Foreword Service Manual
Service Manual Organization
1.2.4 Procedures
Each procedure contains the steps to complete the titled task. Most
procedures have illustrations that graphically show the necessary parts of
each system, subassembly, or component that requires removal,
installation, inspection, test, or adjustment.
1.2.5 Required Tools and Materials

Each procedure is proceeded by a Required Tools and Materials section.
The required tools and materials to complete the tasks are contained in this
section.
1.2.6 Illustrations
The illustrations are graphical representations of the assemblies,
subassemblies, or the titled component. The call-outs, or item numbers,
reference the affected serviceable parts for removal, installation, inspection,
test, or adjustment.
1.2.7 Serviceable Parts

Serviceable parts are the individual parts of an assembly or subassembly
that can be replaced. Serviceable parts have unique part numbers. These
serviceable, or replacement parts are shown in the corresponding parts
manuals. Each haul truck has a service manual and a corresponding parts
manual. The serviceable parts information is maintained by source updates.
Make sure you are using the service manual and the parts manual with the
same serial number to be sure you find the correct serviceable parts
identification information.
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Service Manual Introduction
2 Introduction 23
2.1 Introduction 26
2.2 Safety 27
2.2.1 Visual Safety Alert Devices 27
2.2.3 Health and Safety Information 28
2.2.4 First Aid Kit 28
2.2.5 Protective Equipment 28
2.2.6 Fire and Explosion Hazards 28
2.2.7 Fire Blanket 29
2.2.8 Fire Extinguisher 29
2.2.9 Burn Prevention 29
2.2.10 Oils 29
2.2.11 Coolant 29
2.2.12 Batteries 30
2.2.13 Chemicals 30
2.2.14 Visual Safety Alerts on the haul truck 31
2.2.15 Safety Alert Signs and Label Maintenance 33
2.2.16 Maintenance Preparation 33
2.2.17 Maintenance Parking 34
2.2.18 Brake Safety 34
2.2.19 Anchor Tie-Off Points 35
2.2.20 Safety Harness 36
2.2.21 Jack and Lift Devices 37
2.2.22 Tire Safety 37
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2.2.23 Hydraulic Safety 38

2.2.24 Dump Body Safety 39
2.2.25 General Maintenance Safety 39
2.2.26 Work Area Safety 40
2.2.27 Component Preparation 40
2.3 Torque Charts 41
2.3.1 Torque Chart for Unified Threaded Fasteners 41
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Introduction Service Manual
2.3.2 Torque Chart for Metric Threaded Fasteners 42

2.4 Welding Guidelines 43
2.4.1 Welding Precautions 43
2.4.2 Moisture 43
2.4.3 Buttering Method 43
2.4.4 Ni-Cr-Mo Steel Plate Repair Welding Procedure 45
2.4.5 Reference Specification 45
2.4.6 Base Metals 45
2.4.7 Filler Metal 45
2.4.8 Preparation of Base Metal 45
2.4.9 Pre-heating 46
2.4.10 Welding Position 46
2.4.11 Electrical Properties 46
2.4.12 Welding Instructions 46
2.4.13 Post-weld Heat Treatment: 46
2.4.14 Inspection Criteria 46
Procedures 47
Procedures 48
2.5 Jacking Points Guidance 49
2.5.1 Jacking Guide 49
2.6 Towing or Recovery of a Disabled haul truck 50
2.6.1 Rating for Optional Towing and Recovery Devices 51
2.6.2 51288AH (2 per bumper) 51
2.6.3 51288AM (2 per bumper) 51
2.6.4 51091-K (2 per bumper) 51
2.6.5 Vertical Drag Link Pin Axle Box 52
number 51288AN (includes hook and fasteners) 52
2.6.7 Horizontal Drag Link Pin Axle Box 52
2.7 Service Tools 54
2.7.1 Fixture Dump Cylinder Extend Tool - 10025660 54
2.7.2 Barring Gear Tool - 10339053 54
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2.7.3 Adaptor Hanging Forklift Load 10469271 55

2.7.4 Endplay Measuring Tool 10880099 55
2.7.5 Straight Edge Parallel Tool 11002203 55
2.7.6 Electrical System Repair Kit SVC-200 55
2.7.7 Pin Puller T-075-B 56
2.7.8 Axle Box Stand T-099-A 56
2.7.9 Front Wheel Lifting Bracket T-103-E 56
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2.7.10 Gas Tank Nipple T-107-A 57

2.7.11 Gas Tank Nipple T-107-B 57
2.7.12 Nitrogen Charge Kit T-107-T 57
2.7.13 Pin Puller T-124-C 58
2.7.14 Power Module Lifting Beam T-128-F 58
2.7.15 Rear Wheel Assembly Lifting Beam T-128-K 58
2.7.16 Dump Cylinder Shipping Brackets T-193-A 59
2.7.17 Frame Stand T-367-B 59
2.7.18 Frame Stand T-367-G 59
2.7.19 Engine Endplay Measuring Tool T-481 59
2.7.20 Hydraulic Pressure Test Kit T-493 60
2.7.21 Power Module Shipping Stand T-500-J 60
2.7.22 Rear Brake Disc Hub Puller T-504-A 60
2.7.23 O-ring Seal Kit T-528-A 61
2.8 Useful Information 62
2.8.1 Information Tables 62
2.8.2 Unit of Measure Conversions 63
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Introduction
2.1 Introduction
This chapter contains the information that follows:

• Safety
• Service Tools
• Torque Charts
• Welding Procedures
• Useful Information
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Safety
2.2 Safety
The most important safety defence is to use common sense. Remember,

you are the key to your safety. Good safety preparation can protect you and
other personnel when you do repairs, service, and maintenance work. Some
basic safety tips are shown in this publication. Read the safety information
shown in this publication. Get to know and understand the site safety
procedures that you must follow for your additional safety.
The safety information in this manual does not release the technician from
any site or government safety regulations or programs. The safety
information in this manual is a guideline to safer repairs, service, and
maintenance work.
2.2.1 Visual Safety Alert Devices

A visual safety alert device has a safety symbol, signal word, and a safety
message to the right of the signal word. This combination communicates a
hazard, shows the safety information to prevent the hazard, and shows the
results of hazard avoidance.
Signal words used in this publication:

• DANGER
• WARNING
• CAUTION
• NOTICE
DANGER indicates an imminent dangerous condition that causes serious

injury or death.
WARNING indicates possible dangerous conditions that can cause serious

injury or death.
CAUTION indicates possible hazards that can cause minor injuries.
NOTICE
indicates possible dangerous conditions that can cause equipment
damage.
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2.2.2 Information Alert Device

This information alert device calls the attention of the reader to show
additional information that can make tasks easier to do.
ATTENTION
gives additional information that can make tasks easier to do.
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Safety
2.2.3 Health and Safety Information
2.2.4 First Aid Kit

Prepare for emergencies. Keep a first aid kit in the work area. First aid kits
must include approved supplies for the treatment of small injuries.
first aid kit.TIF
2.2.5 Protective Equipment

Protective equipment is a barrier of protection for the eyes, face, head, body,
and extremities against external hazards. All protective equipment must be
approved for the task and environment. Protective equipment must be
inspected, cleaned and serviced at regular intervals.
ProtectiveEquipment.tif
• Know how to use and wear all protective equipment.

• In the work area, around the haul truck while you do the
repairs, service, and maintenance, wear protective
equipment.
• Wear a rubber apron and rubber gloves to protect your body
from chemicals, and other materials that cause skin damage.
2.2.6 Fire and Explosion Hazards

• Add the fuel after the haul truck has stopped and the electrical
equipment is turned off.
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• Use caution while the fuel is added to the haul truck.

• Pull the fuel nozzle against the fuel neck to prevent sparks.
• Fuel is flammable. Do not smoke while the fuel is added to the
haul truck.
• Add only the fuel recommended by the manufacturer.
• Do not use gasoline, diesel fuel, or flammable solvents to
clean parts.
• Store and keep all flammable fluid and materials in the correct
storage containers at the correct temperatures.
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Safety
• Know the location and the operation of the fire extinguishers.

• Follow the site and local environmental regulations and
procedures for flammable material removal.
2.2.7 Fire Blanket

The haul truck has special material installed that can contain flames, smoke,
heat, and fumes if an engine fire occurs. This material is between the side
of the engine, and behind the ladder on the driver-side of the haul truck.
• If an engine fire occurs, use the ladder in the safest location
to get from the fire hazard.
• Follow the site fire safety procedures.
2.2.8 Fire Extinguisher

• Make sure a fire extinguisher is available in the work area.
2.2.9 Burn Prevention

• Get immediate emergency attention if you are burned.
• Do not touch any part of an engine in operation. Let the engine
cool before any maintenance is done on the engine.
• Release the pressure from the air, fuel, lubrication, or cooling
system lines before you do any maintenance on the related
systems.
• Remove the hydraulic tank filler cap after the engine is
stopped. The filler cap must be cool enough to touch with an
exposed hand. Wear approved gloves and other protective
equipment approved for the task. Follow the site procedures
for the safe removal of the hydraulic tank filler cap.
• The air condition system contains alkali. Alkali can cause
injury. Do not allow the alkali to touch the skin, the eyes or the
mouth. If alkali contacts the skin, eyes, or mouth, get
immediate emergency medical attention.
2.2.10 Oils
• Hot oil and components can cause burns and other injuries.
Make sure hot oils and components do not touch the skin.
2.2.11 Coolant
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• The engine coolant is hot when the engine is in operation. The

coolant is also under pressure. The radiator and the lines to
the heaters or the engine contains hot coolant.
• Contact with hot coolant or steam can cause burns. Allow the
cooling system components to cool before the cooling system
is drained. Check the coolant level only after the engine has
been stopped.
• Follow the site procedures to remove the filler cap. Make sure
the filler cap is cool before the cap is removed.
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Safety
• For coolant leaks or spills, use approved materials to contain

the spills.
• Do not combine used coolant with other chemicals.
2.2.12 Batteries
• Some batteries can contain dangerous acids and gases. If the
battery acid or gas get into the eyes, or touches the skin,
immediately flush the area with clean water. Get medical
attention while you continue to flush the area.
• An expansion at the end of a battery indicates the battery is
frozen. Carefully follow the battery manufacturer repair,
service, and maintenance instructions.
2.2.13 Chemicals
• Follow the manufacturer instructions for the correct directions
of use for specified chemicals.
• Wear the approved protective clothing and equipment for
tasks that include specified chemicals.
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Safety
2.2.14 Visual Safety Alerts on the haul truck

Visual safety alert signs and labels communicate the dangerous areas of
the haul truck. Several visual safety alert signs and labels are attached to
components, and systems on the haul truck.
DO NOT OPERATE WITHOUT GUARDS

This label marks the areas of the haul truck with removable guards. The
guards are removable to give the approved personnel access to the
contained areas. The guards also function for protection from moving parts.
handguards.tif
USE HAND RAILS

This label tells personnel to use the handrails.
handrails.tif
CONTAINS GAS UNDER PRESSURE

This label marks the components and systems that contain gas under
pressure.
highpresgas.tif
HIGH VOLTAGE
This label marks the components and systems with high-voltage electricity.
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highvoltage.tif
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Safety
ELECTRICAL POWER NOT ALL ISOLATED

This label marks the components and systems where electricity can remain
in electrical circuits even if the power is disconnected.
elecpower.tif
CONTAINS FLUID UNDER PRESSURE

This label marks the components and systems that contain fluid under
pressure.
highpresfluid.tif
KEEP FROM BEHIND THE HAUL TRUCK

This label tells all personnel to keep from behind the haul truck. Even if an
operator is in the cab, personnel must keep from behind the haul truck.
clearreartruck.tif
KEEP FROM FRONT OF THE HAUL TRUCK

This label tells all personnel to keep from the front of the haul truck. Even
if an operator is in the cab, personnel must keep from the front of the haul
truck.
clearfronttruck.tif
DO NOT STAND BETWEEN TIRE AND FRAME

This label tells all personnel to keep from between the tire and the frame of
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the haul truck. The tire can press and hold personnel between the frame
when the tire moves.
tireandframe.tif
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Safety
HIGH VOLTAGE (sign)

This label marks the systems, components, and areas that have high-
voltage electricity. Personnel without authorization must keep from these
areas.
highvoltagesign.TIF
AUTHORIZED PERSONNEL ONLY (sign)

This label marks the areas where authorized personnel are allowed.
Personnel without authorization must keep from these areas.
authpersonnel.tif
WEIGHT WARNING
This device tells the minimum weight of a component. Different conditions
can change the weight of a component. Any device used to hold a
component must have the capacity to hold more than the minimum weight
of the component.
Safety_Sign_12_001.TIF
2.2.15 Safety Alert Signs and Label Maintenance

• Keep the safety signs clean.
• Do not block the safety signs and labels from view.
• If a safety sign or label cannot be read, or becomes damaged,
immediately replace the sign or label.
• Abrasive solvents and chemicals can loosen the label
adhesive. Use a soft cloth with water and soap to clean the
signs and labels.
2.2.16 Maintenance Preparation

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• Follow the site tag-out, and lockout procedures.

• Carefully remove stored energy from all systems.
• Keep personnel who are not approved from the work area.
• Put on the correct approved clothing and protective equipment
for the task.
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Safety
2.2.17 Maintenance Parking

• Park the haul truck on a level surface and install wheel chocks
on all of the wheels. If a parking ditch is available, park in the
ditch with the front wheels in the ditch.
• Set the parking brake, and make sure the haul truck cannot
move.
2.2.18 Brake Safety

• Follow the procedures, limits, and safety information provided
by the manufacturer when you do service, repairs, and
maintenance of the brakes.
• Install wheel chocks on all of the wheels when you do
procedures that include the brakes.
• Brakes that are not correctly adjusted can cause hazards.
Make sure to follow all the steps in the procedures for brake
service, repair, and maintenance.
• Do not remove the air from any of the wheels before you install
wheel chocks on all of the wheels.
• Use only the manufacturer approved fluids.
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Safety
2.2.19 Anchor Tie-Off Points
AnchorTie-off.tif
Fig. 2.2-1: Safety Harness Anchor Tie-Off Points
The haul truck has anchor tie-off points. Even if an approved safety harness
is installed to the anchor tie-off points, a safety harness cannot prevent falls.
Common sense and fall hazard awareness are important safety precautions
for work that is done from above the ground.
• The anchor tie-off points can hold a weight capacity of 2300
kg (5071 lb).
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Safety
2.2.20 Safety Harness
harness.tif
Fig. 2.2-2: Sample Safety Harness
• The catch belt (1), connector (2), operations, and weight
capacities are different on different safety harnesses. Make
sure the safety harness installed is approved and can hold
your weight enough to protect you from a fall condition.
• Carefully read the approved safety harness instructions
provided by its manufacturer. Install and use the approved
safety harness within the specifications and the limits shown
in the related manufacturer instructions.
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Safety
2.2.21 Jack and Lift Devices
WARNING! Jacks and lifts cannot hold all weights.

A jack or lift installed as the support to hold loads can break and cause
damage, injury, or death.
► Always install the stands strong enough to hold the weight of the
specified load after the load is lifted.
• Use a jack or a lift that can hold the specified component

weight.
• Do not install a jack or a lift that has cracks, bends, damaged
cables, or any other damage.
2.2.22 Tire Safety

• Unless you are approved, do not do any maintenance,
service, or repair work to the tires.
WARNING! The weight from the tires is a crush hazard.

In any condition, the weight from any tire is enough to cause injury, or death.
► Keep from under a tire that is not completely on the ground.
• Always use the applicable tool for the specified repair, service,
and maintenance on the tires. Know the limits, and the
operations of the special tools.
• Do not inflate the tires above the recommended pressure.
• Before any work in the area of the tires and on the tires, or the
wheels, do an inspection of the tires and wheels.
• Do not release a haul truck into service if the tires have missing
bolts, incorrect tire pressure, cuts, expansion, or damage.
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Safety
2.2.23 Hydraulic Safety

To operate correctly, hydraulic systems must store hydraulic fluid under
high-pressure. Accidents can occur when personnel do not remove the
hydraulic pressure before the repairs are done on hydraulic systems. Even
if the hydraulic system is disconnected and the engine is stopped, the
system can remain under pressure.
The safety information that follows can prevent some accidents while you
do repairs on hydraulic systems:
• Put on approved protective equipment and clothing that can
prevent oil burns.
• You must protect you and other personnel from hot fluids.
• Before you do any work on hydraulic systems, remove all
pressure from the related system.
• The temperature of the fluid kept under pressure increases
and can cause hazards when the pressure is released.
• The incorrect release of high-pressure oil can cause a hose
to move quickly and suddenly. Carefully and slowly relieve
system pressure.
• Follow the specified procedure that gives the safety
information about high-pressure oil release.
• Hydraulic hoses with leaks can cause hot fluid release burns,
cuts, abrasions, and the injection of fluid into the skin. Possible
hydraulic leakage is identified by some moisture with a mark
of oil or dirt near the hydraulic hose.
• Do not move exposed hands or fingers to check hydraulic
hoses for leaks. Put on the correct approved protective
equipment when you check hydraulic hoses for leaks.
• Incorrect coupling causes damage to hydraulic components
under low or high-pressure. Do not connect a high-pressure
pump to a low-pressure system. Do not put a low-pressure
component, hose, or fitting into a high-pressure system.
• Some procedures require the engine to remain in operation.
Know the correct procedure to follow. Know the possible
hazards, and dangers when you do service, and repairs while
an engine is in operation.
• Check the hydraulic systems at intervals for leaks and worn
hoses.
• Keep high-pressure steam or water from the seals of the
hydraulic components.
• Use a solution that cannot damage the component to clean
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hydraulic parts.
• An incorrectly serviced hydraulic system can cause the
component to fail. Safe hydraulic system performance
requires general maintenance.
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Safety
2.2.24 Dump Body Safety

• Install safety cables to hold the dump body while you do work
that requires the dump body in a specified position.
• Completely lower the dump body bore you move the haul
truck.
• The dump system can have pressure even if the engine is not
in operation.
2.2.25 General Maintenance Safety

• Always make sure you have the correct and full instructions
for each task.
• Make sure you have the correct tools for each procedure.
Check the operation of the applicable tools before the start of
each task.
• Read and understand the site instructions before you begin
work on the haul truck.
• Read and understand the safety messages for each
procedure before you begin the task.
• Do not use the haul truck for a work platform.
• Keep other personnel from the haul truck platform while the
haul truck is in operation.
• Before you begin a task, make sure you have the
recommended materials available to complete the task.
• Know the manufacturer approved fluids before you begin work
on the haul truck.
• Contain and remove all cleaning materials according to the
site materials removal procedures, and regulations.
• Follow the local and site flammable material removal
procedures, and regulations.
• Know how to calculate units of measure to the standard used
by the site.
• Calculate the required time necessary to complete a task.
Interrupted tasks at incorrect steps can cause dangerous
conditions.
• The missed steps in a procedure can cause dangerous
conditions. Carefully follow all the steps of each procedure.
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Safety
2.2.26 Work Area Safety

• Remove oil, grease, water, and obstructions from the work
area.
• Apply only approved materials to absorb the spilled fluids from
the ground around the work area.
• Make sure you have enough space to do the repairs, service,
and maintenance tasks.
• Make sure you have enough light and airflow in the work area.
• Check clearances.
• Make sure all attachments have the correct operation.
• Make sure you put on the applicable protective equipment for
the specified task.
• Loose clothing or jewelry can get caught in systems,
components, or parts that move. Do not wear loose clothing,
or jewelry.
2.2.27 Component Preparation

• Remove all dirt from components before any service, repair,
or maintenance of the components.
• Do not clean the haul tuck with the engine in operation.
• Put on the approved protective equipment, and clothing for the
specified task.
• Do not direct spray, or discharge steam or water on the
electrical systems, or electrical components.
• Do not direct spray, or discharge stem or water on the seals
of the hydraulic components.
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Torque Charts
2.3 Torque Charts
2.3.1 Torque Chart for Unified Threaded Fasteners

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Torque Chart for Unified Threaded Fasteners.tif

Fig. 2.3-1: Torque Chart for Metric Unified Threaded Fasteners
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Torque Charts
2.3.2 Torque Chart for Metric Threaded Fasteners
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Torque Chart Metric.tif

Fig. 2.3-2: Torque Chart for Metric Threaded Fasteners
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Welding Guidelines
2.4 Welding Guidelines
This procedure gives guidance for small repairs to the frame where the parts
cannot be heat-treated after repairs. The procedure also applies for the
preparation of bores for the machining, resurfacing, and removal of the
collection of unwanted material from cast surface material.
NOTICE
The dump body manufacturer weld specifications and procedures are
different from the specifications shown in this procedure.
► Refer to the specified dump body manufacturer welding specifications
and procedures to do weld repairs on the dump body.
This chapter contains the following LME-approved welding procedure:

• Ni-Cr-Mo Steel Plate Repair Welding
This chapter also contains the approved LME weld processes that follow:
• Shielded Metal Arc Welding (SMAW)
• Flux-Cored Arc Welding (FCAW)
2.4.1 Welding Precautions
CAUTION! Grounding provides an alternative path around the electrical

system.
► Welding current can cause the electrical circuits of other components
damage.
► Connect the ground directly to the work piece.
Do the steps that follow before the start of any frame welding on the haul
truck.
1. Put the Master Ignition Switch to the OFF position.
2. Remove all pressure from the air and hydraulic tubes, and
lines.
3. Protect the air and hydraulic tubes and lines, and electrical
wiring from the spattering of welding material.
4. Put the 24 VDC Battery Isolator Switch to the OFF position.
2.4.2 Moisture
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Control the electrodes carefully. Follow the electrodes manufacturer storage

instructions. If the electrodes have moisture, follow the manufacturer
instructions to remove the moisture.
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Welding Guidelines
2.4.3 Buttering Method

The method of "buttering" by depositing layers of a filler metal to close the
gap between groove faces to decrease the alloy differential, or "stringer
bead" is the welding method recommended by the manufacturer.
1402000da01.tif
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Welding Guidelines
2.4.4 Ni-Cr-Mo Steel Plate Repair Welding Procedure

This procedure gives guidance for small repairs of alloy structural steel plate
where the parts cannot be heat-treated after repairs. The procedure also
applies for the preparation of bores for the machining, resurfacing, and
removal of the collection of unwanted surface material.
NOTICE
The dump body manufacturer weld specifications and procedures are
different from the specifications shown in this procedure.
► Refer to the specified dump body manufacturer welding specifications
and procedures to do weld repairs on the dump body.
CAUTION! Grounding provides an alternative path around the electrical

system.
► Welding current from the electrical circuits of other components can
damage bearings, cylinders, hydraulic lines, alternator, and electrical
motors.
► Always be directly ground to the work piece.
2.4.5 Reference Specification

• ASTM A829
• ANSI / AWS D1.1 Structural Welding Code
• ASTM A710
2.4.6 Base Metals

• ASTM A710, Grade A, Class 3
• SAE / AISI 8620 or equivalent
2.4.7 Filler Metal

SMAW FCAW Shielding Gas Composition
AWS A5.5/E8018-C3 AWS A5.29/E81T1Ni 1 75% Argon and 25% CO2, Flow rate
30-40 cfh (used with E81T1Ni1)
.
LME/10880897/January 30, 2011/en
2.4.8 Preparation of Base Metal

• Remove metal by machining, air carbon arc cutting, chipping,
or grinding.
• If air carbon arc cutting is used, a preheat temperature of 100
ºC (212 ºF) minimum for a distance equal to the thickness of
the part, but not less than 76.2 mm (3 in) in all directions from
the repair area is required.
• Surface must be ground to remove carbon layer before
welding.
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Welding Guidelines
• Completely remove all defects before welding.

• Configuration of any necessary joint geometry must align with
AWS D1, 1 Section 3, or be approved by the LME Engineering
Department.
• Remove all unwanted material that can damage the weld
quality.
• Use magnetic particle (wet or dry) method to inspect the weld
to make sure all defects are completely removed.
2.4.9 Pre-heating
• Pre-heat and interpass temperature range is 149 ºC (300 ºF)
to 260 ºC (500 ºF).
• Minimum temperature before heat is applied is 21 ºC (70 ºF) .
• Local pre-heating must include an area equal to the thickness
of the material, but not less than 76.2 mm (3 in) in any
direction from the repair area.
2.4.10 Welding Position

• Flat
2.4.11 Electrical Properties

• DCEP current for both the SMAW and FCAW procedures.
• Follow the LME Weld procedures to get electrical current
requirements for different electrode sizes.
2.4.12 Welding Instructions

• The width of the SMAW weld pass is the smaller of not more
than three times the core diameter of the electrode used or
9.53 mm (0.38 in).
• The width of the FCAW weld pass is the smaller of not more
than seven times the core diameter of the electrode used or
9.53 mm (0.38 in) .
• Use an acceptable method to clean the completed weld pass
before the next.
• Do an interpass inspection to make sure the weld aligns to the
specification.
2.4.13 Post-weld Heat Treatment:

LME/10880897/January 30, 2011/en
• The LME Engineering Department must approve the post-

weld heat treatments.
2.4.14 Inspection Criteria

• Use Visual Testing (VT), Ultrasonic (UT) Radiography (RT),
or Magnetic Particle (MP) Standards to inspect the weld
quality.
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Welding Guidelines
• Use the ANSI / AWS D1.1 Structural Welding Code to inspect

and accept the weld.

Procedures
LME/10880897/January 30, 2011/en
FCAW_Welding Procedures_000_01_000.tif
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Welding Guidelines

Procedures
LME/10880897/January 30, 2011/en
SMAW_Welding Procedures_000_01_000.tif
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Jacking Points Guidance
2.5 Jacking Points Guidance
JackingPoints.tif
Fig. 2.5-1: Jacking Points
2.5.1 Jacking Guide

Position Capacity Height for tire lift Jack height for jack
insert
1. Axle Box (2 jacking 90.72 t (100 tn) 101.6 cm (40 in) 71.12 cm (28 in)
points)
2. Front Crossmember 63.5 t (70 tn) 1.47 m (58 in) 83.82 cm (33 in)
3. Hoist Crossmember 127.01 t (140 tn) 1.35 m (53 in) 81.28 cm (32 in)
4. Bumper 45.36 t (50 tn) 1.6 m (63 in) 78.74 cm (31 in)
LME/10880897/January 30, 2011/en
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Towing or Recovery of a Disabled haul truck
2.6 Towing or Recovery of a Disabled haul

truck
The following are recommended towing or recovery instructions for moving

a disabled haul truck for short distances only.
If a disabled haul truck needs to be moved longer distances, the haul truck
must be hauled.
WARNING! Personal injury or loss of life can result when incorrect towing
and recovery procedures are used.
► While rigging the towing equipment, always block the tires to prevent
haul truck movement before releasing the brakes.
► Always dump all material from the dump body before you move a
disabled haul truck.
► Engine power must be available or an auxiliary power unit must be
used to provide steering and braking power. Do not tow or recover a
disabled haul truck without power.
• Do not permit any other person except for the operator on the
disabled haul truck during towing or recover procedures.
• An observer, stationed a safe distance away, must be
available to monitor the towing or recovery procedures.
• Do not use a chain to tow or recover a disabled haul truck.
• Use a cable or wire rope with a loop or rings at the cable ends
and of sufficient strength to handle the load.
• Do not apply quick movements when towing or recovering a
disabled haul truck. Slow, steady force when pulling is more
effective and safer.
• Do not exceed a 10 degree angle from the straight line pull.
• Use both (2) towing points at all times and steer the disabled
haul truck in the direction being towed (pulled).
• Avoid snatch loading caused by sudden tension of the towing
wire.
Check the haul truck to make sure it is equipped with optional tow and
recovery devices on the front bumper, or the rear axle box.
WARNING! There is a maximum travel speed when towing a disabled haul

truck.
► The towing speed when towing a disabled haul truck must not exceed
LME/10880897/January 30, 2011/en
2.41 km/h (1.5 mph).
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2.6.1 Rating for Optional Towing and Recovery Devices
2.6.2 51288AH (2 per bumper)

• Hole (1) rated at 49895 kg (110000 lb) each 10 degree
maximum angle deviation from straight line pull.
• Use a 50.8 mm (2 in) or equivalent Clevis.
Towing_51288AH.tif
2.6.3 51288AM (2 per bumper)

• Use a 63.5 mm (2.5 in) or equivalent Clevis.
• Hook (3) rated at 60781 kg (134000 lb) each 10 degree
• Use a 76.2 mm (3 in) diameter cable, wire rope, sling or
equivalent.
Towing_51288AM.tif
LME/10880897/January 30, 2011/en
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2.6.4 51091-K (2 per bumper)

• Use a 63.5 mm (2.5 in) or equivalent Clevis.
• Hook (5) rated at 29030 kg (64000 lb) each 10 degree
• Use a 50.8 mm (2 in) diameter wire rope, sling or equivalent.
• Bollard (6) rated at 79379 kg (175000 lb) each 10 degree
• Use a 88.9 mm (3.5 in) diameter wire rope, sling or equivalent.
Towing_51091-K.tif
2.6.5 Vertical Drag Link Pin Axle Box

• Hole (7) No Hook.
Do not use for towing.
Towing_Vertical Drag Link Pin Axlebox.tif
number 51288AN (includes hook and fasteners)
• Hook (8)) rated at 31751 kg (70000 lb) each 10 degree
LME/10880897/January 30, 2011/en
Towing_51288AN.tif
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2.6.7 Horizontal Drag Link Pin Axle Box

• Customer to supply rigging. Load must be spread over entire
pin surface.
Towing Horizontal Drag Link Pin Axle Box.tif

LME/10880897/January 30, 2011/en
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Service Tools
2.7 Service Tools
The following service tools are called out for use on different procedures.
The service tools are listed in the Required Tools and Materials at the
beginning of each procedure.
Liebherr Part Number Tool

10025660 Fixture Dump Cylinder Extend Tool
10339053 Barring Gear Tool
10469271 Adaptor Hanging Forklift Load
10880099 Endplay Measuring Tool
11002203 Straight Edge Parallel Tool
SVC-200 Electrical System Repair Kit
T-075-B Pin Puller
T-099-A Axle Box Stand
T-103-F Front Wheel Lifting Bracket
T-107-A Nut
T-107-B Gas Tank Nipple
T-107-T Nitrogen Charging Kit
T-124-C Pin Puller
T-128-F Power Module Assembly Lifting Beam
T-128-K Rear Wheel Assembly Lifting Beam
T-193-A Dump Cylinder Shipping Brackets
T-367-B Frame Stand
T-367-G Frame Stand
T-481 Engine Endplay Measuring
T-493 Hydraulic Pressure Test Kit
T-500-J Power Module Shipping Stand
T-504-A Rear Brake Disc Hub Puller
T-528-A O-ring Seal Kit
2.7.1 Fixture Dump Cylinder Extend Tool - 10025660

This tool is manually operated to extend the dump cylinders.
LME/10880897/January 30, 2011/en
10025660 Fixture Dump Cylinder Extend Tool.tif
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Service Tools
2.7.2 Barring Gear Tool - 10339053

This tool is manually operated to rotate the engine flywheel housing until
the tool engages the ring gears.
10339057_000_01.tif
2.7.3 Adaptor Hanging Forklift Load 10469271

Use this tool to directly attach to the forklift lifter to keep heavy loads stable
to the floor.
10469271_001_01.tif
2.7.4 Endplay Measuring Tool 10880099

Use this tool for taking the engine endplay measurements.
10880099_000_01.tif
2.7.5 Straight Edge Parallel Tool 11002203

This tool is used as the alignment tool to place the connection hub in the
correct position in the alternator shaft.
LME/10880897/January 30, 2011/en
11002203_000_01.tif
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Service Tools
2.7.6 Electrical System Repair Kit SVC-200

The electrical repair kit has the crimp tools necessary to maintain the wiring
of the electrical system.
SVC-101_000_01.tif
2.7.7 Pin Puller T-075-B

The function of the pin puller is to remove the pins from the control arms.
T-075-B_000_01.tif
2.7.8 Axle Box Stand T-099-A

The function of the stand is to hold the axle box.
T-099-A_000_01.tif
LME/10880897/January 30, 2011/en
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Service Tools
2.7.9 Front Wheel Lifting Bracket T-103-E

The function of this lifting bracket is to lift the front wheel for various
maintenance tasks.
T-103-E_000_01.tif
2.7.10 Gas Tank Nipple T-107-A
T-107-A_000_01.tif
2.7.11 Gas Tank Nipple T-107-B

The nipple attaches to the outer end of the fill port of some components and
contains a check valve.
T-107-B_000_01.tif
LME/10880897/January 30, 2011/en
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Service Tools
2.7.12 Nitrogen Charge Kit T-107-T

This function of this kit is to charge the suspensions.
T-107-T_000_01.tif
2.7.13 Pin Puller T-124-C

The function of the pin puller is to remove the pins from the front suspension.
T-124-C_000_01.tif
2.7.14 Power Module Lifting Beam T-128-F

The function of the chain and spreader beam is to lift the engine.
LME/10880897/January 30, 2011/en
T-128-F_000_01.tif
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Service Tools
2.7.15 Rear Wheel Assembly Lifting Beam T-128-K

The function of the rear wheel assembly lifting beam is to lift the rear wheel
assembly.
T-128-K_000_01.tif
2.7.16 Dump Cylinder Shipping Brackets T-193-A

The function of the shipping brackets is to supply support to the dump
cylinder during removal and installation.
T-193-A_000_01.tif
2.7.17 Frame Stand T-367-B

The function of the stand is to hold the frame.
T-367-B_000_01.tif
2.7.18 Frame Stand T-367-G

LME/10880897/January 30, 2011/en
The function of the stand is to hold the frame.
T-367-G_000_01.tif
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Service Tools
2.7.19 Engine Endplay Measuring Tool T-481

The function of the measuring tool is to measure the depth through a hole.
T-481_000_01.tif
2.7.20 Hydraulic Pressure Test Kit T-493

Used to check the hydraulic pressure of hydraulic components.
T-493_000_01.tif
2.7.21 Power Module Shipping Stand T-500-J

This tool is used to support the power module for specified power module
installation or removal procedures.
T-500-J_000_01.tif
LME/10880897/January 30, 2011/en
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Service Tools
2.7.22 Rear Brake Disc Hub Puller T-504-A
T-504-A_000_01.tif
2.7.23 O-ring Seal Kit T-528-A

LME/10880897/January 30, 2011/en
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Useful Information
2.8 Useful Information
This section data has this information:

• Temperature Conversions
• Unit of Measure Conversions
• Fraction Decimal Equivalents
• Torque Chart for Unified Threaded Fasteners
• Torque Chart for Metric Threaded Fasteners
2.8.1 Information Tables

Temperature Conversions
Temperature
-60 °C (-76 °F) -10 °C (14 °F) 50 °C (122 °F) 95 °C (203 °F) 155 °C (310 °F) 210 °C (410 °F)
-55 °C (-67 °F) -5 °C (23 °F) 55 °C (131 °F) 100 °C (212 °F) 160 °C (320 °F) 215 °C (420 °F)
-50 °C (-58 °F) 0 °C (32 °F) 60 °C (140 °F) 105 °C (221 °F) 165 °C (330 °F) 220 °C (430 °F)
-45 °C (-49 °F) 5 °C (41 °F) 65 °C (149 °F) 110 °C (230 °F) 170 °C (340 °F) 225 °C (435 °F)
-40 °C (-40 °F) 10 °C (50 °F) 70 °C (158 °F) 115 °C (239 °F) 175 °C (345 °F) 230 °C (445 °F)
-35 °C (-31 °F) 15 °C (59 °F) 75 °C (167 °F) 120 °C (248 °F) 180 °C (355 °F) 235 °C (455 °F)
-30 °C (-22 °F) 20 °C (68 °F) 80 °C (176 °F) 125 °C (255 °F) 185 °C (365 °F) 240 °C (465 °F)
-25 °C (-13 °F) 25 °C (77 °F) 85 °C (185 °F) 130 °C (265 °F) 190 °C (375 °F) 245 °C (475 °F)
-20 °C (-4 °F) 30 °C (86 °F) 80 °C (176 °F) 135 °C (275 °F) 195 °C (385 °F) 250 °C (480 °F)
-18 °C (0 °F) 35 °C (95 °F) 85 °C (185 °F) 145 °C (295 °F) 200 °C (390 °F)
-15 °C (5 °F) 40 °C (104 °F) 90 °C (194 °F) 150 °C (300 °F) 205 °C (400 °F)
Table 1: Temperature Conversions
The formula for Fahrenheit to Celsius conversion is:

• ((F - 32) x 5) ÷ 9 = C
The formula for Celsius to Fahrenheit conversion is:

• ((C x 9) ÷ 5) ÷ 32 = F
The boiling point for pure water at sea level is 100 °C.
The freezing point for pure water at sea level is 0 °C.

LME/10880897/January 30, 2011/en
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Useful Information
2.8.2 Unit of Measure Conversions

Conversion of metric units of measure into U.S.
equivalents:
Metric multiplied by U.S. Equivalent
millimeter (mm) 0.03937 inch (in.)
meter (m) 39.37 inch (in.)
meter (m) 3.281 foot (ft)
kilometer (km) 0.621 mile
square millimeter (mm2) 0.00155 square inch (in2)
square meter (m2) 10.76 square foot (ft2)
square meter (m2) 1.196 square yard (yd2)
cubic centimeter (cm3) 0.06102 cubic inch (in3)
cubic meter (m3) 35.31 cubic foot (ft3)
cubic meter (m3) 1.308 cubic yard (yd3)
liter (L) 61.02 cubic inch (in3)
liter (L) 2.113 pint (US liquid) (pt)
liter (L) 1.0566 quart (US liquid) (qt)
liter (L) 0.2642 gallon (US liquid) (gal)
joule (J) 0.7375 pound force foot (lbf ft)
newton (N) 0.02248 pound force (lbf)
kilonewton (kN) 224.808 pound force (lbf)
newton per square meter (N/m2) 0.00145 pounds per square inch (psi)
newton meter (Nm) 8.8507 pound force inch (lbf in)
newton meter (Nm) 0.7375 pound force foot (lbf ft)
bar (bar) 14.50 pounds per square inch (psi)
kilopascal (kPa) 0.1450 pounds per square inch (psi)
kilogram square centimeter (kg/ 14.22 pounds per square inch (psi)
cm2)
gram (gr) 0.0353 ounce (oz)
kilogram (kg) 2.205 pound (lb)
metric ton (t) 1.102 ton (short) (tn)
LME/10880897/January 30, 2011/en
Table 2: Conversion of metric units of measure into U.S. equivalents:
Conversion of U.S. Units of Measures into Metric

Equivalents:
U.S. Equivalent multiply by Metric
inch (in.) 25.4 millimeter (m)
inch (in.) 2.54 centimeter (cm)
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Useful Information
U.S. Equivalent multiply by Metric

inch (in.) 0.0254 meter (m)
foot (ft) 0.3048 meter (m)
square inch (in ) 2 645.16 square millimeter (mm2)
square foot (ft2) 0.0929 square meter (m2)
square yard (yd2) 0.8361 square meter (m2)
cubic inch (in3) 16.39 cubic centimeter (cm3)
cubic inch (in3) 0.0164 liters (L)
cubic foot (ft3) 0.0283 cubic meter (m3)
cubic yard (yd3) 0.7646 cubic meter (m3)
pint (US liquid)(pt) 0.4732 liter (L)
quart (US liquid)(qt) 0.9463 liter (L)
gallon (US liquid)(gal) 3.785 liter (L)
pound force (lbf) 4.448 newton (N)
pound force inch (lbf in) 0.1129 newton meter (Nm)
pound force foot (lbf ft) 1.3558 newton meter (Nm)
pound force foot (lbf ft) 1.3558 joule (J)
pounds per square inch (psi) 0.0689 bar (bar)
pounds per square inch (psi) 6.8947 kilopascal (kPa)
pounds per square inch (psi) 0.0703 kilogram square centimeter (kg/cm2)
ounce (oz) 28.249 gram (gr)
pound (lb) 0.4536 kilogram (kg)
ton (short) (tn) 0.9072 metric ton (t)
Table 3: Conversion of U.S. Units of Measures into Metric Equivalents:
Fraction Decimal Equivalents

Fraction of One Inch Working Equivalent Exact Decimal
1/64 .0156 .015625
1/32 .0312 .031250
3/64 .0469 .046875
1/16 .0625 .062500
5/64 .0781 .078125
3/32 .0938 .093750
LME/10880897/January 30, 2011/en
7/64 .109 .109375

1/8 .125 .125000
9/64 .141 .140625
5/32 .156 .156250
11/64 .172 .171875
3/16 .188 .187500
13/64 .203 .203125
7/32 .219 .218750
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Useful Information

15/64 .234 .234375
1/4 .250 .250000
17/64 .266 .265625
9/32 .281 .281250
19/64 .297 .296875
5/16 .312 .312500
21/64 .328 .328125
11/32 .344 .343750
23/64 .359 .359375
3/8 .375 .375000
25/64 .391 .390625
13/32 .406 .406250
27/64 .422 .421875
7/16 .438 .437500
29/64 .453 .453125
15/32 .469 .468750
31/64 .484 .484375
1/2 .500 .500000
33/64 .516 .515625
17/32 .531 .531250
35/64 .547 .546875
9/16 .562 .562500
37/64 .578 .578125
19/32 .594 .593750
39/64 .609 .609375
5/8 .625 .625000
41/64 .641 .640625
21/32 .656 .656250
43/64 .672 .671875
11/16 .688 .687500
45/64 .703 .703125
23/32 .719 .718750
47/64 .734 .734375
LME/10880897/January 30, 2011/en
3/4 .750 .750000

49/64 .766 .765625
25/32 .781 .781250
51/64 .797 .796875
13/16 .812 .812500
53/64 .828 .828125
27/32 .844 .843750
55/64 .859 .859375
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Useful Information

7/8 .875 .875000
57/64 .891 .890625
29/32 .906 .906250
59/64 .922 .921875
15/16 .938 .937500
61/64 .953 .953125
31/32 .969 .968750
63/64 .984 .984375
Table 4: Fraction Decimal Equivalents
LME/10880897/January 30, 2011/en
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Service Manual Technical Description
3 Technical Description 67
3.1 Component Weights and Dimensions 68
3.1.1 Frame with Power Module 68
3.1.2 Frame 68
3.1.3 Superstructure Assembly 68
3.1.4 Front Wheel Assembly 68
3.1.5 Lower Control Arm 68
3.1.6 Upper Control Arm 69
3.1.7 Front Suspension 69
3.1.8 Rear Suspension 69
3.1.9 Rim 69
3.1.10 Tire and Rim 70
3.1.12 Planetary Gear Box 70
3.1.13 Planetary Gear Box Assembly 70
3.1.14 Fuel Tank Assembly 70
3.1.15 Fuel and Hydraulic Tank Assembly 71
3.1.16 Dump Cylinder 71
3.1.17 Power Module Assembly 71
3.1.19 Air Cleaner 72
3.1.20 Cab with Air Conditioning 72
3.1.21 Additional Component Weights 72
LME/10880897/January 30, 2011/en
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Technical Description Service Manual
Component Weights and Dimensions
3.1 Component Weights and Dimensions
Most of the component weights shown in this section are the original
manufacturer specified or calculated weights. The weights shown in this
section are given for safety purposes. Other conditions can change the
specified and calculated weights. Therefore, the weights shown must be
applied as the minimum component weight. Follow the site rules and
regulations about weight compliance.
3.1.1 Frame with Power Module

• length 11075 mm (436.02 in)
• height 4140 mm (162.99 in)
• width 4445 mm (175 in)
• weight 44924 kg (99040 lb)
WEIGHTS_DIMENSIONS_000_01_000.tif
3.1.2 Frame
• length 10999 mm (433.03 in)
• height 4140 mm (162.99 in)
• width 3583 mm (141.06 in)
• weight 26056 kg (57444 lb)
3.1.3 Superstructure Assembly

• length 8535 mm (336.02 in)
• height 2670 mm (105.12 in)
• width 3785 mm (149.02 in)
• weight 12700 kg (27999 lb)
3.1.4 Front Wheel Assembly

• length 1190 mm (46.85 in)
LME/10880897/January 30, 2011/en
• height 1475 mm (58.07 in)

• width 1475 mm (58.07 in)
• weight (empty) 4168 kg (9189 lb)
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3.1.5 Lower Control Arm

• length 1120 mm (44.09 in)
• height 335 mm (13.19 in)
• width 1370 mm (53.94 in)
• weight 876 kg (1931 lb) x 2
3.1.6 Upper Control Arm

• length 1500 mm (59.05 in)
• height 585 mm (23.03 in)
• width 1750 mm (68.9 in)
• weight 1023 kg (2255 lb) x 2
3.1.7 Front Suspension

• length 1760 mm (69.29 in)
• diameter 455 mm (17.91 in)
• weight (empty) 893 kg (1969 lb) x 2
3.1.8 Rear Suspension

• length 1270 mm (50 in)
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3.1.9 Rim
• height 1855 mm (73.03 in)
• width 1295 mm (50.98 in)
• weight 2865 kg (6316 lb) x 6
3.1.10 Tire and Rim

• height 3915 mm (154.13 in)
• width 1400 mm (55.12 in)
• weight 6674 kg (14714 lb) x 6
3.1.11 Traction Motor

• length 1525 mm (60.04 in)
• height 1065 mm (41.93 in)
• width 1170 mm (46.06 in)
• weight 3900 kg (8598 lb) x 2
3.1.12 Planetary Gear Box

• length 2700 mm (106.3 in)
• width 1675 mm (65.94 in)
• weight 11370 kg (25067 lb) x 2
LME/10880897/January 30, 2011/en
3.1.13 Planetary Gear Box Assembly

• length 3900 mm (153.54 in)
• width 1675 mm (65.94 in)
• weight 15460 kg (34083 lb) x 2
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3.1.14 Fuel Tank Assembly

• length 1730 mm (68.11 in)
• height 1810 mm (71.26 in)
• width 1655 mm (65.16 in)
3.1.15 Fuel and Hydraulic Tank Assembly

• length 1730 mm (68.11 in)
• height 1855 mm (73.03 in)
• width 1830 mm (72.05 in)
3.1.16 Dump Cylinder

• length 2720 mm (107.09 in)
3.1.17 Power Module Assembly

• length 6223 mm (245 in)
• height 3657.6 mm (144 in)
• width 3479.8 mm (137 in)
LME/10880897/January 30, 2011/en
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3.1.18 Traction Alternator

• length 1400 mm (55.12 in)
• height 1575 mm (62.01 in)
• width 1040 mm (40.94 in)
• weight 4467 kg (9848 lb)
3.1.19 Air Cleaner

• length 925.58 mm (36.44 in)
• height 1212.85 mm (47.75 in)
• width 806.45 mm (31.75 in)
• weight 200 kg (441 lb) x 2
3.1.20 Cab with Air Conditioning

• length 2140 mm (84.25 in)
• height 1600 mm (62.99 in)
• width 1655 mm (65.16 in)
3.1.21 Additional Component Weights

Component Weight
Axle Box 4354 kg (9599 lb)
Control Box (Siemens) 3312 kg (7302 lb)
Drag Link with Bushings 435 kg (959 lb) (each)
Dump Body 42468 kg (93626 lb)
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Dump Pump (dry) 101 kg (223 lb) (each)

Dump Valve (empty) 146 kg (322 lb)
Front Brake Caliper 122 kg (269 lb)
Grid Box (Mosebach) 1820 kg (4012 lb)
Grid Box (Siemens) 2082 kg (4590 lb)
Idler Arm 376 kg (829 lb)
Individual Resistor Grids 46 kg (101 lb)
Kingpin (Upper) 238 kg (525 lb)
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Component Weight
Kingpin (Lower) 238 kg (525 lb)
Main Blower (Siemens) 2575 kg (5677 lb)
Pump Drive Gear Box (dry) 160 kg (353 lb)
Radiator (dry) 2336 kg (5150 lb)
Radiator Cowling and Grill (dry) 730 kg (1609 lb)
Rear Brake Caliper 42 kg (93 lb)
Rear Control Arm 936 kg (2064 lb)
Steering Accumulator (dry) 850 kg (1874 lb)
Steering Arm 201 kg (443 lb) (each)
Steering Cylinder (dry) 196 kg (432 lb) (each)
Steering Pump 31 kg (68 lb) (each)
Tie Rod 184 kg (406 lb) (each)
ATTENTION
The weight of the dump body can change.
► Refer to your local Liebherr Service Representative for the correct
weight of the dump body installed on the haul truck.
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Service Manual Maintenance
4 Maintenance 75
4.1 Maintenance Plan 78
4.1.1 Preventive Maintenance Program 78
4.2 Oil and Lubricant Specifications 79
4.3 Major Component Replacement Guidance 86
4.4 Preventive Maintenance Daily Inspections and Checks 87
4.5 Preventive Maintenance Master Schedule 89
4.5.1 Preventive Maintenance Reference Structure 95
4.7 LME-00-01-01 - Battery Maintenance 97
4.8 LME-20-01-00 - Oil Sampling Guideline 98
4.9 LME-20-08-01 - Air Intake System Inspection and Filter
Replacement Procedures 100
4.10 LME-30-01-01 - Axle Box Inspection 102
4.11 LME-40-01-01 - Hydraulic Hoses Inspection 104
4.12 LME-40-02-00 - Pump Drive Service Procedure 105
4.13 LME-40-03-01 - Brake Accumulator Pre-Charge Check, Drain,
4.13.1 Brake Accumulator Pre-charge Check 106
4.13.2 Brake Accumulator Drain 106
4.13.3 Brake Accumulator Pre-Charge 107
4.14 LME-40-04-01 - Steering Accumulator Pre-Charge Check, Drain,
4.14.1 Steering Accumulator Pre-charge Check 110
4.14.2 Steering Accumulator Drain 110
Steering Accumulator Pre-Charge 111
LME/10880897/January 30, 2011/en
4.14.3
4.15 LME-40-05-00 - Unloader Accumulator Pre-Charge Check,
Drain, and Pre-Charge Procedures 114
Procedure 114
4.15.2 Unloader Accumulator Drain Procedure 115
4.15.3 Unloader Accumulator Pre-Charge Procedure 115
4.16 LME-80-16-00 - Suspension Monitoring and Maintenance 118
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Maintenance Service Manual
4.16.1 Pre-Maintenance Fault Review 118

4.16.2 Visual Inspection 118
4.16.3 Suspension Charge Check 119
Faults) 120
4.18 LME-20-02-02 - Brake and Steering Pressure Filter Replacement
Procedure 123
4.19 LME-20-03-02 - Dump System Filter Replacement Procedure 125
4.20 LME-110-01-00 - Grid Motor Inspection Guidelines 128
4.22 LME-10-01-01 - Exhaust Bellows and Blankets Inspection 130
4.23 LME-20-04-00 - Gear Oil Cooling System Filters Replacement
Procedure 131
4.24 LME-80-02-02 - Rear Brake Pad and Disc Check Procedure 132
4.25 LME-80-15-01 - Front Brake Pad and Disc Check Procedure 134
4.27 LME-20-06-00 - Front Wheel Oil Drain and Fill Procedures 137
4.27.1 Front Wheel Oil Drain 137
4.27.2 Front Wheel Oil Fill 137
4.28 LME-80-04-02 - Wear Limit Check Procedure 139
4.28.1 Drag Links and Rear Control Arm Bushing Check 139
4.28.2 Steering Cylinder and Tie Rod Bushing Check 140
4.28.3 Idler Arm Bearing Check 141
4.30 LME-80-03-01 - Lower Kingpin Bushing Wear Check Procedure 145
4.30.2 Additional Information 145
4.31 5000-Hour Preventive Maintenance 149
4.32 LME-20-07-00 - Rear Wheel Oil Drain and Fill Procedures 150
4.32.1 Rear Wheel Oil Drain Procedure 150
4.32.2 Rear Wheel Oil Fill Procedure 151
4.33 LME-30-02-01 - Rear Control Arm Fasteners Torque Procedure 152
4.34 LME-80-05-02 - Rear Brake Assembly Fasteners Torque
Procedure 155
LME/10880897/January 30, 2011/en
4.35 LME-80-06-02 - Steering Cylinder Fasteners Torque Procedure 159

4.36 LME-80-09-01 - Tie Rod Fastener Torque Procedure 163
4.37 LME-80-11-00 - Lower Kingpin Fasteners Torque Procedure 167
4.38 LME-80-13-01 - Steering Arm Fasteners Torque Procedure 169
4.39 LME-80-14-00 - Upper Kingpin Fastener Torque Procedure 171
4.41 LME-80-10-00 - Replace Lower Kingpin Fasteners 174
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4.42 LME-80-12-01 - Steering Arm Fasteners Replacement 176

4.43 Conditional-Hours Preventive Maintenance References 178
4.44 LME-80-07-02 - Front Brake Assembly Fasteners Torque
Procedure 179
4.45 LME-80-08-02 - Rear Wheel Assembly Fasteners Torque
Procedure 181
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Maintenance Plan
4.1 Maintenance Plan
This maintenance plan chapter has the following sections:

• Oil and Lubricant Specifications
• Major Component Replacement Guidance
• Preventive Maintenance Daily Inspections and Checks
• Preventive Maintenance Schedule and Associated
Maintenance References
The maintenance plan gives general information about how to maintain the
haul truck. Additional service information is provided in the specified
component or system chapter.
4.1.1 Preventive Maintenance Program

Liebherr recommends a preventative maintenance schedule to maintain the
safe and proper operation of the haul truck. Failure to follow the Liebherr
factory recommended preventative maintenance schedule can effect
warranty consideration of failed components that occur from lack of routine
or recommended maintenance. The climate, terrain, and mine operations
can be very different from mine to mine. Use this schedule only as an
example of the minimum recommended requirements. The application, haul
profile, and load factors can dictate an increase in routine maintenance.
These changes to the schedule must agree with the local conditions and
operation for the haul truck.
As the maintenance program is updated, the new information is posted on

the Customer Support internet site. Affiliates have the responsibility to
provide mining customers with these changes, which are supplied as
Maintenance Update Service Information documents.
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Oil and Lubricant Specifications
4.2 Oil and Lubricant Specifications
The oils and lubricants must follow the International Standards Organization
(ISO) Clean Code 18/16 to get the best operating performance from the haul
truck hydraulic system.
FRONT SUSPENSION APPROVED OILS**

LME Part Manufacturer Product Brand Name SAE Grade ISO Grade Min Temp Max Temp Comments
Number (°C) (°C)
-5081-B Mobil Mobilfluid 424 N/A 46 - -
N/A Shell Donax TM N/A 46 - -
10330278 Liebherr Hydraulic Plus N/A VG 15-46 - -
Arctic VG 15-46
N/A Texaco TDH 1893 10W-30 N/A - -
N/A Chevron 1000 THF N/A 68 - -
N/A PETROBRAS LUBRAX 10W-30 N/A
UNITRACTOR
N/A Petro-Canada Duron XL 0W-30 N/A
N/A Conoco PowerTran Fluid N/A N/A 61 cSt @
40C
FRONT SUSPENSION OIL VOLUME*

LME Part Number Volume L (US Gal)
51784-Y 17 (4.5)
51784AR 17 (4.5)
51784AW 17 (4.5)
9636974 17 (4.5)
933549901 42 (11)
933550101 42 (11)
* Volumes are estimates, please reference the appropriate parts and maintenance manuals for your component
for proper fill and check procedures.
** Fluids are approved for all components or models unless otherwise specified
REAR SUSPENSION APPROVED OILS**
LME Part Manufacturer Product Brand Name SAE Grade ISO Grade Min Temp Max Temp Comments
Number (°C) (°C)
-5081-B Mobil Mobilfluid 424 N/A 46 - -
N/A Shell Donax TM N/A 46 - -
10330278 Liebherr Hydraulic Plus N/A VG 15-46 - - Required in
Arctic VG 15-46 PN 94005372
& 94007278
N/A Texaco TDH 1893 10W-30 N/A - -
N/A Chevron 1000 THF N/A 68 - -
LME/10880897/January 30, 2011/en
UNITRACTOR
N/A Petro-Canada Duron XL 0W-30 N/A
N/A Conoco PowerTran Fluid N/A N/A 61 cSt @ 40C
REAR SUSPENSION OIL VOLUME*

51784-Z 18.5 (4.9)
51784AK 18.5 (4.9)
51784AX 18 (4.8)
51784AP 37 (9.8)
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REAR SUSPENSION OIL VOLUME*

10468322 37 (9.8)
9614138 44.5 (11.8)
94005372 44.5 (11.8)
94007278 44.5 (11.8)
968592401 42 (11)
FRONT WHEEL APPROVED OILS**
LME Part Manufacturer Product Brand SAE Grade ISO Grade Min Temp Max Temp Comments
Number Name (°C) (°C)
-5087-B Mobil Mobilgear SHC N/A 680 25 50
680
N/A Chevron Tegra Synthetic N/A 680 - -
Gear Lubricant
N/A Petro-Canada Super Gear Fluid N/A 680 - -
N/A Texaco PinnacleEP 460 N/A 460 -40 25
-5087-D Mobil Mobilgear SHC N/A 320 -40 25
320
N/A Mobil Mobilgear SHC N/A 460
460
N/A Conoco Syncon EP Plus N/A 680
Gear Oil
N/A Conoco Syncon Premium N/A 680
EP Gear Oil
N/A Shell Hyperia S N/A 680
N/A Bel-Ray Synthetic Gear N/A 680
Oil 66960
FRONT WHEEL OIL VOLUME*

90005622 60 (16)
90005623 60 (16)
933435701 60 (16)
933435801 60 (16)
933523301 60 (16)
933523401 60 (16)
970375501 60 (16)
970375601 60 (16)
51015-V 60 (16)
51018BD 60 (16)
51018BG 60 (16)
51018BH 60 (16)
LME/10880897/January 30, 2011/en
51018BL 60 (16)
933549901 43 (11)
933550101 43 (11)
FRONT WHEEL APPROVED GREASE

LME Part Number Manufacturer Product Brand Name NLGI Comments
-5079-A Mobil XHP 320 Mine 0
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PUMP DRIVE APPROVED OILS**
-5087-A Mobil Mobilube HD 85W-140 N/A - -
Plus
N/A Chevron RPM Universal 85W-140 N/A - -
Gear
Lubricants
N/A Petro-Canada TRAXON E 80W-140 N/A - -
Synthetic
N/A Fuchs Titan Super 85W-140 N/A - -
Gear
N/A Shell Spirax EW 85W-140 N/A - -
N/A RPM Universal 6 85W-140 N/A
N/A Esso GX Gear Oil 85W-140 N/A
TRM-5
N/A Conoco Universal Gear 85W-140 N/A
Lubricant
PUMP DRIVE OIL VOLUME*

10468889 8.5 (2.25)
13591-F 8.5 (2.25)
13591-A 8.5 (2.25)
13591-B 8.5 (2.25)
PUMP DRIVE APPROVED GREASE***

10496177 Mobil Mobilgrease XHP 222 2
N/A Mobil Mobilgrease CM-S 2
N/A PETROBRAS LUBRAX INDUSTRIAL 2
GCS-2-EP
GEAR DRIVE APPROVED OILS**
-5087-D Mobil Mobilgear SHC N/A 320 -20 50
320
N/A Chevron Tegra N/A 320 - -
Synthetic Gear
Lubricant
LME/10880897/January 30, 2011/en
-5087-C Mobil Mobilgear SHC N/A 220 -40 25

220
-5087-B Mobil Mobilgear SHC N/A 680 - -
680
N/A Petro Canada Enduratex N/A 320
Synthetic EP
320
N/A Caltex Meropa N/A 320
Synthetic EP
N/A Mobil Mobilgear SHC N/A 460
460
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GEAR DRIVE APPROVED OILS**

N/A Petro Canada Traxon E 80W-140 N/A
Synthetic
N/A Conoco Syncon EP N/A 320
Plus Gear Oil
N/A Conoco Syncon N/A 320
Premium EP
Gear Oil
N/A Shell Hyperia S N/A 320
N/A Bel-Ray Synthetic Gear N/A 320
Oil 66920
GEAR DRIVE OIL VOLUME*

90000835 280 (74)
90000836 280 (74)
90000837 280 (74)
90000838 280 (74)
90000839 280 (74)
90000840 280 (74)
933224401 280 (74)
939677301 280 (74)
968447001 280 (74)
968447101 280 (74)
968447201 280 (74)
968447301 280 (74)
970604101 280 (74)
970604201 280 (74)
970604301 280 (74)
970604401 280 (74)
51018AL 246 (54)
51018AP 246 (54)
51018AT 246 (54)
51018AX 246 (54)
51018AZ 246 (54)
51018AZ 246 (54)
51018BB 246 (54)
51018BC 246 (54)
51018BE 246 (54)
51018BF 246 (54)
969038701 55 (14.5)
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HYDRAULIC SYSTEMS APPROVED OILS**
-5081-D Mobil DTE 15M N/A 46 -20 50
11002163 Mobil DTE 10 Excel N/A 46
46
N/A Esso UNIVIS N32 N/A 32 - -
N/A Shell Donax TC30 30 N/A -40 25
N/A Esso UNIVIS N32 N/A 32 - -
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HYDRAULIC SYSTEMS APPROVED OILS**

N/A John Deere Bio Hy-Gard 5W-30 N/A
N/A Sun Oil Company Sunvis 832WR N/A 32
N/A Mobil Mobiltrans HD 10W N/A
N/A PETROBRAS LUBRAX 10W N/A
TAC-4
N/A PETROBRAS LUBRAX MD 10W N/A
400
N/A Petro-Canada Produro TO-4+ N/A (55.8)
Synthetic All
Season
N/A Conoco Powerflow AW N/A 46
HVI
N/A Conoco Powerdrive 10W N/A
Fluid
HYDRAULICS SYSTEMS OIL VOLUME*

LME Part Number Truck Model Volume L (US Gal)
Hoist Reservoir T282 1302 (340)
Brake and Steering Reservoir T282 924 (244)
Hydraulic reservoir TI 274 1100 (290)
ENGINE APPROVED OILS**
LME Part Number Manufacturer Product Brand SAE Grade ISO Grade Comments
Name
-5078-C Mobil Delvac 1300 15W-40 N/A
Super
For MTU Engines see
MTU Lubrication
Guide A001061/33E
for the latest approved
oil requirements.
For Cummins Engines
see Cummins Service
Bulletin 3810340-07
for the latest approved
oil requirements.
APPROVED COOLANTS**
LME Part Number Manufacturer Product Brand Name Comments
-5083-A Kost USA DefendAL HD NF ELC
LME/10880897/January 30, 2011/en
For MTU Engines see MTU

Lubrication Guide
A001061/32E for the latest
approved coolant
requirements.
For Cummins Engines see
Cummins Lubrication Guide
3666132-04 for the latest
approved coolant
requirements.
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COOLANT SYSTEM VOLUME*

Engine Truck Model Volume L (US Gal)
MTU20V T282 870 (230)
QSK60 T282 814 (215)
QSK60 TI 274 870 (230)
AIR CONDITIONING SYSTEM FREON
LME Part Number Manufacturer Product Brand Name Classification Comments
Liebherr AC systems
utilize R134a
refrigerant and PAG 46
compressor lubricating
oil.
AUTOLUBE SYSTEM APPROVED GREASE**

-5079-A Mobil XHP 320 Mine 0
N/A Mobil Mobilux EP-2 2
N/A Mobil Mobilux EP-0 0
N/A Conoco Super-Sta M No. 2 2
N/A Conoco Super-Sta M No. 0 0
N/A Conoco Megaplex XD5 No. 2 2
N/A Conoco Megaplex XD5 No. 0 0
N/A Century Lubricants Replex 2
N/A Century Lubricants Replex 1
N/A Bel-Ray MOLYLUBE 126 EP 1
N/A Bel-Ray MOLYLUBE SP4 0
N/A Caltex Starplex Moly MPGM 2
AUTOLUBE SYSTEM VOLUME*

51417AF 95 (25)
10339756 95 (25)
10299454 57 (15)
ALTERNATOR APPROVED GREASE**
10496084 Mobil Mobilith SHC 220 2
N/A Conoco Triton 220 Grease 2
Revision Dates Approved Description
LME/10880897/January 30, 2011/en
WHEEL MOTOR COOLING BLOWER APPROVED GREASE**
10496085 Mobil Polyrex EM 2
N/A Shell Aeroshell 7 N/A
N/A Shell Albida LC2 2
N/A Conoco Polytak 2 2
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TRACTION MOTOR APPROVED GREASE**

10496083 Shell Retinax Grease LX2 2
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Major Component Replacement Guidance
4.3 Major Component Replacement Guidance
LME/10880897/January 30, 2011/en
Major Component Replacement Guideline_000_Rotated.tif

Fig. 4.3-1: Major Component Replacement Guidance
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Preventive Maintenance Daily Inspections and Checks
4.4 Preventive Maintenance Daily Inspections

and Checks
4.4.1 Setup
► Follow the haul truck safety precautions. [Reference: Haul Truck
Safety]
ATTENTION
If a member of the maintenance crew does not have daily access to the
haul trucks, this list of inspections and checks should be incorporated into
the pre-operations safety check for the operator.
4.4.2 Procedure
1. Check the engine oil level.
2. Check the fuel level.
3. Check the fluid level in the dump system hydraulic tank .
4. Check the fluid level in the steering and brake hydraulic tank .
5. Inspect the steering linkage for loose or missing components.
6. Inspect the suspensions and the control arms for loose or missing
components.
7. Check that the tires are inflated to a serviceable level.
8. Check the tire and rim assemblies for indications of incorrect torque
and broken fasteners.
9. Check that the rims are free of damage.
10. Check the visual indicator on the dump system pressure filters, if they
are lifted, schedule a filter change.
11. Check the visual indicator on the brake and steering system pressure
filter, if they are lifted, schedule a filter change.
12. Check the axle box.
– The access door must close securely.
– Make sure the cooling air outlets and air ducts are not damaged
and are free of obstructions.
13. Check the exhaust system:
– All the brackets must be in place.
– Investigate blackened areas that indicate a leak.
– Make sure the exhaust is not blocked or clogged.
LME/10880897/January 30, 2011/en
14. Inspect all the belts on all rotating components for wear, twists or loose
fit.
15. Inspect all the guards to make sure that they are correctly installed and
not damaged.
16. Inspect the radiator grill for obstructions and check the coolant level.
17. Inspect the frame and make sure there are no missing or loose
component fasteners.
18. Make sure that the fire extinguishers are fully charged.
19. Clean out the air cleaner dust bin.
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Preventive Maintenance Daily Inspections and Checks
20. Make sure that the air cleaner housings have no damaged or loose
fasteners.
21. Check the air intake ducting and hump hoses (flexible rubber ducting
connectors).
– Make sure that there are no signs of damage or deformations.
– Make sure that the hump hoses are correctly installed.
22. Inspect the dump body, as follows:
– Make sure that the dump body pivot pins are in place with the
retaining bolts in place.
– Make sure that the lighting on the dump body is correctly
attached and light bulbs are serviceable.
– Make sure that the rock knockers and mud guards are in good
condition and correctly attached, as applicable.
– Make sure the proximity switch target is not damaged.
– Inspect the dump body for deformation or damaged.
23. Inspect the components on deck as follows:
– Make sure that the grid and control box are free of obstruction
and that all doors are securely closed.
– Clean and adjust the mirrors as applicable.
– Make sure the ladders are free of debris.
24. Inspect the components in the cab as follows:
– While the engine is running, push the reset button on the filter
restriction indicator and verify the position indicator did rise after
being reset and remained in the green area. If the position
indicator rose to the red area, or did not rise after reset, tell the
correct maintenance person.
– Make sure all circuit breakers are closed.
– Make sure the system warning lights and alarms are operational.
– Make sure the horn is functional.
– Make sure the backup alarm is operational.
– Make sure all the lights are operational.
– Examine the cab air vent and replace the filter if necessary.
– Make sure that the wipers are operational and that there is
sufficient washer fluid.
– Examine the seat belts for wear or damage.
– Make sure the cab floor is free of debris and that the windows
are clean.
25. After the haul truck has been started, make sure that all the gauges
have normal indications.
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Preventive Maintenance Master Schedule
4.5 Preventive Maintenance Master Schedule

[Reference: ]
Maintenance/Inspection After Tasks to be Performed

Service Hours
500 hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
Intervals
Special
Electrical, 24VDC
• Examine the condition of the batteries and make sure all connections
are secure.
• Test the engine shutdown feature by pressing the shutdown switch

inside the cab.
• Test the engine shutdown feature by pressing the ground-level

shutdown switch.
Engine
• Examine the engine and area around the engine for fluid leaks.
• Examine the exhaust system for leaks and loose fasteners.
• Examine the turbo chargers for leaks, vibration, and unusual noise.
• Examine the crankcase breather assembly. Verify piping is intact and

connections are secure.
• Inspect the exhaust bellows and flexible blanket.
as prescribed Perform engine maintenance as described in engine maintenance

by engine manual (MTU or Cummins).
manufacturer
Fluids, Filters, and Lubrication

• Replace the breather filter for the gear oil cooling system.
• Replace the breather filter for the brake and steering hydraulic tank.
• Replace the breather filter for the dump system hydraulic tank.
• Replace engine air cleaner filters.
• Examine the entire air intake system for damage, loose connections,
LME/10880897/January 30, 2011/en
and loose fasteners.
• Using the auto-lube test feature, inspect each lubricated joint for
evidence of fresh grease.
• Take oil samples and check fluid fill levels. * Sample oil for Cummins
engines every 250 hrs.
• Replace the engine oil and oil filters.
• Check the visual indicators on each filter housing. Replace or investigate

if an indicator is not seated.
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Service Hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
500 hours
Intervals
Special
Fluids, Filters, and Lubrication
• Inspect the fuel lines for leaks and excessive wear.
• Replace brake and steering system pressure filter element.
• Replace dump system pressure filter element and return filter element
(if equipped).
• Replace the breather for the pump drive gear box.
• Replace the filter elements in the gear oil cooling system.
• Replace pre-filter / water separator and primary fuel filters. NOTE: Filter
life expectancy is based on fuel quality. Ensure the fuel used meets the
standards specified by your engine manufacturer.
• Drain and replace the oil in each front wheel.
• Take a sample of the engine coolant. Adjust the coolant concentration

and fill level as necessary.
• Replace the oil in the pump drive gear box.
• Drain and replace the oil in each gearset.
Frame Assembly
• Inspect the exterior and interior of axle box.
• Inspect the dump body pivot pin and retainer bolt. Verify the joint is
receiving an adequate supply of fresh grease.
• Examine the hoist cylinder bushings and pins (upper and lower) .
• Check rear control arm bushing and pin cover. If any signs of contact
between cover and control arm, control arm bushing may be worn,
perform bushing check. Repair damage to cover or cover fasteners.
• Ensure handrails, ladders, and steps are in place and securely fastened.
• Remove and inspect the pivot pin retainer bolt, look for indications of the
bolt being subjected to shear stress. Replace the retainer bolt,
regardless of condition.
• Perform a visual inspection of the frame for damage and cracks.

LME/10880897/January 30, 2011/en
• Inspect the fuel and hydraulic tank mounting bolts, ensure they are not
loose or damaged.
• Torque retainer bolts of rear control arm-to-frame and rear control arm-
to-axle box back to original value.
Hydraulic
• Inspect all the hydraulic hoses for leaks and excessive wear.
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Service Hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
500 hours
Intervals
Special
Hydraulic
• Inspect the hoist and steering cylinders for damage or significant leaks.
A light film of oil around the gland wipers is considered normal.
• Inspect and lubricate the U-joints on the pump drive shaft and the pump
drive gear box input shaft bearing.
• Check the precharge for the brake accumulators and record the results.
• Check the precharge for the steering accumulator and record the result.
• Check the precharge for the unloader accumulator and record the result.
Operator's Cab
• Ensure the seats are securely fastened to cab deck. Examine the seat
belts for damage.
• Inspect and lubricate the cab door latches.
• Inspect the cab mounts and shunt bolts below the ROPS cab, ensure
they are not loose or damaged.
Radiator
• Examine the fan blades for damage.
• Examine the cooling hoses for leaks, loose clamps, and wear.
• Inspect all mounting hardware and stabilizers, ensure they are not loose
or damaged.
Wheels, Tires, Suspensions, and Brakes
• Inspect the integrity and condition of the steering stop pads.
• Inspect front wheel assembly for leaks (specifically the brake calipers
and face seal).
• Inspect the rear wheel assembly to axle box connection for loose or
damaged fasteners (specifically those in the five to seven o'clock
position).
• Examine the front control arm bushings.
• Perform a suspension assessment using the data collected by the weigh

LME/10880897/January 30, 2011/en
system download.
• Inspect the front brake pad and disc thickness.
• Inspect the rear brake pad and disc thickness.
• Perform wear limit checks for the drag links and rear control arm
bushing, steering cylinder and tie rod bushing, and idler arm bearing.
• Perform the lower king pin bushing wear check (includes toe-in check).
• Torque the steering arm fasteners back to the original value.

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Service Hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
500 hours
Intervals
Special
Wheels, Tires, Suspensions, and Brakes
• Torque the upper and lower kingpin fasteners back to the original value,
generally at a 5000 hour interval to coincide with rim removal, allowing
full access to all fasteners.
• Torque rear brake caliper fasteners back to the original value.
• Torque tie rod bushing retainer fasteners back to original value.
• Torque steering cylinder pin retainer fasteners back to original value.
10000 Discard and replace the steering arm fasteners, regardless of the bolt
condition.
10000 Discard and replace the lower kingpin fasteners, regardless of the bolt
condition.
conditional Torque front brake caliper fasteners back to the original value whenever
part is accessible.
conditional Torque rear wheel assembly to axle box fasteners back to original value
whenever part is accessible.
conditional Torque rear brake adapter and disc mounting fasteners back to original
value whenever part is accessible.
conditional Inspect the front control arms based on the following intervals. If a crack
is discovered replace the control arm. • Service hours ≤ 20K, inspect
every 5000 hours • Service hours > 20K < 30K, inspect every 2500 hours
• Service hours ≥ 30K, inspect every 1500 hours
Traction Alternator
• Visually inspect the main rectifier enclosure. Verify all fasteners are
secure. Replace any worn seals.
• Remove outlet box cover. Visually inspect stator output leads, protective
sleeving, and insulation for cracking or other signs of physical damage.
• Clean inside the alternator outlet box and HARTING plug using
compressed dry air < 100 PSI.
• Visually inspect the grease expulsion port. Lubricate the bearing

following the guidelines explained in Siemens SSB49-2.
• Verify the exciter leads at terminal strip are secure.

LME/10880897/January 30, 2011/en
6000 Measure the insulation to ground on main rotating assembly. Record the
resistance reading after one minute of applying 500 volts from a megger.
The reading must be > or = 1MΩ.
6000 Measure the insulation to ground on main stator assembly. Record the
resistance reading after one minute of applying 500 volts from a megger.
The reading must be > or = 1MΩ.
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Service Hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
500 hours
Intervals
Special
Traction Alternator
6000 Measure the insulation to ground on exciter and PMG stationary fields.
Record the resistance reading after one minute of applying 500 volts
from a megger. The reading must be > or = 1MΩ.
6000 Measure the insulation to ground on the exciter armature assembly.
Record the resistance reading after one minute of applying 500 volts
from a megger. The reading must be > or = 1MΩ.
6000 Verify the exciter armature and rotating rectifier connections are secure.
Control Box
• Vacuum inside the front and rear cabinet compartments. Compressed
dry air < 100 PSI is also permissible, if necessary.
• Inspect the condition of the control box access covers. Ensure the foam
sealing strip is intact and that each cover latches properly.
• Remove and replace the Cyclone main filter element.
• Check the water/glycol cooling circuit for signs of leakage and loose
connectors.
• Verify the electrical wiring inside the control box is secure. Check for
loose connections at plugs, terminals, etc.
• Verify the fastener hardware inside the control box is secure. Check for
loose fasteners such as bolts, nuts, etc.
• Download the fault history file from the PLC.
• Remove and replace the Cyclone secondary filter element.
Grid Box Assembly

• Measure the winding insulation to ground. Record the resistance
reading after 30 secs. of applying 500 volts from a megger. NOTE:
Siemens grid box resistance must be > 1MΩ.
• Verify the grid blower motor electrical connections are secure.
• Assess the grid blower motor by listening for unusual noise, particularly
the grid blower motor bearings.
• Visually inspect the grid motor fan wheel for cracks.

LME/10880897/January 30, 2011/en
• Using a flashlight, visually inspect the grid resistors (while installed) for
signs of damage. Look for damage such as melted elements or
permanent deflection of the ribbon elements.
• Visually inspect the condition of the grid blower motor. The interior and
exterior of the motor should be free of dirt, oil, grease, water, carbon
dust, etc. Periodic cleaning is mandatory.
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Service Hours
1000 hours
1500 hours
2000 hours
2500 hours
3000 hours
5000 hours
500 hours
Intervals
Special
Main Blower Motor
• Assess the main blower motor by listening for unusual noise, particularly
the main blower motor bearings.
• Measure the winding insulation to ground. Record the resistance

reading after 30 secs. of applying 500 volts from a megger. The reading
must be > 5MΩ.
• Regrease the main blower bearings.
Traction Motor
• Regrease the traction motor bearings.
LME/10880897/January 30, 2011/en
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4.5.1 Preventive Maintenance Reference Structure

The maintenance references use the following identification structure:
System Code Series Number Revision

LME→ 00 →Electrical, 24VDC 00→ 00
10→Engine
20→Fluids, Filters, and
Lubrication
30→Frame Assembly
40→Hydraulic
50→Operator Cab
60→Radiator
70→Safety Related
80→Wheels, Tires,
Suspensions, and Brakes
90→Traction Alternator
100→Control Box
110→Grid Box Assembly
120→Main Blower Motor
130→Traction Motors
Example:
PM Legend.tif
Fig. 4.5-1: Preventive Maintenance Reference Structure
LME/10880897/January 30, 2011/en
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500-Hour Preventive Maintenance References
4.6 500-Hour Preventive Maintenance

References
The following procedures are linked to the 500-hour preventive

maintenance (PM) tasks. Use this as supporting material when performing
the associated PM task.
Reference ID Description/Title
LME-00-01-01 [Reference: Battery Maintenance]
LME-20-01-00 [Reference: Oil Sampling Guideline]
LME-20-08-01 [Reference: Air Intake System Inspection and
Replacement Procedures]
LME-30-01-01 [Reference: Axle Box Inspection]
LME-40-01-01 [Reference: Hydraulic Hoses Inspection]
LME-40-02-00 [Reference: Pump Drive Service Procedure]
LME-40-03-01 [Reference: Brake Accumulator Pre-Charge Check,
Drain, and Pre-Charge Procedure]
LME-40-04-01 [Reference: Steering Accumulator Pre-Charge Check,
Drain, and Pre-Charge Procedure]
LME/10880897/January 30, 2011/en
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LME-00-01-01 - Battery Maintenance
4.7 LME-00-01-01 - Battery Maintenance
Setup
Safety]
► Charge the Front Suspensions, if necessary.
Procedure
1. Do a visual inspection of the battery box and the battery connections.
– Clean dirt and debris from inside the battery box.
– Make sure the battery box drain lines are not blocked.
– Check cables for signs of damage, and replace as necessary.
– Check cables for loose connections, and tighten connections as
necessary.
– Check battery posts for corrosion on the terminals, and clean as
necessary.
– Check the battery hold-down clamps for damage, and tighten
clamps as necessary.
2. Check electrolyte levels of the batteries.
– Remove the vent caps, look into the fill wells and check the
electrolyte level. Cloudy or tainted electrolyte can be a result of
overcharging or excessive vibration.
– Add distilled water until the electrolyte level is 3 mm (0.12 in)
below the bottom of the fill wells. The minimum level is at the top
of the plates.
– Clean and replace the vent caps.
LME/10880897/January 30, 2011/en
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LME-20-01-00 - Oil Sampling Guideline
4.8 LME-20-01-00 - Oil Sampling Guideline
Setup
Safety]
4.8.2 General Oil Sampling Guidelines

Proper sampling procedures build the foundation of an effective oil analysis
program. Follow these guidelines to ensure the samples best represent the
body of oil being analyzed.
• Oil sampling must be done during normal operation of the
equipment or within 30 minutes after the haul truck is shut
down. This ensures that the oil is warm and truly
representative of the conditions within the compartment.
• It is important that the sample container is totally clean and
free of moisture before the sample is taken.
• The container should be properly sealed to prevent any
contamination or loss of oil during transit.
• Ensure the sample information sheet is completely and
correctly filled out.
• Courier or mail the sample to the laboratory immediately, so
as to receive the analysis results as soon as possible.
• Do not mix coolant sample pumps and oil sample pumps.
• Always check oil level after taking each sample and replenish
fluid as needed.
• Where equipped, inspect magnetic plugs installed on
reservoirs or sample ports.
Oil Sampling Locations

Oil samples are taken from the following locations every 500 hours:
1. Engine oil
2. Bearing housing of left and right rear wheel assembly
3. Left and right front wheels
4. Brake and steering hydraulic tank
LME/10880897/January 30, 2011/en
5. Dump system hydraulic tank

6. Pump drive gear box
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LME-20-01-00 - Oil Sampling Guideline
Method 1: Suction (Vacuum) Pump

1. Install a used sample bottle on the suction pump.
2. Insert pump hose into the tank to approximately midpoint. Make sure
the sample is taken from about the midpoint or within the working level
of the oil in the compartment and not from the bottom where sludge
accumulates.
3. Operate the pump until the bottle is 3/4 full then discard this sample.
4. Install a clean sample bottle on pump and fill to 3/4 full and properly
seal, and forward this sample to the laboratory.
ATTENTION
Do not operate the pump on its side or overfill the sample bottles.
5. Flush the pump with clean oil, or properly clean as per the
maintenance instruction.
Method 2: Pressure Line or Valve Connection Oil

Sampling
1. A suitable drain valve can be connected to the "T" in an oil pressure
line. This discharge side of the valve should be fitted with a pipe plug
or cap.
2. Flush the sample line before taking the oil sample. This is done by
flowing oil through the line to eliminate any residual oil from the sample
line (the exact volume can vary based on the length and diameter of
the sample line).
3. Move a clean sample bottle into the stream and fill to 3/4 full and
properly seal the bottle and then forward the sample to the laboratory.
Method 3: During Oil Change

1. Do not take sample as oil starts to drain.
2. Do not take sample as oil finishes draining.
3. Take sample directly into sample bottle after the oil has been running
for a short period.
4. Do not take sample from the oil collected in another container.
5. Fill the sample bottle 3/4 full and properly seal the bottle and then
forward the sample to the laboratory.
LME/10880897/January 30, 2011/en
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LME-20-08-01 - Air Intake System Inspection and Filter Replacement
Procedures
4.9 LME-20-08-01 - Air Intake System Inspection

and Filter Replacement Procedures
Setup
1. Follow the haul truck safety precautions.[Reference: Haul Truck
Safety]
Air Intake System Inspection Procedure

Follow this procedure to inspect the air filter system.
CAUTION
The air cleaner prevents unwanted dirt and debris from entering the engine.
► Be careful not to permit dirt and other unwanted material into the air
intake system.
Inspect the entire air intake system, from each air cleaner housing to the
engine turbo inlet ports. Look for damage or wear that allows unfiltered air
to enter the system.
1. Inspect the piping for pin holes, cracks, loose connections, or other
damage.
2. Inspect the piping weld seams for pin holes, cracks, corrosion, or other
damage.
3. Make sure all piping is aligned to minimize joint stress.
4. Make sure all piping supports are intact and securely fastened.
5. Inspect each hump hose for cracks, tears, or joint separation.
– A proper hump hose connection consists of two clamps per side,
equally spaced with no contact between the two clamps.
– The fastener portion of the clamps should be positioned 180º
from one another.
Air Filter Replacement Procedure

Follow this procedure to replace the air filters.
LME/10880897/January 30, 2011/en
1. Open the dust cups by releasing the latches. Remove the dirt and
unwanted material.
2. Visually inspect the pre-cleaner tubes for blockage. Clear dirt using a
rigid brush.
3. Inspect the ejection valves in each dust cup for damage. The valves
should open freely.
4. Open the service cover by releasing the latches.
5. Remove and discard the primary filter element.
6. Remove and discard the safety filter element.
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LME-20-08-01 - Air Intake System Inspection and Filter Replacement
Procedures
7. Inspect the interior of the filter housing for cracks, holes, or damage.
8. Thoroughly inspect the new safety filter for damage before installing.
9. Install the new safety filter element, making sure to seat the filter
properly.
10. Thoroughly inspect the new primary filter for damage before installing.
11. Install the new primary filter element, making sure to seat the filter
properly.
12. Inspect and replace any damaged seals or gaskets.
13. Reattach all the service covers and fasten the latches. Do not force a
cover to close. If there is difficulty closing a cover check the filter for
proper seating.
14. Repeat the above steps for the opposite side of the haul truck.
LME/10880897/January 30, 2011/en
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LME-30-01-01 - Axle Box Inspection
4.10 LME-30-01-01 - Axle Box Inspection
Setup
Safety]
Exterior Inspection of the Axle Box

Visually inspect the exterior of the axle box for the conditions that follow:
1. Weld beads and base material are free of visual evidence of cracks.
2. Mounting brackets and connection points are not bent, deformed, or
broken.
3. Mounting bolts and hose clamps are tight.
4. Rear wheel assembly to axle box fasteners are not loose or damaged.
5. Hose connections are not leaking or loose.
6. Axle box door is in place and the door seals correctly.
7. Hoses and wires passing through the axle box exterior are not worn
or chaffed.
8. Axle box grommet shows no sign of excessive wear, cracking, or
damage.
9. Bulkhead openings for hoses and wiring are correctly sealed.
10. Axle box cooling ducts are in good condition and correctly connected.
11. Cable clamps at cable entry into axle box are tight and all support
chains are intact and securely mounted.
Interior Inspection of the Axle Box

Remove accumulated dirt from inside the axle box, and do a visual
inspection of the interior of the axle box for the following conditions:
1. Accessible weld beads and base material are free of visible evidence
of cracks.
2. Mounting brackets and connection points are not bent, deformed, or
broken.
3. Hoses and hose connections are not leaking or loose.
4. Final drive shows no sign of oil leaking.
LME/10880897/January 30, 2011/en
5. Hydraulic lines are not leaking or loose.

6. Fire sleeve material is intact and clamps secure.
7. Wiring is correctly supported and not missing clamps.
8. Axle box service lighting works correctly.
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LME-30-01-01 - Axle Box Inspection
Oil Leakage Inspection

1. Clean the exterior surface of the cap fitting.
2. Place a small container below the cap fitting:
– If there is oil leakage during the inspection, the container can be
used to contain the spill.
– The container can also be used to measure the volume of fluid
loss.
3. Loosen and remove the cap fitting (1) from the bulkhead connector.
4. With the cap removed, do a visual inspection of the outlet for any signs
of oil leakage.
5. If oil leakage is found, carefully document the leakage amount and
report the condition to your maintenance supervisor.
ATTENTION
Oil leakage from the hose outlet indicates the shaft seals are leaking.
► If you find any oil leakage, increase the frequency of the hose
inspection until the leak can be repaired.
► Failure to inspect and empty oil from the drainage hose can cause
damage to the traction motor.
► The need to replace the gear set can be determined based on the
collected volume or a noticed increase in volume between
inspections.
6. Reinstall the cap and clean up any oil spills.
7. Repeat [Reference: step 1] to [Reference: step 6] for the opposite rear
wheel assembly.
LME/10880897/January 30, 2011/en
LME-30-01-01_300_04.tif
Fig. 4.10-1: Oil Leakage Inspection Location
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LME-40-01-01 - Hydraulic Hoses Inspection
4.11 LME-40-01-01 - Hydraulic Hoses Inspection
Setup
Safety]
Procedure
WARNING! Hydraulic fluid can inject the skin and cause injury if ingested.
► Always put on protective equipment when you do procedures that
include maintenance on hydraulic systems and components.
1. Do a visual inspection of the complete hydraulic circuit for signs of

leaking hydraulic fluid. Leaking fluid can collect airborne dust and dirt
and will run down vertical surfaces.
2. Replace the hoses or fittings if any of these conditions are found:
– Inspect the external surface of the hoses for signs of hardening,
softening, cracking, kinking, crushing, flattening, or twisting
conditions.
– Inspect hoses for signs of heat damage such as blistering or
charred surfaces.
– Inspect hoses and fittings for leaking, restricted, crimped,
cracked or broken material.
– Inspect hoses for wear and abrasion caused by mechanical
movement.
– Inspect hoses for any damage that extends through the outer
reinforcement ply.
– Inspect hoses for deformation or changes in shape, such as
bulging or swelling of the hose (regardless of applied system
pressure).
– Inspect for improperly joined hoses (such as splices made by
sliding hose ends over a piece of tubing and clamping the hose
to the tube).
– Inspect hose fittings for evidence of external damage, leakage,
corrosion, including damage that may have been induced from
improper installation (damaged threads, damaged hexes, etc.).
– Inspect hose-to-fitting termination points for signs of hose
LME/10880897/January 30, 2011/en
slippage or separation from the fitting.

– Inspect the hose runs for correct routing. Make sure lengths are
sufficient and not causing a radius to be too close or tight.
– Inspect the hose runs for locations where straps or fasteners
have come loose, causing a hose to no longer be secure.
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LME-40-02-00 - Pump Drive Service Procedure
4.12 LME-40-02-00 - Pump Drive Service

Procedure
Setup
Safety]
WARNING! Fall prevention!

► Always put on an approved safety harness and attach it to an
applicable anchor-tie-off point when you do any maintenance task
above ground.
Required Tools and Materials

Tools and Materials Liebherr Part Number Notes
Lithium NLGI 1 grease N/A Commercially available
Lithium NLGI 2 grease N/A Commercially available
Table 2: Required Tools and Materials
Procedure
1. Remove the necessary guards to get access to the U-joint.
2. Using a pipe wrench, move the drive shaft back and forward checking
for play between the traction alternator and U-joint.
– If play is discovered, investigate and correct the cause.
3. Using a pipe wrench, move the drive shaft back and forward checking
for play between the pump drive and the U-joint.
– If play is discovered, investigate and correct the cause.
4. Apply lithium NLGI 1 grease to the U-joints, and the slip shaft.
5. Apply lithium NLGI 2 grease to the input bearing on the pump drive.
6. Install any guards removed at the start of this procedure.
LME/10880897/January 30, 2011/en
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LME-40-03-01 - Brake Accumulator Pre-Charge Check, Drain, and
Pre-Charge Procedures
4.13 LME-40-03-01 - Brake Accumulator Pre-

Charge Check, Drain, and Pre-Charge
Procedures
4.13.1 Brake Accumulator Pre-charge Check

1. Follow the haul truck safety precautions. [Reference: haul
truck Safety]

3/4 inch wrench N/A Commercially available
Nitrogen Charging Kit T-107-T [Reference: Service Tools]
1. Remove all hydraulic pressure from the fluid side of each accumulator
before you begin the brake accumulator pre-charge procedure.
2. Make sure the bleeder valve (1) is fully closed.
3. Disconnect the tank hose assembly (4) from the charging assembly
(5).
4. Remove the valve cap (7).
5. Connect the adapter (3) to the valve stem (8).
6. Tighten the adapter (3) by hand securely enough to prevent gas
leakage, but do not over tighten.
7. Open the shutoff valve (2).
DANGER! The accumulators are pressurized with nitrogen gas.

► Pressurized gas can cause injury and can force the valve stem
assembly from the accumulator if the valve assembly is turned before
the pressure is released.
► Make sure you turn only the small swivel nut and always put on
protective clothing, gloves, and face and eye shields when you do
procedures that includes charging or discharging a pressurized
system.
8. Put a 3/4 inch wrench on the swivel nut (9) of the valve stem (8).
9. Turn the swivel nut (9) counterclockwise four full turns, or until the pre-
charge pressure shows on the gauge (6).
10. Record the pressure indication.
LME/10880897/January 30, 2011/en
11. Turn the swivel nut (9) clockwise to the fully closed position.
12. Open the bleeder valve (1).
13. Disconnect the adapter (3) from the valve stem (8).
14. Install the valve cap (7).
15. If the accumulator pressure is more than 124 bar (1798 psi), do to the
[Reference: Brake Accumulator Drain Procedure].
16. If the accumulator pressure is less than 124 bar (1798 psi), do the
[Reference: Brake Accumulator Drain Procedure]
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4.13.2 Brake Accumulator Drain

(5).

system.
9. Carefully open and close the bleeder valve (1) until the necessary
pressure, 124 bar (1800 psi), shows on the gauge.
- OR -
10. To completely drain the pressure:
– Open the bleeder valve (1) until all the pressure is released from
the accumulator.
– Turn the swivel nut (9) clockwise to the fully closed position.
– Open the bleeder valve (1).
– Disconnect the adapter (3) from the valve stem (8).
– Install the valve cap (7).
LME/10880897/January 30, 2011/en
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4.13.3 Brake Accumulator Pre-Charge

Nut T-107-A [Reference: Service Tools]
Nipple T-107-B [Reference: Service Tools]
Nitrogen N/A Commercially available
1. Make sure the bleeder valve (1) and shutoff valve (2) are fully closed.
2. Connect and tighten the tank hose assembly (4) from the charging
assembly (5) to the nitrogen tank.
NOTICE
Some nitrogen tanks use different nipples and nuts than those installed on
the tank hose assembly.
► It may be necessary to replace the installed nipple with T-107-B and
the installed nut with T-107-A. [Reference: Service Tools]

system.
8. Slowly open the nitrogen tank valve and the shutoff valve (2), and then
close the two valves to let the gauge (6) adjust.
9. If the accumulator pressure is more than 124 bar (1798 psi),
– Decrease the brake accumulator pre-charge by performing the
[Reference: Brake Accumulator Drain Procedure]
10. Once the correct pressure, 124 bar (1798 psi), shows on the gauge
LME/10880897/January 30, 2011/en
(6), complete the remaining steps.

11. Close the shutoff valve (2) and the nitrogen tank valve.
16. Disconnect the tank hose assembly (4) from the nitrogen tank.
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LME/10880897/January 30, 2011/en
LME-40-03-01_300_01.tif
Fig. 4.13-1: Brake Accumulator Pre-Charge Check, Drain, and Pre-Charge Procedures
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LME-40-04-01 - Steering Accumulator Pre-Charge Check, Drain, and
4.14 LME-40-04-01 - Steering Accumulator Pre-

Procedures
4.14.1 Steering Accumulator Pre-charge Check

1. Follow the haul truck safety precautions. [Reference: Haul
Truck Safety]
2. Relieve the hydraulic pressure on the fluid side of the
accumulator before you start this procedure.

(5).
DANGER
The accumulators are pressurized with nitrogen gas.
procedures that include charging or discharging a pressurized
system.
charge pressure shows on the gauge (6). Record the pressure
LME/10880897/January 30, 2011/en
indication.
13. If the accumulator pressure is more than 117 bar (1700 psi) , do the
[Reference: Steering Accumulator Drain Procedure]
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4.14.2 Steering Accumulator Drain

(5).
DANGER
system.
- OR -
the accumulator.
LME/10880897/January 30, 2011/en
4.14.3 Steering Accumulator Pre-Charge

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NOTICE
DANGER
system.
9. If the accumulator pressure is more than 117 bar (1700 psi):
– Follow the Steering Accumulator Drain procedure to decrease
the steering accumulator pre-charge.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
LME-40-04-01_300_01.tif
Fig. 4.14-1: Steering Accumulator Pre-Charge Check, Drain, and Pre-Charge Procedures
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LME-40-05-00 - Unloader Accumulator Pre-Charge Check, Drain, and
4.15 LME-40-05-00 - Unloader Accumulator Pre-

Procedures

Procedure
Truck Safety]
2. Make sure the hydraulic pressure on the fluid side of each
accumulator is relieved before proceeding.

(5).

system.
LME/10880897/January 30, 2011/en

14. If the accumulator pressure is more than 124 bar (1798 psi), do to the
[Reference: Unloader Accumulator Drain Procedure].
15. If the accumulator pressure is less than 124 bar (1798 psi), do the
[Reference: Unloader Accumulator Pre-charge Procedure].
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4.15.2 Unloader Accumulator Drain Procedure

(5).

system.
- OR -
the accumulator.
LME/10880897/January 30, 2011/en
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4.15.3 Unloader Accumulator Pre-Charge Procedure

NOTICE

system.
9. If the accumulator pressure is more than 124 bar (1798 psi),
– Decrease the brake accumulator pre-charge by performing the
[Reference: Unloader Accumulator Drain Procedure]
LME/10880897/January 30, 2011/en

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LME/10880897/January 30, 2011/en
LME-40-03-01_300_01.tif
Fig. 4.15-1: Unloader Accumulator Pre-Charge Check, Drain, and Pre-Charge Procedures
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LME-80-16-00 - Suspension Monitoring and Maintenance
4.16 LME-80-16-00 - Suspension Monitoring and

Maintenance
4.16.1 Pre-Maintenance Fault Review

Truck Safety]
2. Charge the Front Suspensions, if necessary.
3. Charge the Rear Suspensions, if necessary.
• Review the percentage of suspension pressure
faults over the most recent one hundred load
cycles. The Additional Information section gives
guidance information on performing the
suspension fault review. The fault review is most
effective when performed at the beginning of a
maintenance event or in preparation of a
maintenance event allowing time to investigate
possible issues found.
• If more than 50% of the load cycles, for a
particular suspension during the most recent
100 load cycles, recorded a pressure fault or
warning (the sum of both) continue the
procedure that follows.
NOTICE
If there is an indication that the suspension may be compressed more than
normally observed (has dropped), during loaded operations, or while
parked for maintenance, this is also a reason to proceed to the Visual
Inspection.
4.16.2 Visual Inspection

1. Clean the suspension. Remove the protective shield if the suspension
has one installed.
2. Closely inspect the complete component for leaking oil, deformities in
the glad seal, peeling, or flaking of the exposed chrome or any other
signs of problems.
3. Soap the suspension to identify any nitrogen leaks that possibly
caused the suspension to loose the charge. Pay attention to the areas
around the charge valve, transducer, glad seal, and flange.
LME/10880897/January 30, 2011/en
4. If any part of the chrome is scuffed, notched, scratched, or damaged,

inspect the seal directly in that area for evidence of the initial failure.
5. If the suspension seal is extruded, cracked, or shows other signs of
failure, replace the suspension during this maintenance event, or
schedule the suspension replacement soon.
6. Investigate the source of any leaking oil conditions. Leaking oil
conditions are normally shown by a collection of dust or dirt.
7. If suspension is leaking oil and the leak source cannot be corrected in
place, replace the suspension during this maintenance event, or
schedule the suspension replacement soon.
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8. Inspect the suspension pin and bushings for signs of excessive wear
or damage.
9. Verify the pin/bushing joint is being lubricated by looking for evidence
of fresh grease.
10. Inspect the charge valve and transducer for signs of leaking or
damage.
11. Make sure the charge valve cap is correctly installed.
12. Check for signs of leaking or damage through a soap test to determine
if nitrogen is escaping.
13. If the transducer or charge valve needs replacement, remove the
suspension charge in accordance with all safety requirements.
14. Replace the failed part, and charge the suspension. [Reference: Front
Suspension Charge Procedure], or [Reference: Front Suspension
Charge Procedure]
15. If no problem was found, then continue on the Suspension Charge
Check. [Reference: Front Suspension Charge Procedure]
4.16.3 Suspension Charge Check

1. Jack the haul truck frame. Follow the Jacking Points Guidelines to
know the locations to jack the haul truck frame.[Reference: Jacking
Points Guidelines]
2. Fully extend the suspension and record the charge pressure.
3. If the pressure is low, based on the pressures shown in the related
charge procedures, and the transducer reads accurately when it is
compared to a reference pressure gauge,
– Recharge the suspension and verify oil level in accordance with
the related front or rear suspension check procedure.
[Reference: Front Suspension Test and Charge Procedure], or
[Reference: Rear Suspension Test and Charge Procedure]
4. Record the suspension charge in a suspension log.
LME/10880897/January 30, 2011/en
LME-80-16-00_01.tif
Fig. 4.16-1: Suspension Charge Log (Sample)
- OR -
5. Replace the suspension. If the suspension has been recharged within
the last 500 hours, and the charge has again been lost and a cause
cannot be identified as something that can be corrected on the haul
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truck, replace the suspension. Record the reason for removal in LISA
or on the Component Exchange Report as "suspension would not hold
charge", and list the intervals of the recent charges.
General Notes:
If the suspension charge pressure and the transducer both check out
as acceptable, but there are still a high percentage of faults/warnings
being recorded in the download data, the root cause is most likely
something other than the suspension. In this case, other weigh system
related components, for example, you can investigate the weigh
system setup parameters, signal wiring and connectors, and other
related systems.
Additionally, it is important to correctly document this observation in

the suspension log stating that erroneous faults are showing up in the
downloaded data. This ensures a record of the occurrence is archived
and available for future troubleshooting purposes.
ATTENTION
Two thresholds are used in the above procedure:
• 50% of the load cycles showing a pressure fault or warning.
• recharge interval of 500 operating hours.
► These are not strict mandates. Local conditions can dictate a different
threshold. Affiliates with experience indicating that a different
threshold is more appropriate are encouraged to provide that
feedback to the LME Maintenance and Reliability Group.

Faults)
1. Load the .cvs file into the Suspension Health Monitor .exe file and
review the last 100 load cycles (under File / Open Files, navigate to
the location of your .cvs file for the truck in question).
2. If the Suspension Health Monitor .exe file is not available, review the
most recent rows of columns Q, R, S, and T within the .csv file for the
haul truck in question, which will be the rows at the bottom of the
spreadsheet.
3. 0 indicates no pressure faults or warnings occurred, 1 indicates a low
pressure fault, 2 indicates a low pressure warning, and a 3 indicates
both a low pressure fault and warning occurred.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
LME-80-16-00_300_01.tif
Fig. 4.16-2: Suspension Maintenance Flowchart
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References

LME-20-02-02 [Reference: Brake and Steering Pressure Filter
Replacement Procedure]
LME-20-03-02 [Reference: Dump System Filter Replacement
Procedure]
LME-110-01-00 [Reference: Grid Motor Inspection Guidelines]
LME/10880897/January 30, 2011/en
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LME-20-02-02 - Brake and Steering Pressure Filter Replacement
Procedure
4.18 LME-20-02-02 - Brake and Steering Pressure

Filter Replacement Procedure
Setup
1. Follow the haul truck safety precautions. [Reference: Haul Truck
Safety]
2. Make sure that the engine is not in operation.
3. Bleed the brake and steering accumulators.
4. Make sure that the hydraulic fluid in the brake and steering system is
cool.
Procedure
1. Close the supply and return shutoff valves for the brake and steering
system on the hydraulic tank.
2. Check the visual indicator (2) and record the result.
3. Put an applicable container below the pressure filter to collect the
hydraulic oil.
4. Turn the vent plug (1) one and a half turns to open.
5. Remove the port plug (9) and drain plug (8) and let the hydraulic oil
drain.
6. Install and tighten the port plug (9) and drain plug (8).
7. Remove the cap (7).
8. Loosen the set screw (4).
9. Remove the tube (6) and O-rings (3).
10. Remove the filter element (5).
11. Inspect the filter element (5), and O-rings (3).
12. Replace any damaged parts.
13. Install the O-rings (3), new filter element (5), and tube (6).
14. Tighten the set screw (4).
15. Install and tighten the cap (7) to not more than 20 N m (15 lbf ft).
16. Tighten the vent plug (1).
17. Make sure that the visual indicator (2) is pushed fully in.
18. Repeat steps 2-17 above for the return filters, if equipped.
19. Open the supply and return shutoff valves for the brake and steering
system on the hydraulic tank.
LME/10880897/January 30, 2011/en
20. Start the engine and let the engine operate until the brake and steering
system is at normal operating temperature.
21. Make sure there are no leaks.
22. Stop the engine.
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LME-20-02-02 - Brake and Steering Pressure Filter Replacement
Procedure
LME/10880897/January 30, 2011/en
LME-20-02-02_300_04.tif
Fig. 4.18-1: Brake and Steering Pressure Filter Replacement Procedure
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LME-20-03-02 - Dump System Filter Replacement Procedure
4.19 LME-20-03-02 - Dump System Filter

Replacement Procedure
Setup
Safety]
2. Lower the dump body. [Reference: Dump Body Lift or Lower for
Service (Hydraulically)][Reference: Dump Body Lift or Lower for
Service (Hydraulically)]
3. Make sure that the engine is not in operation.
4. Make sure that the hydraulic fluid in the dump system is cool.
Procedure
1. Close the supply and return shutoff valves for the dump system on the
hydraulic tank.
2. Check the visual indicator (2) and record the result.
3. Put an applicable container below the pressure filter to collect the
hydraulic oil.
4. Turn the vent plug (1) one and a half turns to open.
5. Remove the port plug (9) and drain plug (8) and let the hydraulic oil
drain.
6. Install and tighten the port plug (9) and drain plug (8).
7. Remove the cap (7).
8. Loosen the set screw (4).
9. Remove the tube (6) and O-rings (3).
10. Remove the filter element (5).
11. Inspect the filter element (5), and O-rings (3).
12. Replace any damaged parts.
13. Install the O-rings (3), new filter element (5), and tube (6).
14. Tighten the set screw (4).
15. Install and tighten the cap (7) to not more than 20 N m (15 lbf ft).
16. Tighten the vent plug (1).
17. Make sure that the visual indicator (2) is pushed fully in.
18. Repeat steps 2-17 above for the return filters (10), if equipped.
19. Open the supply and return shutoff valves for the dump system on the
LME/10880897/January 30, 2011/en
hydraulic tank.
20. Start the engine and let the engine operate until the dump system is
at normal operating temperature.
21. Make sure there are no leaks.
22. Stop the engine.
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LME/10880897/January 30, 2011/en
LME-02-03-02_300_01.tif
Fig. 4.19-1: Dump System Filter Replacement Procedure
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06-500_000_01_Return Line Servicing.tif

Fig. 4.19-2: Dump System Filter Replacement Procedure
LME/10880897/January 30, 2011/en
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LME-110-01-00 - Grid Motor Inspection Guidelines
4.20 LME-110-01-00 - Grid Motor Inspection

Guidelines
Setup
Safety]
Procedure
WARNING! The grid motor is a component that contains high voltage.

► Only approved personnel must do the maintenance on electrical
equipment.

Megohmmeter N/A Commercially available
Electrical cleaning solvent N/A Commercially available
1. Check the interior and exterior of the motor. Motor performance is best
when clean and free of dirt, oil, grease, water, etc. Excessive
contamination may prevent proper ventilation and can lead to motor
failure.
2. Oil or grease can be removed using an electrical cleaning solvent. Be
sure not to get any solvent on the surface of the commutator.
3. Remove carbon dust by blowing out the motor using CDA < 7 bar (100
psi). Direct the airflow downwards, working from top to bottom. Slowly
rotate the armature to ensure as much carbon dust as possible is
removed.
4. Measure winding insulation resistance using a megohmmeter. Keep
records of the insulation resistance readings and monitor the trends
over time. Investigate any significant drop in insulation resistance.
5. Verify electrical wiring is securely fastened and connections are tight.
Torque fasteners based on the size and grade of the hardware being
used.
6. Check for excessive vibration. Possible causes are improper
LME/10880897/January 30, 2011/en
alignment, an unbalanced coupling sheave, damaged motor bearings,

or loose mounting bolts.
7. Listen for unusual noises, especially in the area of the bearings.
Mechanical rubbing or rumbling noises can indicate internal damage.
Check the motor thoroughly for signs of loose hardware.
8. Correct the problems that are discovered or schedule the repairs at
the earliest opportunity, depending on the severity of the conditions
found during inspection.
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References

LME-10-01-01 [Reference: Exhaust Bellows and Blankets Inspection]
LME-20-04-00 [Reference: Gear Oil Cooling System Filters
Replacement Procedure]
LME-80-02-02 [Reference: Rear Brake Pad and Disc Check
Procedure]
LME-80-15-01 [Reference: Front Brake Pad and Disc Check
Procedure]
LME/10880897/January 30, 2011/en
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LME-10-01-01 - Exhaust Bellows and Blankets Inspection
4.22 LME-10-01-01 - Exhaust Bellows and

Blankets Inspection
Setup
Safety]
Procedure
1. Remove the exhaust blankets from the expansion joints.
2. Do the following steps to complete a visual inspection of the expansion
joints:
– Inspect the external surface for signs of carbon soot. This can
indicate leakage of exhaust gases.
– Inspect the external surface for signs of damage caused by
metal-to-metal contact. Wear locations will appear more shiny or
polished than the surrounding area.
– Inspect each of the expansion joints for holes and cracks.
– Replace the expansion joint if you find any damage.
3. Do the following steps to complete a visual inspection of the exhaust
blankets:
– Inspect the inner and outer shell of the blankets for damage.
– Inspect the excessive wear and age deterioration (tears and
gouges, seam separation, contamination, etc.).
– Inspect for compression of the insulation material.
– Replace the blanket if you find any indications of damage or
wear.
DANGER! Leakage from the exhaust system can cause fire.

► Make sure the exhaust system components and insulation is correctly
installed.
4. Reinstall the exhaust blanks to the expansion joints.
LME/10880897/January 30, 2011/en
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LME-20-04-00 - Gear Oil Cooling System Filters Replacement
Procedure
4.23 LME-20-04-00 - Gear Oil Cooling System

Filters Replacement Procedure
Setup
Safety]
Procedure
1. Remove and discard the filters (1).
2. Fill new filters with the applicable oil.
3. Install the new filters (1).
4. Start the haul truck.
5. Do a check for leaks
ATTENTION
The gear oil will not circulate unless the temperature conditions are met.
6. Verify that both gear sets have the proper oil level.
7. Shutdown the haul truck.
LME/10880897/January 30, 2011/en
05-700_000_01_Gear Oil Cooling Filter Service.tif

Fig. 4.23-1: Gear Oil Cooling System Filters Replacement Procedure
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LME-80-02-02 - Rear Brake Pad and Disc Check Procedure
4.24 LME-80-02-02 - Rear Brake Pad and Disc

Check Procedure
Setup
Safety]
Procedure
This procedure is used to inspect the thickness of the rear brake pads and
brake discs.

Loctite® N/A Commercially available
CAUTION
Disc damage can occur if only one brake pad is replaced.
► Replace the brake pads as a complete set.
1. Measure the thickness of each brake pad. The minimum pad thickness
is 3 mm (0.12 in).
– Replace the brake pads on or before the minimum dimension is
reached.
2. Without disassembling the brakes, do a visual inspection of each brake
pad for damage.
Replace the brake pad if you find any of the following conditions:
• If any of the brake pads show indications of cracks or
char damage.
• If the brake pads, or any part of the brake pads show
flaking, or detachment from the backing plate.
3. If brake pad requires replacement, install new end plate fasteners
using Loctite® 271 in the following manner:
– Apply several drops to the three end threads on each bolt and
LME/10880897/January 30, 2011/en
apply several drops down one side of each female threaded hole.
– Torque the bolts to a range of 515 N m (380 lbf ft) to 624 N m
(460 lbf ft).
4. Measure the thickness of each brake disc from several points around
the circumference of each brake disc. The minimum thickness is 22
mm (0.87 in)
– Replace the brake disc on or before the minimum dimension is
reached.
5. Visually inspect each brake disc for any of the following conditions:
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LME-80-02-02 - Rear Brake Pad and Disc Check Procedure
• Abnormal wear patterns

• Heat damage or discoloration
• Cracks, warps, or heavy scoring
• If you find any condition that is more than
1.5 mm (0.06 in) in depth, replace the
brake disc.
• If the disc has cracks that travel across the
entire face of the disc, replace the disc.
6. Follow the same procedure for the opposite rear brake assembly.
LME/10880897/January 30, 2011/en
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LME-80-15-01 - Front Brake Pad and Disc Check Procedure
4.25 LME-80-15-01 - Front Brake Pad and Disc

Check Procedure
Setup
Safety]
Procedure
This procedure is used to inspect the thickness of the front brake pads and
brake discs.

Loctite® N/A Commercially available
CAUTION
Disc damage can occur if only one brake pad is replaced.
► Replace the brake pads as a complete set.
1. Measure the thickness of each brake pad. The minimum pad thickness
is 3 mm (0.12 in).
– Replace the brake pads on or before the minimum dimension is
reached.
2. Without disassembling the brakes, do a visual inspection of each brake
pad for damage.
Replace the brake pad if you find any of the following conditions:
• If any of the brake pads show indications of cracks or
char damage.
• If the brake pads, or any part of the brake pads show
flaking, or detachment from the backing plate.
3. If brake pad requires replacement:
– Install new end plate fasteners using Loctite® 271 in the following
manner:
LME/10880897/January 30, 2011/en
• Apply several drops to the three end threads on

each bolt and apply several drops down one side
of each female threaded hole.
• Torque the bolts to a range of 515 N m (380 lbf ft)
to 624 N m (460 lbf ft).
4. Measure the thickness of each brake disc from several points around
the circumference of each brake disc. The minimum thickness is 29
mm (1.14 in)
– Replace the brake disc on or before the minimum dimension is
reached.
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LME-80-15-01 - Front Brake Pad and Disc Check Procedure
5. Visually inspect each brake disc for any of the following conditions:
• Cracking
• Warping
• Heavy scoring
• If these conditions exceed more than 1.5
mm (0.06 in) in depth, replace the brake
disc.
• If the disc has cracks that travel across the
entire face of the disc, replace the disc.
6. Follow the same procedure for the opposite front brake assembly.
LME/10880897/January 30, 2011/en
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References

LME-20-06-00 [Reference: Front Wheel Oil Drain and Fill Procedure]
LME-80-04-02 [Reference: Wear Limit Check Procedures]
LME/10880897/January 30, 2011/en
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LME-20-06-00 - Front Wheel Oil Drain and Fill Procedures
4.27 LME-20-06-00 - Front Wheel Oil Drain and

Fill Procedures
4.27.1 Front Wheel Oil Drain

Truck Safety]
2. Turn the front wheel until two of the oil screw plugs are at the
12 o'clock and 6 o’clock position.
3. Take an oil sample before you start the front wheel oil drain
procedure. [Reference: Oil Sampling Guideline]
1. Put an applicable container below the oil drain plug (2).
NOTICE
The oil capacity for the front wheel hub is 60 L (15.9 gal)
► Use a container large enough to contain this quantity of fluid.
2. Remove the oil drain plug (2).
3. Remove the oil fill plug (1) and let the oil drain.
4. After the oil has drained, install the oil fill plug (1), and the oil drain plug
(2).
5. Clean the oil from the surface of the wheel.
LME/10880897/January 30, 2011/en
08-505_000_Front Wheel Bearing.tif

Fig. 4.27-1: Front Wheel Oil Drain Procedure
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LME-20-06-00 - Front Wheel Oil Drain and Fill Procedures
4.27.2 Front Wheel Oil Fill

Mobilgear SHC 680 N/A [Reference: Oil and Lubricant
Specifications]
1. Remove the top oil fill plug (1).
NOTICE
The oil capacity for the front wheel hub is 60 L (15.9 gal)
2. Remove one of the oil level plugs (2), or (3).
3. Slowly pour or pump the specified oil into the oil fill port. Permit enough
time for the trapped air to escape.
4. Continue to pour or pump until oil is at the oil level mark or oil begins
to flow from the oil level plug.
5. Install the oil fill (1) and oil level plugs (2), and (3), and torque to 165
N m (122 lbf ft). .
6. Clean the oil from the surface of the wheel.
7. Operate the haul truck for a half an hour and then check the oil level.
LME/10880897/January 30, 2011/en
08-510_000_Front Wheel Bearings.tif

Fig. 4.27-2: Front Wheel Oil Fill
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LME-80-04-02 - Wear Limit Check Procedure
4.28 LME-80-04-02 - Wear Limit Check

Procedure
4.28.1 Drag Links and Rear Control Arm Bushing Check

Truck Safety]
1. With an empty truck on a smooth flat surface, chock both front tires,
with front and rear blocks.
2. Mount the dial indicator as shown.
3. Center the dial indicator in its operating range.
WARNING! The haul truck can move suddenly.

► Keep all personnel away from the work area in case of sudden
movement.
4. Release all brakes.
5. Place the shift selector in forward; gently apply power to the truck until
all slack is taken from the bushing.
6. Read the indicator and record the reading.
7. Place the shift selector in reverse; gently apply power to the truck until
all slack is taken from the bushing.
8. Read the indicator and record the reading.
9. Take the difference of the two readings. If the difference is > 3 mm
(0.12 in), disassemble and replace the worn part.
10. Repeat the procedure for the opposite side of the haul truck.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
LME-80-04-02_000_01.tif
Fig. 4.28-1: Drag Links and Rear Control Arm Bushing Check Procedure
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4.28.2 Steering Cylinder and Tie Rod Bushing Check

1. Mount the dial indicator to the item that is being measured.

► Stay clear of moving parts.
2. Start the truck and turn the steering wheel until all slack is taken out
of the steering components.
3. While holding pressure on the steering system, zero the indicator.
4. Turn the steering wheel the opposite direction until all slack is taken
out of the steering components.
5. The indicator should now show the total slack, if not, zero the indicator
and turn the wheel back to the original position, and take the reading
again.
6. If the total slack reading is > 2.4 mm (0.09 in), then the component
should be disassembled and the worn part replaced.
7. Repeat the procedure for the opposite set of steering assembly
components.
LME-80-04-01_300_02.tif
Fig. 4.28-2: Steering Cylinder and Tie Rod Bushing Check Procedure
LME/10880897/January 30, 2011/en
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4.28.3 Idler Arm Bearing Check

1. Adjust the steering direction straight ahead (front tires should be
parallel with the center-line of the truck).
2. Mount the dial indicator.

► Install a lockout or tag-out device to prevent engine operation during
this procedure.
3. Position a pry bar of 1.8 m (5.91 ft) in length.
LME-80-04-01_300_03.tif
Fig. 4.28-3: Idler Arm Bearing Check Procedure
NOTICE
Mount the indicator into a separate support from the bar fulcrum base used
for the bar. The indicator support must be very sturdy to insure that the
movement measured is in the idler arm and bearing assembly and not
movement in the support that make up the dial indicator support.
4. Zero the indicator.
5. With another person observing movement in the dial indicator,
gradually apply a force of approximately 90 kg (198 lb) downward; note
the dial indicator reading and record reading.
LME/10880897/January 30, 2011/en
6. Repeat steps 4-5 three separate times and average the readings
using:
Average movement = (Reading 1 + Reading 2 + Reading 3) / 3
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7. If average movement is > than 5 mm (0.2 in) then the idler arm bearing
assembly should be scheduled for disassembly and further inspection
within the next 1000 operating hours. Once disassembled, the
necessary repairs can be determined by using information provided in
Figure 4 as a guideline.
LME-80-04-01_300_04.tif
Fig. 4.28-4: Idler Arm Bearing Check Procedure
LME/10880897/January 30, 2011/en
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References

maintenance (PM) task. Use this as supporting material when performing
LME-80-03-01 [Reference: Lower Kingpin Bushing Wear Check
Procedure]
LME/10880897/January 30, 2011/en
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LME-80-03-01 - Lower Kingpin Bushing Wear Check Procedure
4.30 LME-80-03-01 - Lower Kingpin Bushing

Wear Check Procedure
Setup
Safety]
► All tires must be inflated to the correct pressure.
► The front and rear suspensions must have the correct charge.
4.30.2 Additional Information

• Use the same location on the spindle flange for both
measurements.
• Keep the measuring device as horizontal as possible.
• Keep the measuring device as perpendicular to the side of the
frame as possible.
• Mark the X1 and X2 measurement location, with detection paint
to make it easier to take future measurements.
4.30.3 Procedure
1. Park the haul truck fully loaded on a level area.
2. Adjust the steering direction straight ahead.
3. Chock the wheels and disable the truck using the proper logout
procedure.
4. Measure distance X and Y horizontally between the points shown.
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06-400_000_01_Toe In Check.tif
Fig. 4.30-1: X and Y Horizontal Measurements
5. Calculate Z by using the following formula:
Z=Y-X
– If Z is between zero and 25 mm (0.98 in), the toe-in is set

correctly.
– If Z is not between zero and 25 mm (0.98 in), the toe-in setting
is out of tolerance.
Excessive lower kingpin bushing wear can cause this condition.
Continue the procedure regardless of the Z measurement
results.
6. Unload truck and move it to a designated work area.
7. Adjust the steering direction straight ahead.
8. Chock the wheels and disable the haul truck using the correct lockout,
or tag-out procedure.
9. Using a tape measure, measure the distance from the frame to the
adjacent unused spindle flange edge (at end of radius curvature). This
measurement should be taken horizontally between the two points
shown.
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LME-80-03-01-531_300_01.tif
Fig. 4.30-2: Dimension X Measurement (haul truck empty without jacks installed) - driver side, front wheel
assembly, aft direction
10. This measured distance is dimension X1.
11. Jack-up one side of the truck only. The measurement of the left, and
the right sides should be taken separately, using the front
crossmember jack location. [Reference: Jacking Points Guidance]
12. Raise the truck until the front tire on the side being measured can
rotate freely.
LME/10880897/January 30, 2011/en
LME-80-03-01-531_300_02.tif
Fig. 4.30-3: Dimension X Measurement (haul truck empty with jacks installed) - driver side, front wheel assembly,
aft direction
13. Take another measurement using the same point on the spindle flange
(at end of radius curvature). but the adjacent frame location will now
be lower. This change is caused by the suspension extending when
the truck is jacked-up.
This measured distance is dimension X2.

14. Use the formula that follows to get the Z1 measurement.
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Z1 = X2 - X1
– If Z1 is < 13 mm (0.51 in), the kingpin bushing wear is acceptable.

– If Z1 reaches > 13 mm (0.51 in), schedule the kingpin bushing
replacement procedure during the next maintenance
opportunity.
– If Z1 > 19 mm (0.75 in), replace the bushing as soon as possible.
15. Lower the haul truck.
16. Repeat the procedure for the opposite side of the haul truck.
17. If the kingpin bushings are acceptable, but the toe-in is out of
tolerance, continue troubleshooting to determine a root cause for the
change in the toe-in setting.
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5000-Hour Preventive Maintenance

LME-20-07-00 [Reference: Rear Wheel Oil Drain and Fill Procedure]
LME-80-05-02 [Reference: Rear Brake Assembly Fasteners Torque
Procedure]
LME-80-06-02 [Reference: Steering Cylinder Fasteners Torque
Procedure]
LME-80-09-01 [Reference: Tie Rod Fasteners Torque Procedure]
LME-80-11-00 [Reference: Lower Kingpin Fasteners Torque
Procedure]
LME-80-13-01 [Reference: Steering Arm Fasteners Torque
Procedure]
LME-80-14-00 [Reference: Upper Kingpin Fasteners Torque
Procedure]
LME/10880897/January 30, 2011/en
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LME-20-07-00 - Rear Wheel Oil Drain and Fill Procedures
4.32 LME-20-07-00 - Rear Wheel Oil Drain and Fill

Procedures
4.32.1 Rear Wheel Oil Drain Procedure

Truck Safety]
2. Turn the rear wheel until the oil fill plug is at the 12 o'clock
position, and the oil drain plug is at the bottom.
3. Take an oil sample before you start the rear wheel oil drain
procedure. [Reference: Oil Sampling Guideline]
1. Put an applicable container below the oil drain plug at the bottom
center position.
NOTICE
The oil capacity for the front wheel hub is 280 L (74 gal).
► Use a container large enough to contain this quantity of fluid.
2. Remove the oil drain plug (1) at the bottom center.
3. Remove the oil fill plug (2) at the top center and let the oil drain.
4. When all the oil has drained, install the oil fill and oil drain plugs.
5. Clean all oil from the surface of the wheel.
6. Remove all tools, equipment, and unwanted materials from the work
area.
LME/10880897/January 30, 2011/en
531-532_300_01_Drain and Replace Gearset Oil.tif

Fig. 4.32-1: Rear Wheel Oil Drain Procedure
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LME-20-07-00 - Rear Wheel Oil Drain and Fill Procedures
4.32.2 Rear Wheel Oil Fill Procedure

Mobilgear SHC 320 50 5087-D [Reference: Oil and Lubricant
Specifications]
1. Remove the oil fill plug (1).
2. Remove one of the oil level plugs (2).
3. Slowly pour or pump the specified lubricant through the oil fill plug (1).
Permit enough time for the trapped air to escape.
4. Continue to pour or pump until the oil begins to flow from the oil level
plug.
5. Install the oil fill plug and the oil level plug.
6. Remove all oil from the surface of the wheel.
7. Operate the haul truck for a half an hour, then check the oil level.
8. Inspect for leaks from the wheel seals.
531-532_300_02_Drain and Replace Gearset Oil.tif

LME/10880897/January 30, 2011/en
Fig. 4.32-2: Rear Wheel Oil Fill Procedure
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LME-30-02-01 - Rear Control Arm Fasteners Torque Procedure
4.33 LME-30-02-01 - Rear Control Arm Fasteners

Torque Procedure
Setup
Safety]
► [Reference: Torque Charts]
Procedure
Us the following procedure to torque the rear control arm fasteners.
Torque Specification Table

Position Torque Specification
1, 3 380 N m (280 lbf ft) 8 locations (lubricated)
2, 4 922 N m (680 lbf ft) 4 locations (lubricated)
5 922 N m (680 lbf ft) 3 locations (lubricated)
Table 1: Torque Specification Table
1. Do a visual inspection of the fastener joints for signs of self loosening
or relaxation. If you find a fastener to have loosened, move to
[Reference: step 4] of this procedure.
• Early indications can appear in the form of wear marks
at or near the fastened joint.
• If the fastener(s) was previously marked using torque
detection paint or seal, inspect the integrity of the
marking, and verify the fastener has not rotated. LME/10880897/January 30, 2011/en
Marked Fastener_01.tif Marked Fastener_02.tif
Fig. 4.33-1: Example of Fasteners Marked with Torque Detection Paint

2. Torque each fastener back to the specified values shown on the
Torque Specification table. [Reference: Torque Specification Table]
– Fasteners secured with safety wire only require re-torque if the
lock wire has been compromised.
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– When applying torque to an existing fastener, pay attention to

excessive fastener movement. Significant bolt rotation can
indicate the fastener joint has been over-stressed or degraded
in some manner. In this case, move to [Reference: step 4]. of this
procedure.
– Applying torque detection paint after the fastener has been
torqued can serve as a visual indicator for future inspections.
3. Where applicable, check that the safety lock wire is correctly attached.
Do the following steps if a fastener is found to have loosened:

4. Thoroughly inspect the associated component and/or assembly for
signs of damage or excessive wear.
5. Remove the complete set of fasteners for the related joint. Also remove
any other damaged parts or hardware. The amount of disassembly will
be dependent on the extend of damage that is found.
6. Discard the set of used fasteners. Replace the damaged parts or other
affected hardware as determined appropriate.
7. If necessary, re-tap the joint threads to remove contamination or
thread-locking compound.
8. Install and torque new fasteners to the specifications shown in the
9. Record findings of loosened fasteners by making a Service Action data
entry in LISA II under the text tab in the comments text box, or other
appropriate maintenance log file.
– Include a brief description of what specifically was replaced and
the corrective action taken.
10. Finalize by completing [Reference: step 3]
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LME/10880897/January 30, 2011/en
531-532_300_02_Torque Rear Control Arm.tif

Fig. 4.33-2: Rear Control Arm Fasteners Torque Procedure
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LME-80-05-02 - Rear Brake Assembly Fasteners Torque Procedure
4.34 LME-80-05-02 - Rear Brake Assembly

Fasteners Torque Procedure
Setup
Safety]
2. Bleed the brake accumulators. Brake System Accumulator Bleed
Procedure
1 515 N m (380 lbf ft) 12 locations (dry)
Bleeder Screw 11 N m (100 lbf in) to 14 N m (120 lbf in)
6 380 N m (280 lbf ft) 12 locations
1. Open the bleeder screw to release pressure at each caliper.
marking, and verify the fastener has not rotated.
LME/10880897/January 30, 2011/en

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in some manner. In this case, move to [Reference: step 7] of this
procedure.
4. Tighten the bleeder screws.
5. Repeat [Reference: step 1] to [Reference: step 4] for each caliper on
both rear wheel assemblies.
6. Close the access panel on the axle box door.

13. Finalize by completing [Reference: step 4] to [Reference: step 6.]
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LME-80-05-02_300_01.tif
Fig. 4.34-2: Rear Brake Assembly Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-05-02_300_02.tif
Fig. 4.34-3: Rear Brake Assembly Fasteners Torque Procedure
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LME-80-06-02 - Steering Cylinder Fasteners Torque Procedure
4.35 LME-80-06-02 - Steering Cylinder Fasteners

Torque Procedure
Setup
Safety]
Procedure
2 Install hand tight. Tighten an additional 1-1/2 full
rotations and align with lock washer tabs. Bend lock
washer tab into nut slot.
1. Do a visual check of the fastener joint for signs of self loosening or
relaxation. If you find a fastener to have loosened, move to [Reference:
step 4]. of this procedure.
LME/10880897/January 30, 2011/en

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procedure.

any other damaged parts or hardware.
appropriate maintenance log file. Include a brief description of what
specifically was replaced and the corrective action taken.
10. Finalize by completing [Reference: step 3.]
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LME-80-06-01_300_01.tif
Fig. 4.35-2: Steering Cylinder Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-06-01_300_03.tif
Fig. 4.35-3: Steering Cylinder Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-09-01 - Tie Rod Fastener Torque Procedure
4.36 LME-80-09-01 - Tie Rod Fastener Torque

Procedure
Setup
Safety]
Procedure
2, 3 Install hand-tight. Tighten an additional 1-1/2 full
rotations and align with lock washer tabs. Bend lock
washer tab nut slot.
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procedure.

10. Finalize by completing [Reference: step 3.]
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LME-80-09-00_300_01.tif
Fig. 4.36-2: Tie Rod Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-09-00_300_03.tif
Fig. 4.36-3: Tie Rod Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-11-00 - Lower Kingpin Fasteners Torque Procedure
4.37 LME-80-11-00 - Lower Kingpin Fasteners

Torque Procedure
Setup
Safety]
► Make arrangements to have the front rims removed.
Procedure

LME/10880897/January 30, 2011/en

procedure.
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LME-80-11-00 - Lower Kingpin Fasteners Torque Procedure
3. Repeat [Reference: step 1] and [Reference: step 2] for the opposite

side of the haul truck.
4. Install the front rims.

6. Discard the set of used fasteners following the instructions provided
in Replace Lower Kingpin Fasteners Procedure. [Reference: Replace
Lower Kingpin Fasteners Procedure]
7. Replace the damaged parts or other affected hardware as determined
appropriate.
9. Finalize by completing [Reference: step 3] and [Reference: step 4.]
LME-80-11-00_300_02.tif
Fig. 4.37-2: Lower Kingpin Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-13-01 - Steering Arm Fasteners Torque Procedure
4.38 LME-80-13-01 - Steering Arm Fasteners

Torque Procedure
Setup
Safety]
► Replace the Steering Arm Fasteners. [Reference: Steering Arm
Fastener Replacement Procedure]
Procedure
1, 2 3300 N m (2434 lbf ft) 8 locations

LME/10880897/January 30, 2011/en

procedure.
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LME-80-13-01 - Steering Arm Fasteners Torque Procedure
3. Repeat [Reference: step 1] , and [Reference: step 2] for the opposite


5. Discard and replace the complete set of used steering arm fasteners.
See the Steering Arm Fastener Replacement Procedure for detailed
instructions and important fastener preparation information.
[Reference: Steering Arm Fastener Replacement Procedure]
6. Replace the damaged parts or other affected hardware as determined
appropriate.
8. Finalize by completing [Reference: step 3] and [Reference: step 4.]
LME-80-13-01_300_01.tif
Fig. 4.38-2: Steering Arm Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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LME-80-14-00 - Upper Kingpin Fastener Torque Procedure
4.39 LME-80-14-00 - Upper Kingpin Fastener

Torque Procedure
Setup
Safety]
► Make arrangements to have the front rims removed. [Reference: Front
Rim Removal]
Procedure
Anti-seize 10171336 [Reference: Oil and Lubricant
Specifications]

1. Do a visual inspection of the fasteners for signs of self loosening or
step 4] of this procedure.
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LME-80-14-00 - Upper Kingpin Fastener Torque Procedure

in some manner. In this case, move to [Reference: step 4.] of this
procedure.
3. Repeat [Reference: step 1], and [Reference: step 2] for the opposite
4. Install the front wheels. [Reference: Front Wheel (Complete)
Installation]

6. Discard and replace the complete set of used upper kingpin fasteners
using Liebherr recommended anti-seize only. [Reference: Required
Tools and Materials]
10. Finalize by completing [Reference: step 3].
LME/10880897/January 30, 2011/en
LME-80-14-00_300_02.tif
Fig. 4.39-2: Upper Kingpin Fasteners Torque Procedure
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References

LME-80-10-00 [Reference: Replace Lower Kingpin Fasteners]
LME-80-12-01 [Reference: Steering Arm Fastener Replacement
Procedure]
LME/10880897/January 30, 2011/en
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LME-80-10-00 - Replace Lower Kingpin Fasteners
4.41 LME-80-10-00 - Replace Lower Kingpin

Fasteners
Setup
Safety]
2. Make arrangements to have the front rim removed.
Procedure
Anti-Seize 10171336 [Reference: Oil and Lubricant
Specifications]

1. Visually inspect each of the lower kingpin fasteners for obvious signs
of self loosening or relaxation.
– Include a brief description of what specifically was discovered
and the corrective action taken.
3. The lower control arm must be detached from the kingpin to replace
the lower kingpin fasteners.
4. Once the control arm has been lowered, inspect the lower kingpin and
lower kingpin bushing for signs of significant wear.
5. Prepare the new fasteners by applying Liebherr anti-seize only. Apply
to the bottom threads (1-1/2") only.
LME/10880897/January 30, 2011/en
NOTICE
The weight of the lower kingpin is 238 kg (525 lb).
► Make sure the kingpin is properly supported while replacing the
fasteners.
6. Remove and replace one fastener at a time to prevent having to
completely separate the kingpin from the spindle. Remove fasteners
using a cross pattern, rather than circular or side-by-side.
– If necessary, re-tap the joint threads to remove contamination or
anti-seize compound.
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LME-80-10-00 - Replace Lower Kingpin Fasteners
– Discard the used fasteners.

7. Continue until a new set of lower kingpin fasteners have been installed.
8. Torque each fastener using a cross pattern, tighten to 793 N m (585
lbf ft). using the same pattern, increase to following the torque
specifications shown in the Torque Specifications Table. [Reference:
Torque Specification Table]
9. Reassembly the lower control arm.
10. Repeat [Reference: step 1] to [Reference: step 9] for the opposite site
of the haul truck.
11. Install the front rims.
12. Verify steering and toe-in setting before releasing the truck back into
service.
LME-80-10-00_300_01.tif
Fig. 4.41-1: Replace Lower Kingpin Fasteners Procedure
LME/10880897/January 30, 2011/en
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LME-80-12-01 - Steering Arm Fasteners Replacement
4.42 LME-80-12-01 - Steering Arm Fasteners

Replacement
Setup
Safety]
Procedure
This procedure applies to the steering arm to spindle connections.

Anti-Seize 10171336 [Reference: Oil and Lubricant
Specifications]

1, 2 3300 N m (2434 lbf ft) 8 locations
1. Do a visual inspection of the steering arm fasteners for signs of self
loosening or relaxation.
NOTICE
The weight of the steering arm is 201 kg (443 lb), and the weight of the tie
rod is 184 kg (406 lb).
► Use an applicable device that can safely lift and support this weight.
3. Remove each of the steering arm fasteners.
LME/10880897/January 30, 2011/en
4. Discard the used fasteners.

5. Once the steering arm is separated from the spindle, clean and inspect
the contact faces.
6. If necessary, re-tap the joint threads to remove contamination or anti-
seize compound.
NOTICE
The fasteners used on this connection are one-time use fasteners.
► Replace the fasteners each time a fastener looses torque.
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LME-80-12-01 - Steering Arm Fasteners Replacement
7. Install using the Liebherr anti-seize only. [Reference: Required Tools

and Material]. Apply to the bottom threads 1" only. Install the new set
of fasteners back to the specified values shown on the Torque
Specification table. [Reference: Torque Specification Table.]
LME-80-12-01_300_01.tif
Fig. 4.42-1: Steering Arm Fasteners Replacement
LME/10880897/January 30, 2011/en
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Conditional-Hours Preventive Maintenance References
4.43 Conditional-Hours Preventive Maintenance

References
The following procedures are linked to the Conditional-hour preventive

maintenance (PM) task. Use this as supporting material when performing
LME-80-07-02 [Reference: Front Brake Assembly Fasteners Torque
Procedure]
LME-80-08-02 [Reference: Rear Wheel Assembly Fasteners Torque
Procedure]
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LME-80-07-02 - Front Brake Assembly Fasteners Torque Procedure
4.44 LME-80-07-02 - Front Brake Assembly

Setup
Safety]
► Remove the tire and rim assembly. [Reference: Front Wheel
Removal]
► Bleed the accumulators.
Procedure
1 1004 N m (741 lbf ft) 6 locations, per caliper
Bleeder screw 11 N m (100 lbf in) to 14 N m (120 lbf in)
1. Open the bleeder screw to release pressure at each caliper.
2. Do a visual check of the fastener joint for signs of self loosening or
step 7] of this procedure.
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LME-80-07-02 - Front Brake Assembly Fasteners Torque Procedure

procedure.
4. Tighten the bleeder screws.
5. Repeat [Reference: step 1] to [Reference: step 4] for each caliper on
both of the front wheels.
6. Reinstall the tire and the rim assembly.

13. Finalize by completing [Reference: step 4] to [Reference: step 6.]
LME/10880897/January 30, 2011/en
LME-80-07-02_300_01.tif
Fig. 4.44-2: Front Brake Assembly Fasteners Torque Procedure
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LME-80-08-02 - Rear Wheel Assembly Fasteners Torque Procedure
4.45 LME-80-08-02 - Rear Wheel Assembly

Setup
Safety]
Procedure
Specifications]
• Follow this procedure to torque the rear wheel assembly

fasteners.
• This procedure assumes the rims have already been
removed, allowing full access to all bolts.

1. Do a visual check of the rear wheel assembly fasteners for signs of
self-loosening or relaxation. If you find a fastener to have loosened,
move to [Reference: step 5] of this procedure.
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2. Using a crossing pattern, torque each fastener back to the specified
values shown on the [Reference: Torque Specification Table].
procedure.
3. Reinstall the tire and rim assembly.
4. Repeat [Reference: step 1] to [Reference: step 3] for the opposite side
of the haul truck.

6. Remove the loosened fastener for the joint in question.
7. Discard the used fastener. Replace the damaged parts or other
affected hardware as determined appropriate. If necessary, clean and
re-tap the joint threads to remove contamination or thread locking
compound.
8. Lubricate the new fastener with Liebherr anti-seize only and torque the
fastener to the specifications shown in the [Reference: Torque
Specification Table]
10. Finalize by completing [Reference: step 3 ] and [Reference: step 4.]
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LME-80-08-01_300_01.tif
Fig. 4.45-2: Rear Wheel Assembly Fasteners Torque Procedure
LME/10880897/January 30, 2011/en
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Service Manual Power Module (Drive System)
5 Power Module (Drive System) 185

5.1 Power Module 186
5.1.1 Power Module Assembly Removal 187
5.1.4 Power Module Assembly Installation 190
5.2 Engine 193
5.2.1 Engine Removal 195
5.2.4 Engine Installation 198
5.2.7 Engine Flywheel Runout Check 201
5.2.10 Engine Endplay Measurements 203
5.3 Exhaust System 205
5.3.1 Exhaust System Removal 206
5.3.4 Exhaust System Installation 213
5.4 Engine Air Cleaner 220
5.4.1 Engine Air Cleaner Ducts Removal 221
5.4.4 Engine Air Cleaner Ducts Installation 223
5.5 Traction Alternator 225
5.5.1 Traction Alternator Removal 226
5.5.4 Traction Alternator Installation 229
5.5.7 Traction Alternator Measurements 233
5.6 Air Cleaner Restriction Check 235
5.7 Fuel System 236
5.7.1 Fuel and Hydraulic Tank Drain 236
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Power Module (Drive System) Service Manual
Power Module
5.1 Power Module
04-000_000_01_Power Module Assembly.tif
The power module assembly is in the engine compartment on the haul truck.
The power module assembly is installed on a skid as a unit. A rollout
assembly can attach to the skid for the separate removal of each power
module component, or the complete unit.
The power module is kept from contact with the haul truck frame by rubber
isolators. The isolators are installed between the power module and the
frame.
The service and maintenance personnel can access the module by the
ladders on each side of the engine compartment.
The power module assembly has the components that follow:

• [Reference: Engine]
• [Reference: Traction Alternator]
• [Reference: Radiator]
LME/10880897/January 30, 2011/en
The power module assembly connects to the systems that follow:

• [Reference: AC Drive Cooling System]
• [Reference: Exhaust System]
• [Reference: Fuel System]
• [Reference: Engine Air Cleaner]
• [Reference: Electrical Power and Distribution]
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Power Module
5.1.1 Power Module Assembly Removal
5.1.2 Setup
Safety]
► Make sure enough space is available in front of the haul truck to allow
for the removal of the power assembly.
► Lift and put the dump body into the correct position for the specified
maintenance procedure .
► Remove the hood and the grill. [Reference: Hood and Grill Removal]
► Remove the alternator cooling duct from the top of the traction
alternator. [Reference: Traction Alternator Cooling Duct Removal]
► Disconnect the gearbox drive flange on the pump drive from the
traction alternator.
► Disconnect the exhaust pipe flanges.
► Drain the radiator.
WARNING! Fluids under pressure can cause injury.

► Remove all pressure from the brake and steering systems .
► Close the fuel and hydraulic valves.
► Disconnect the inlet ducts from the air cleaner to the engine.

Power Module Assembly Lifting T-128-F [Reference: Service Tools]
Beam
Power Module Shipping Stand T-500-J [Reference: Service Tools]
5.1.3 Procedure
NOTICE
The empty weight of the power module is more than 20000 kg (44092 lb).
► Install a lift that can hold the empty power module assembly weight.
LME/10880897/January 30, 2011/en
1. Make sure all of the supply line shutoff valves are in the OFF position.
2. Tag and disconnect the air, oil, and the fuel lines in the area of the
power module assembly.
3. Install protective covers on all of the disconnected lines.
4. Open the engine ports.
5. Tag, and disconnect the electrical cables in the area of the power
module assembly.
6. Disconnect the ground straps installed between the power module
assembly and the frame.
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Power Module
7. Remove the capscrews (6), lockwashers (7), and washers (8) to

disconnect the alternator bracket.
CAUTION! The lift points on the engine and the traction alternator cannot
hold the weight of the power module assembly.
► Attach the chains approved to hold the weight of the power module
assembly to the engine skid lift points.
8. Install the chain and the spreader to the power module lifting beam.
[Reference: Service Tools]
9. Connect the front lifting points and slide the module forward, then rest
it on the bumper. At this step, all four lifting points can be connected
and the module can then be removed from the haul truck.
10. Install the left and the right rollout rails and the front rail support.
11. Remove the tension from the chains.
12. Remove the locknuts (5), cinch washers (4), Fibromounts (3), washers
(2), and capscrews (1).
13. Lift the engine skid from the rear approximately 50 mm (1.97 in) to 75
mm (2.95 in).
14. Install the left and the right rollout assemblies.
15. Lower the power module assembly until the rollers are against the rails
of the rollout assemblies.
CAUTION! The lift points on the engine and the traction alternator cannot
hold the weight of the power module assembly.
► Attach the chains approved to hold the weight of the power module
assembly to the engine skid lift points.
16. Install the chain and the power module assembly lifting beam to the
front of the engine skid. [Reference: Service Tools]
17. Lift the engine skid enough to remove the weight from the front shock
mounts.
18. Carefully and slowly, move the front skid mounts from the front
bumper.
19. Install wooden supports between the skid mounts and the bumper to
make the power module assembly level.
20. Make the power module assembly level and put the front skid mounts
against the wooden supports on the front bumper.
21. Lift the power module assembly enough to clear the front bumper.
22. Carefully move the power module assembly forward away from the
haul truck.
23. Install the front and the rear engine stands to the power module
assembly.
24. Put the power module assembly on the power module shipping stand.
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04-100_000_01_Power Module.tif
Fig. 5.1-2: Power Module Assembly Removal
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Power Module
5.1.4 Power Module Assembly Installation
5.1.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from the
power module assembly removal procedure. [Reference: Power
Module Removal]

Power Module Assembly Lifting T-128-F [Reference: Service Tools]
Beam
Power Module Shipping Stand T-500-J [Reference: Service Tools]
5.1.6 Procedure
CAUTION! The lift points on the engine and traction alternator cannot hold
the power module assembly.
► Attach the chains to the lift points on the engine skid.
1. Install the power module assembly lifting beam to the four lift points of
the engine skid. [Reference: Service Tools]
2. Install the left and right rollout roller assemblies.
NOTICE
The weight of the power module assembly without fluids is more than 20000
kg (44092 lb).
► Use an applicable lift device that can hold this weight.
3. Adjust the chain and spreader beam to keep the power module
assembly level.
4. Lift the power module assembly enough to remove the front and rear
engine stands.
5. Remove the front and rear engine stands from the power module
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assembly.
6. Lift the power module assembly enough from the front bumper until
you can move the power module.
- OR -
7. Remove the power module assembly from the power module shipping
stand. [Reference: Service Tools]
8. Carefully and slowly, move the power module assembly lifting beam
in position on the rollout rails.
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Power Module
9. Carefully and slowly, move the power module assembly back into
position on the shock mounts.
10. Lower the power module assembly against the rubber shock mounts.
11. Remove the power module assembly lifting beam from the front of the
engine skid. [Reference: Service Tools]
12. Lift the aft of the engine skid 50 mm (1.97 in) to 75 mm (2.95 in).
13. Remove the left and right rollout rails and the front rail support.
14. Remove the left and right rollout roller assemblies.
15. Lower the power module assembly until it is against the rubber shock
mounts.
16. Install the capscrews (1), washers (2), cinch washers (4), Fibromounts
(3), and locknuts (5).
17. Install the fasteners and washers from the rubber shock mounts that
hold the power module assembly to the main frame.
18. Connect the ground straps between the power module assembly and
the main frame.
19. Remove the tags and connect all the necessary electrical cables in the
area of the power module assembly.
20. Remove the protective covers on all the disconnected and open lines.
21. Remove the tags and connect all the necessary air, oil, and fuel lines.
22. Install the capscrews (6) and lockwashers (7), and washers (8) to
connect the hose support bracket to the traction alternator.
23. Make sure that all supply line shutoff valves are in the ON position.
24. Connect the inlet ducts from the air cleaner to the engine.
25. Open the fuel and hydraulic valves.
26. Fill the coolant in the radiator. [Reference: Radiator Coolant Fill]
27. Connect the exhaust pipe flanges.
28. Connect the gearbox drive flange on the pump drive from the traction
alternator.
29. Install the alternator cooling duct to the top of the traction alternator.
30. Install the hood and grill. [Reference: Hood and Grill Installation]
31. Lower the dump body. [Reference: Dump Body Lower]
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Power Module
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04-100_000_01_Power Module.tif
Fig. 5.1-3: Power Module Assembly Installation
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Engine
5.2 Engine
04-000_000_01_Engine.tif
Fig. 5.2-1: MTU, 20V400 Engine
The engine on the haul truck is an MTU, 20V4000, Diesel engine with 2722
kW (3650 hp).
The engine connects the systems that follow:

• [Reference: Traction Alternator]
• [Reference: Radiator]
• [Reference: AC Drive Cooling System]
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• [Reference: Fuel System]

• [Reference: Exhaust System]
These components are attached to the engine:

• Starters
• Battery Charging Alternator
The Traction Control Unit (TCU) in the Siemens AC Drive System controls
the speed of the engine. The engine has a governor, but the output from the
accelerator pedal is not directly connected to the engine governor. The TCU
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Engine
supplies the engine speed command. The engine governor can override the
speed command from the TCU to prevent some conditions. For example,
an override condition can occur to decrease smoke during the acceleration,
or to prevent the dangerous operation of the engine.
Refer to the Siemens manual and the MTU engine manual for more data.
The haul truck has two heavy-duty, dual-step engine air cleaners. Air goes
through the air cleaners and the ducts to the engine intake.
The air cleaners remove unwanted material from the air. The air cleaners
have an upper and lower body, and dust bins. The upper body has the
primary and safety filter elements. The lower body has air cleaner tubes.
The tubes do the initial removal of most of the dust that goes into the system.
The dust bins collect the dust that is removed from the airflow.
The filter elements must be serviced when the airflow is at the maximum
limit set by the engine manufacturer. There are restriction indicators in the
cab that show the airflow of the engine. A manometer or an air service gauge
calibrated in inches of water is used for the check of the airflow pressure
returned to the engine.
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Engine
5.2.1 Engine Removal
5.2.2 Setup
Safety]
► Remove the power module assembly. [Reference: Power Module
Assembly Removal]
5.2.3 Procedure
1. Remove the radiator from the engine skid.
NOTICE
The minimum weight of the radiator fan is 151 kg (333 lb).
2. Attach an applicable lift device or support to the radiator fan (1).
3. Remove the capscrews (6), washers (5), and radiator fan (1).
4. Attach the rigging for the engine (2) and the engine rollout assembly
(7) as shown in the recommended procedure of the manufacturer.
5. Remove the traction alternator from the engine .
- OR -
6. Remove the capscrews (3) and washers (4).
7. Remove the engine (2) from the engine skid.
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LME/10880897/January 30, 2011/en
04-100_000_01_Engine.tif
Fig. 5.2-2: Engine Removal (Page 1 of 2)
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Engine
04-100_000_02_Engine.tif
Fig. 5.2-3: Engine Removal (Page 2 of 2)
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Engine
5.2.4 Engine Installation
5.2.5 Setup
Safety]
5.2.6 Procedure
Anti-seize N/A Commercially available
1. Attach the recommended rigging for the engine (2) and the engine
rollout assembly (7) as shown in the manufacturer's recommended
procedure.
2. Put the engine (2) in position on the engine skid (7).
3. Lubricate the capscrews (3) with anti-seize.
4. Install the capscrews (3) and washers (4).
5. Tighten the capscrews (3) to 381 N m (281 lbf ft).
NOTICE
The weight of the radiator fan is 151 kg (333 lb).
6. Attach an applicable lift device or support to the radiator fan (1).
8. Install the radiator fan (1), capscrews (6), and washers (5).
10. Install the traction alternator to the engine (2).
11. Install the radiator to the engine skid (7).
12. Install the power module assembly. [Reference: Power Module
Assembly Removal]
13. Inspect for the correct installation of the power module assembly.
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LME/10880897/January 30, 2011/en
04-100_000_01_Engine.tif
Fig. 5.2-4: Engine Installation (Page 1 of 2)
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Engine
04-100_000_02_Engine.tif
Fig. 5.2-5: Engine Installation (Page 2 of 2)
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Engine
5.2.7 Engine Flywheel Runout Check
5.2.8 Setup
Safety]

Flywheel Measurement Fixture 10880099 [Reference: Service Tools]
Depth micrometer N/A Commercially available
5.2.9 Procedure
1. Use a dial indicator to check the flywheel radial runout.
2. Turn the flywheel 360 degrees to measure the radial runout.
If the measurement is more than 0.15 mm (0.01 in) to 0.18 mm (0.01

in),
3. See the engine manufacturer for data.
If the measurement is in these limits 0.15 mm (0.01 in) to 0.18 mm (0.01

in),
4. Use a dial indicator to do a check of the flywheel face runout.
5. Turn the flywheel 360 degrees to measure the radial runout.
If the measurement is more than 0.15 mm (0.01 in) to 0.18 mm (0.01

in),
6. See the engine manufacturer for data.
If the measurement is in these limits 0.15 mm (0.01 in) to 0.18 mm (0.01

in),
7. The engine flywheel runout is satisfactory.
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04-400_000_01_Engine Flywheel Runout Check.tif

Fig. 5.2-6: Engine Flywheel Run-Out Check
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Engine
5.2.10 Engine Endplay Measurements
5.2.11 Setup
Safety]

5.2.12 Procedure
1. Use a straight edge, gauge blocks, depth micrometer, and pry bar to
get the next measurement. [Reference: Service Tools]
- OR -
2. Use the flywheel measurement fixture, a depth micrometer, and a pry
bar to get the next measurement.
3. Carefully remove one of the side covers from the engine and prevent
damage to the gasket.
4. Attach the straight edge and gauge blocks to the rear face of the
flywheel housing with clamps.
- OR -
5. Attach the flywheel measurement fixture to the rear face of the flywheel
housing. [Reference: Service Tools]
6. Measure the width of the straight edge or measurement tool and record
it as "X".
7. Carefully use the pry bar to prevent damage to the internal
components and move the crankshaft forward until it stops.
8. Use the depth micrometer to measure four times the distance between
the measurement tool and the flywheel housing, at every 90 degrees.
9. Calculate the average of the four measurements, subtract X, and
record as Absolute Forward Position (AFP).
10. Carefully use the pry bar to prevent damage to the internal
LME/10880897/January 30, 2011/en
components and move the crankshaft rearward until it stops.

11. Use the depth micrometer to measure four times the distance between
the measurement tool and the flywheel housing, at every 90 degrees.
12. Calculate the average of the four measurements, subtract X, and
record as Absolute Rearward Position (ARP).
13. Use this formula to calculate and record the Total Engine Endplay:
– Total Engine Endplay equals AFP minus ARP.
14. Use this formula to calculate and record Half of Endplay:
– Half of Endplay equals the Total Engine Endplay divided by two.
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Engine
15. Use this formula to calculate the quantity of shims you must add or
remove to the alternator.
– Shims Necessary equals AFP minus Half of Endplay.
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04-400_000_400_Engine Endplay Measurement.tif

Fig. 5.2-7: Engine Endplay Measurements
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Exhaust System
5.3 Exhaust System
The exhaust system pipes go from the engine to the right side of the haul
truck.
The exhaust system links with these systems and components:

• [Reference: Superstructure]
The exhaust gases from the engine go through the exhaust ducts to the front
area of the dump body. The exhaust system on the haul truck has mufflers.
The hot exhaust gases go into the mufflers and to the side of the dump body
and the superstructure.
A pressure gauge can be connected to the port with a thread on the mufflers
to check the back pressure of the exhaust system.
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Exhaust System
5.3.1 Exhaust System Removal
5.3.2 Setup
Safety]
5.3.3 Procedure
1. Loosen the clamps (2).
NOTICE
Before you remove the pipes, mark each pipe in relation to the next to make
installation easier.
2. Remove the exhaust pipes (1).
NOTICE
The weight of the mufflers is 24 kg (53 lb).
► Use an applicable lift device that can hold that weight.
5. Remove the lower halves of the brackets (4) and mufflers (3).
6. Remove the clamp blankets (11).
8. Remove the exhaust pipes (8) and (9).
9. Remove the locknuts (18), capscrews (16), and washers (17).
10. Remove the brackets (15) from the bracket (14).
11. Remove the locknuts (22) and washers (23).
12. Remove the clamp blankets (21).
15. Remove the clamps (42).
17. Remove the exhaust blankets (39).
18. Remove the locknuts (26), washers (25), capscrews (24), and rod (28).
19. Remove the locknuts (26), washers (25), capscrews (24), rods (27),
and (27A).
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20. Remove the locknuts (33), washers (32), capscrews (31), brackets
(34), and (38).
21. Remove the locknuts (35), washers (36), and capscrews (37).
22. Remove the exhaust pipes (40) and gaskets (41).
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LME/10880897/January 30, 2011/en
04-100_000_01_Exhaust System.tif
Fig. 5.3-1: Exhaust System Removal (Page 1 of 6)
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Exhaust System
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Exhaust System
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Exhaust System
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Exhaust System
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Exhaust System
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Exhaust System
5.3.4 Exhaust System Installation
5.3.5 Setup
Safety]
► Make sure the exhaust system is in the same configuration from the
exhaust system removal procedure. [Reference: Exhaust System
Removal]
5.3.6 Procedure
1. Install the exhaust pipes (5) and gaskets (4).
2. Install the locknuts (1), washers (2), capscrews (12) and (13), washers
(11), and brackets (10) and (14).
3. Install the locknuts (6), capscrews (9), lockwashers (7), and washers
(8).
4. Put the slots of the exhaust blankets (3) in position around the bracket
(14) .
5. Install the exhaust pipes (18) and (16), and clamps (15).
6. Tighten the clamps (15).
7. Install the clamp blankets (17).
8. Install the exhaust pipes (20) and (19) to the exhaust pipe (16) with
the clamps (15).
9. Tighten the clamps (15) and install clamp blankets (17).
10. Install the washer (8) and nut (6).
11. Install the exhaust pipe (25).
14. Install the locknuts (21) and washers (22).
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21. Install the locknuts (26) and washers (27).
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Exhaust System
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Fig. 5.3-7: Exhaust System Installation (Page 1 of 6)
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Exhaust System
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Exhaust System
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Exhaust System
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Exhaust System
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Exhaust System
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Engine Air Cleaner
5.4 Engine Air Cleaner
The engine uses air cleaners to prevent unwanted particles and materials
to get in the engine. The haul truck has two heavy-duty, dual-stage engine
air cleaners. Air goes through the air cleaners and the ducts to the engine
intake.
The engine air cleaners connects with these systems and components:
The air cleaners remove unwanted material from the air. The air cleaners
have an upper body, lower body, and dust bins. The upper body has the
primary and safety filter elements. The lower body has air cleaner tubes.
The tubes do the initial removal of most of the dust that goes into the system.
The dust bins collect the dust that is removed from the airflow.
You must do the servicing of the filter elements when the airflow is at the
maximum permitted restriction set by the engine manufacturer. There are
restriction indicators in the cab to show the airflow to the engine. You can
measure the airflow back pressure to the engine with a manometer or an air
servicing gauge calibrated in inches of water.
Consult your local engine service provider for the exact site specified engine
restriction requirements. The engine restriction requirements depend on
elevation and ambient air temperatures.
If the primary filter element becomes unserviceable, there is a safety

element to prevent the flow of unwanted material to the engine.
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Engine Air Cleaner
5.4.1 Engine Air Cleaner Ducts Removal
5.4.2 Setup
Safety]
5.4.3 Procedure
ATTENTION
This procedure is for the left side of the haul truck.
► Removal of the air cleaner ducts on the right side is the same
procedure as the left side.
1. Mark and reference the tubes before they are removed. This will make
installation easier.
2. Identify Disconnect the air restrictor lines (8) and put protective covers
on the lines.
3. Remove the T-bolt clamps (10) and the elbows (9).
4. Remove the locknuts (4) capscrews (5), washers (6), and clamps (3).
5. Remove the T-bolt clamps (7).
6. Remove the hose hump (12) and the tube (11).
7. Remove the locknuts (18) capscrews (19), washers (20), and clamps
(17).
9. Remove the tube (13) and the hose hump (14).
11. Remove the hose hump (2) and the tube (16).
12. Put protective covers on the tubes and open ports.
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Engine Air Cleaner
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04-100_000_01_Engine Air Cleaner Ducts.tif

Fig. 5.4-1: Engine Air Cleaner Ducts Removal
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Engine Air Cleaner
5.4.4 Engine Air Cleaner Ducts Installation
5.4.5 Setup
Safety]
► Make sure that all the inlet tubes are clean, free of unwanted material
or contamination, and without damage.
5.4.6 Procedure
ATTENTION
This procedure is for the left side of the haul truck.
► Installation of the air cleaner ducts on the right side is the same
procedure as the left side.
1. Install the hose hump (2) and the tube (16).
2. Install two T-bolt clamps (1) turned 180 degrees from each other.
3. Install the tube (13) and the hose hump (14).
5. Install the locknuts (4) capscrews (5), washers (6), and clamps (3).
6. Install the hose hump (12) and the tube (11).
8. Install the locknuts (18) capscrews (19), washers (20), and clamps
(17).
9. Install the elbows (9) and T-bolt clamps (10).
10. Remove the protective covers and connect the air restrictor lines (8).
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04-100_000_01_Engine Air Cleaner Ducts.tif

Fig. 5.4-2: Engine Air Cleaner Ducts Installation
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Traction Alternator
5.5 Traction Alternator
The traction alternator on the haul truck is part of the Siemens AC Drive
System and the Power Module.
The traction alternator links with these systems and components:

• [Reference: AC Drive System]
• [Reference: Pump Drive]
The traction alternator is the 3-phase AC electrical power supply for the AC
Drive System and connects to the pump drive transmission.
Refer to the Electrical Power and Distribution chapter for more information
on the traction alternator. [Reference: Electrical Power and Distribution]
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Traction Alternator
5.5.1 Traction Alternator Removal
5.5.2 Setup
Safety]
5.5.3 Procedure
NOTICE
The weight of the traction alternator is 4467 kg (9848 lb).
1. Attach an applicable lift device to the lift points on the traction alternator
(3).
2. Loosen and move the traction alternator screen guards to the aft of the
alternator.
3. Remove the bolts (4).
4. Use a barring tool on the engine to rotate the engine crankshaft when
you remove the bolts (4).
5. Remove the screws (2) and washers (1).
CAUTION! A support to hold the rotor is necessary.

► Damage to the rotor and the starter can occur if the rotor is not
supported before its removal.
► Before you remove the last bolt from the flex plate, position the rotor
so the threaded hole in the hub is in the 12 o'clock position.
6. Insert a section of all-thread into the hub so that you can see
approximately 76.2 mm (3 in) above the alternator housing.
7. Put a steel plate over the all-thread so it rests on the housing.
8. Install hardware to secure the plate and all-thread.
10. Remove the pump drive shaft guard and the drive shaft.
11. Remove the traction alternator (3) and put protective covers on all
open ports.
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LME/10880897/January 30, 2011/en
04-100_000_01_Traction Alternator.tif
Fig. 5.5-1: Traction Alternator Removal (Page 1 of 2)
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Traction Alternator
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Fig. 5.5-2: Traction Alternator Removal (Page 2 of 2)
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Traction Alternator
5.5.4 Traction Alternator Installation
5.5.5 Setup
Safety]
► Do the engine flywheel check. [Reference: Engine Flywheel Runout
Check]
► Do the alternator measurements. [Reference: Traction Alternator
Measurements]
► Do the engine endplay measurements. [Reference: Engine Endplay
Measurements]

Loctite® 242 N/A Commercially available
5.5.6 Procedure
1. Loosen and move the alternator screen guards to the aft of the
alternator.
2. Remove the bolts (9) and flex plate from the rotor.
If the quantity of the Shims Necessary is a positive number,

3. Install the necessary shims, plus or minus 0.13 mm (0.01 in) to the
alternator rotor.
If the quantity of Shims Necessary is a negative number,

4. Remove the necessary shims, plus or minus 0.13 mm (0.01 in) from
the alternator rotor.
5. Install the bolts (9) to the rotor.
6. Tighten the dry bolts (9) to 380 N m (280 lbf ft).
NOTICE
The weight of the traction alternator is 4467 kg (9848 lb).
LME/10880897/January 30, 2011/en
7. Attach an applicable lift device to the lift points on the traction alternator
(3).
8. Lift the traction alternator (3) and keep the traction alternator level.
9. Install guide studs in the screw holes of the flywheel housing.
10. Slowly align the alternator (3) with the engine and the guide studs.
11. Align the holes in the flexible coupling with their opposite holes in the
flywheel.
12. Continue to move the alternator (3) to the engine until both are fully
together.
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Traction Alternator
13. Apply a thin layer of anti-seize lubricant to the screws (2) and
capscrews (6).
15. Install the screws (2), washers (1), and remove the guide studs.
17. Tighten the screws (2) to 125 N m (92 lbf ft).
18. Move the alternator screen covers in position.
19. Apply a thin layer of Loctite® 242 to the bolts (4).
20. Remove the support from the rotor after the flex plate is inside the
flywheel.
21. Install the bolts (4) and use a barring tool on the engine to rotate the
engine crankshaft during the installation.
22. Tighten the bolts (4) to 305 N m (225 lbf ft).
23. Check the engine endplay measurements. [Reference: Engine
Endplay Measurements]
If the engine endplay measurements are not the same, you must stop
the installation and,
1. Remove the alternator and do the alternator shim
measurements.
If the engine endplay measurements are the same as in the setup,

1. Install the alternator screen guards.
2. Install the side cover to the engine.
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Traction Alternator
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Fig. 5.5-3: Traction Alternator Installation (Page 1 of 2)
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Fig. 5.5-4: Traction Alternator Installation (Page 2 of 2)
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Traction Alternator
5.5.7 Traction Alternator Measurements
5.5.8 Setup
Safety]
Required Tools and Materials for Traction Alternator

Measurements
Dial indicator with a magnetic base N/A [Reference: Service Tools]
Table 5: Required Tools and Materials for Traction Alternator Measurements
5.5.9 Procedure
1. Put the alternator in a horizontal position.
2. Remove the protective screens from the engine end of the traction
alternator.
3. Hold the engine end of the rotor with an applicable support and fully
align the rotor to the center of the windings.
4. Attach a dial indicator with a magnetic base to the frame face of the
traction alternator.
5. Set the pointer of the dial indicator on the pump drive mount flange.
6. Set the dial indicator to zero.
7. Carefully pull the rotor of the engine end forward until it fully stops.
8. Use the dial indicator to measure the distance the rotor moves from
the initial position to the forward position.
9. Release the rotor.
If the measurement is more than 0.25 mm (0.01 in),

10. See the OEM of the alternator, or your Liebherr service representative.
If the measurement is less than 0.25 mm (0.01 in),

11. Get and record five more measurements.
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If all the measurements are not equal to the first measurement or less
than 0.13 mm (0.01 in) of the first measurement,
12. See the OEM of the alternator, or your Liebherr service representative.
If all the measurements are equal to the first measurement or less than
0.13 mm (0.01 in) of the first measurement,
13. Use a depth micrometer, and a straight edge and gauge blocks to get
the next measurement.
- OR -
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Traction Alternator
14. Use a depth micrometer and the engine endplay measuring tool to get
the next measurement. [Reference: Service Tools]
15. Measure the distance from the frame mount surface to the flex plate
at the areas between the flex plate mount bolts.
16. Add or remove shims to make sure that the distance from the frame
mount surface to the flex plate is zero, plus or minus 0.13 mm (0.01
in).
Fig. 5.5-5: Traction Alternator Measurements
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Air Cleaner Restriction Check
5.6 Air Cleaner Restriction Check
5.6.1 Setup
Safety]
5.6.2 Procedure
1. Disconnect the air restriction line (2) from the air cleaner duct (1).
2. Attach a manometer or an air service gauge, calibrated in inches of
water, to the air intake duct.
3. Start the engine.
4. Operate the engine at maximum power.
5. Record the indication of airflow restriction shown on the manometer
or the air service gauge.
6. Stop the engine.
7. Disconnect the water manometer or air service gauge.
8. Connect the air restriction line (2) to the air cleaner duct (1).
The elevation and the ambient temperature determines the maximum

airflow restriction. Get the maximum airflow restriction limit from the engine
OEM.
9. Do the air cleaner service procedure. [Reference: Air Intake System
Inspection and Replacement Procedures]
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04-700_000_01_Air Cleaner Restriction Check.tif

Fig. 5.6-1: Air Cleaner Restriction Check
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Fuel System
5.7 Fuel System
The engine on the haul truck is an MTU, 20V4000, Diesel engine with 2720
kW (3650 HP). The engine uses diesel fuel to operate. The fuel is kept in
the fuel tank and the fuel and hydraulic tank. There are fuel filters to clean
the fuel before it goes in the engine.
The fuel system links with these systems and components:

• [Reference: Hydraulic Power and Distribution]
The fuel tank is on the right side of the haul truck. The fuel and hydraulic
tank is on the left side of the truck. The fuel goes through pipes and filters
to the engine. There is a fuel sensor on the top of the tank.
5.7.1 Fuel and Hydraulic Tank Drain
5.7.2 Setup
Safety]
► It is not necessary to drain the fuel from the fuel tank on the right side
of the haul truck. You must close the shutoff valve to the RACOR and
close the crossover valve. If the right side tank is to be drained, leave
the crossover valve open.
5.7.3 Procedure
WARNING! Fuel can cause skin irritation.

► Always put on protective clothing and eye protection when you work
with fuel.
NOTICE
The capacity of the fuel tank is 1514 L (400 gal).
► Make sure that the capacity of the container is enough.
1. Put an applicable container below the central service assembly.
2. Drain the fuel from the fuel tank through the central service assembly.
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Service Manual Cooling Systems
6 Cooling Systems 237

6.1 Radiator 238
6.1.1 Adding Coolant 238
6.1.2 Cleaning 239
6.1.3 Replacement Tubes 239
6.1.4 Cores with Center Tanks 239
6.1.5 Tank Gasket 239
6.1.6 Radiator Removal 241
6.1.9 Radiator Installation 247
6.1.12 Radiator Tubes Replacement 253
6.1.15 Radiator Coolant Fill 256
6.2 AC Drive Cooling System 257
6.2.1 Main Blower Housing 257
6.2.2 Auxiliary Inverter 258
6.2.3 Parameters 258
6.2.4 Auxiliary Inverter Field Test 259
6.2.5 AC Drive Cooling System Motor Removal 261
6.2.8 AC Drive Cooling System Motor Installation 263
6.2.11 Main Blower Troubleshooting 265
6.3 Alternator Cooling Duct 266
6.3.1 Alternator Cooling Duct Removal 266
6.3.4 Alternator Cooling Duct Installation 268
6.4 Axle Box Cooling Duct 270
6.4.1 Axle Box Cooling Duct Removal 270
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6.4.4 Axle Box Cooling Duct Installation 271

6.5 Gear Oil Cooling Condenser 274
6.5.1 Gear Oil Cooling Condenser Removal 274
6.5.4 Gear Oil Cooling Condenser Installation 275
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Cooling Systems Service Manual
Radiator
6.1 Radiator
05-000_000_01_Radiator.tif
Fig. 6.1-1: Radiator
The radiator is attached to the engine skid. The sight gauge lets you see the
level of coolant in the radiator. The sight gauge is on the left side of the haul
truck near the ladder. The fill cover is on the hood of the superstructure.
The radiator links with these systems:

The engine sends hot coolant to the radiator. The radiator decreases the
temperature of the coolant and sends cool coolant back to the engine.
The radiator has cooling tubes that can be replaced separately. The rubber
grommets at the ends of the cooling tubes let the tubes expand and retract.
6.1.1 Adding Coolant

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When you add coolant to the radiator, the thermostats are closed and there
is air in the radiator. When the engine is warm, the thermostats in the radiator
open and coolant flows through the radiator. The level of the coolant can
decrease suddenly when the air is released.
If the coolant is low, then wait for the engine and radiator to cool down before
the you open the cap. Slowly add the correct mixture as recommended by
the OEM of the engine. If water is used, only use distilled water or engine
damage can occur. MTU Engine Operating Instructions, if available.
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Radiator
After adding coolant, allow the engine to run in unloaded condition for
approximately 10 minutes. stop the engine and check coolant level. Add
coolant and repeat until level is correct.
6.1.2 Cleaning
To clean the radiator use a high pressure, hot water cleaner at a maximum
of 83 bar (1204 psi). The cores are coated with an epoxy. Use caution when
cleaning to prevent damage to the coating.
6.1.3 Replacement Tubes

Radiator cores can be repaired with special rubber plugs if replacement
tubes are not available. Install the plugs dry. The plugs are not
recommended for systems that operate over 1 bar (15 psi).
6.1.4 Cores with Center Tanks

To repair cores with center tanks, you must completely remove the tubes
and grommets from the top core before the bottom core is disassembled.
This is to allow the tubes in the bottom core to lift enough to clear the bottom
of the header plate. When the tubes are fully lifted, the upper end can extend
into the plate above and cause damage to the tube during removal. Do not
bend the tubes when you remove the tubes from the lower core.
6.1.5 Tank Gasket

Apply a light layer of grease on the two sides of the gasket to make a better
seal before the gasket installation.
Be careful not to damage the tank gasket during the installation.

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Radiator
05-000_000_01_Radiator Tank Gasket.tif

Fig. 6.1-2: Tank Gasket
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Radiator
6.1.6 Radiator Removal
6.1.7 Setup
Safety]
► Remove the hood and grill. [Reference: Hood and Grill Removal]
► Drain the radiator.
6.1.8 Procedure
NOTICE
The weight of the radiator without fluids is 2336 kg (5150 lb).
1. Attach applicable lift eyes (M25 swivel, or a 25.4 mm (1 in) coarse) in
the holes on the top of the radiator (35).
2. Disconnect the hoses (45) and put protective covers on the hoses and
open ports.
3. Remove the U-bolts (5), locknuts (1), and washers (2).
4. Remove the capscrews (10), and washers (11).
5. Remove the clamps (7), hoses (8), pipes (9) and (13), and gaskets
(12).
6. Remove the clamps (3), hoses (4), and pipes (6), and (14).
7. Remove the capscrews (16), lockwashers (17), gasket (18), and pipe
(15).
8. Remove the locknuts (27), washers (26), and U-bolts (19).
9. Remove the capscrews (30), and washers (31).
10. Remove the clamps (20), hoses (21), pipes (33), (34), (28) and (29),
and gaskets (32).
11. Remove the capscrews (23), lockwashers (24), pipes (22), and
gaskets (25).
12. Remove the capscrews (39), lockwashers (38), and move the brace
away from the radiator.
NOTICE
The weight of the fan guard is 35 kg (77 lb).
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13. Remove the locknuts (36), capscrews (40), washers (37), and fan
guards (44).
14. Remove the locknuts (52), capscrews (47), washers (46).
15. Remove the fan ring (51) from the radiator (35).
CAUTION! The fan and ring clearance is 19.05 mm (0.75 in).

► To prevent damage to the fan blades, be careful when you remove
the ring.
16. Remove the locknuts (50), capscrews (48), washers (49).
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Radiator
17. Remove the locknuts (41), capscrews (43), and washers (42).
18. Carefully pull the radiator (35) from the fan and away from the engine.
19. Put the radiator (35) on wooden blocks or applicable supports.
20. Slowly put the radiator (35) on the front radiator frame face on wooden
blocks or applicable supports.
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Radiator
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Fig. 6.1-3: Radiator Removal (Page 1 of 4)
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Radiator
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Radiator
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Radiator
6.1.9 Radiator Installation
6.1.10 Setup
Safety]
► Make sure the radiator is in the same configuration from the radiator
removal procedure. [Reference: Radiator Removal]
Required Tools and Materials for the Radiator Installation

Table 4: Required Tools and Materials for the Radiator Installation
6.1.11 Procedure
NOTICE
The weight of the radiator without fluids is 2336 kg (5150 lb).
1. Carefully put the radiator (35) in position on the engine skid.
2. Install the locknuts (41), capscrews (43), and washers (42).
3. Assemble the fan ring (51) with the locknuts (50), capscrews (48), and
washers (49).
4. Install the ring (51) to the radiator (35) with the locknuts (52),
capscrews (47), and washers (46).
CAUTION! The fan and ring clearance is 19.05 mm (0.75 in).

► To prevent damage to the fan, adjust the ring with the jack bolt until
you have the correct clearance.
NOTICE
The weight of the fan guard is 35 kg (77 lb).
5. Install the fan guards (44), locknuts (36), capscrews (40), and washers
(37).
6. Install the capscrews (39) and washers (38) to attach the brace to the
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radiator.
7. Install the capscrews (23), lockwashers (24), pipes (22), and gaskets
(25).
NOTICE
Install correctly the T-bolt clamps to prevent damage to the hoses.
► Make sure that you install the second T-bolt clamps of the series 180
degrees from the first T-bolt clamps.
8. Install the T-bolt clamps (20), hoses (21), pipes (33), (34), (28) and
(29), and gaskets (32).
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Radiator
9. Install the capscrews (30), and washers (31).

10. Install the locknuts (27), washers (26), and U-bolts (19).
11. Install the capscrews (16), lockwashers (17), gasket (18), and pipe
(15).
12. Install the T-bolt clamps (3), hoses (4), and pipes (6), and (14).
13. Install the T-bolt clamps (7), hoses (8), pipes (9) and (13), and gaskets
(12).
14. Install the capscrews (10), and washers (11).
15. Install the U-bolts (5), locknuts (1), and washers (2).
16. Remove the protective covers and connect the hoses (45).
17. Install the hood and grill. [Reference: Hood and Grill Installation]
18. Fill the coolant in the radiator.
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Radiator
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Fig. 6.1-7: Radiator Installation (Page 1 of 4)
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Radiator
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Radiator
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Radiator
6.1.12 Radiator Tubes Replacement
6.1.13 Setup
Safety]

Epoxy N/A Commercially available
Installation tool for the removal and N/A Commercially available
installation of radiator tubes
6.1.14 Procedure
CAUTION! Carefully clean the cores with a layer of epoxy coating to prevent
damage to the coating.
► Do a test on a small section of one tube before you start to clean. Use
a high pressure, hot water washer at a maximum of 83 bar (1204
psi).
1. To remove the tubes, increase the temperature of the tubes and

grommets with hot water.
2. Use a breaker tool at the top and bottom, but not at the middle of tube,
to loosen the tube from the grommet.
3. Put the upper jaw of the installation tool around the circular part of the
bottom of the tube below the flat part.
4. Put the lower jaw in position until the taper section of the jaw is between
the grommet and metal ferrule, but not on the grommet.
5. Close the handles of the installation tool together.
6. Lift the tube only until the bottom of the tube is away from the grommet.
7. Remove the installation tool.
8. Pull the tube out only a small distance to allow you to pull the tube
down and out of the top grommet.
9. Remove the tube.
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10. Discard the used rubber grommets.

11. Clean the tube holes and remove the unwanted material.
12. Make sure that the tube holes are dry and install new rubber
grommets.
13. Lightly hit the grommet with a rubber hammer until the shoulder of the
grommet is against the metal ferrule on the header plate.
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Radiator
If you install the used tube,

14. Use a fine grit emery cloth to polish wheel and to clean the ends of the
tube and remove the unwanted material.
15. Apply a layer of petroleum jelly to the inner holes of the grommets and
the outer ends of the tubes.
16. Push the top end of the tube into the grommet of the top header plate.
17. Adjust the bottom of the tube to the center of the grommet of the bottom
header plate.
18. Use your hand or the installation tool to push the tube down and into
the grommet.
19. Push the tube down until the formed bead is in the locking groove of
the bottom grommet.
20. Make sure that the formed bead is correctly installed in the bottom
grommet.
21. Make sure that the tubes are straight and correctly aligned.
22. Make sure that the top and bottom baffles are correctly installed.
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04-300_000_01_Radiator Tubes.tif
Fig. 6.1-11: Replacement of the Tubes
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Radiator
6.1.15 Radiator Coolant Fill
6.1.16 Setup
Safety]

Anti-freeze N/A BASF G05 or equivalent
6.1.17 Procedure
WARNING! Fluid expands and pressurizes when it is at high temperature.

► Make sure the system is cool before you add coolant to the radiator.
► Do not add fluid or make visual checks of fluid level to a hot engine.
1. Make sure that the system is cool.

2. Open the fill access cover for the radiator.
3. Fill the system with an approved coolant until it reaches the bottom of
the fill neck.
4. Start the haul truck .
5. Let the engine operate until it is at the normal temperature of operation.
When the engine is at the normal temperature of operation, the thermostats

open and fluid moves through the system.
6. Do a visual check of the radiator sight gauge.
7. Stop the engine.
8. Do a visual check of the radiator sight gauge and add recommended
coolant as necessary.
9. Close the fill access cover for the radiator.
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AC Drive Cooling System
6.2 AC Drive Cooling System
The function of the AC drive cooling system is to cool the control box, traction
alternator, and traction motors.
AC Drive Cooling System_01_Rev001.tif

Fig. 6.2-1: AC Drive Cooling System
Legend:
1. Control Box 3. Axle Box
2. Traction Alternator 4. Blower Pressure Switches
6.2.1 Main Blower Housing

The main blower is a three-phase twin AC motor blower system that pulls
air through the front vents of the control box and pushes air out of the
rectifier/alternator and axle box. The main function of the main blower is to
keep the control box (1), rectifier, alternator (2), and axle box (3) from
overheating. The main blower is powered from the auxiliary inverter. The
TCU controls the speed of the main blower and feedback is provided in the
form of two blower pressure switches (4) wired in series located inside of
the axle box. If pressure inside the axle box is equal to the atmospheric
pressure, then the connections to the main blower are made at the rear of
the blower in the center of the housing inside a junction box.
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6.2.2 Auxiliary Inverter

The auxiliary inverter, a stand-alone AC drive, takes inputs from the auxiliary
transformer and uses it to control the main blower motor (AC). It receives a
set point from the SiBAS computer, then outputs the correct blower motor
frequency.
The transformer provides power for the main blower via two contactors, a
diode rectifier, and a current limiting circuit. This configuration allows the
TCU to connect the inverter to either the high- or low-tap of the transformers
secondary windings.
6.2.3 Parameters
Minimum Frequency 2 Hz
Maximum Frequency 43 Hz (sea level) 50 Hz (high altitude)
Ramp up time 60 seconds
Ramp down time 100 seconds
Rated motor current 90 amps (60 Hp Mtr) 110 Amps (75 Hp Mtr)
Rated motor voltage 340V
Start up voltage 0V
Minimum DC Bus voltage 240 Volts
Maximum DC Bus voltage 800 Volts
Maximum measurement current 446 Amps
Maximum measurement voltage 840 Volts
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6.2.4 Auxiliary Inverter Field Test

1. With the haul truck at idle, verify the DC Bus set-point and actual bus
voltage is 1140V.
2. Check AC phase to phase voltage in CBs 141 and 142.
– Verify the input CB141 tap is approximately 230V line-to line (be
careful not to touch high-voltage).
– Verify the input of CB142 (2.4 tap) is approximately 340V line-to-
line (be careful not to touch high-voltage).
3. Remove the frontal cover of the auxiliary inverter box and get access
to the auxiliary inverter terminals.
4. Check DC input of the auxiliary inverter X1 (+) and X2 (-) terminals.
5. Check phase to phase voltage outputs of the auxiliary inverter, X4, X5,
X6.
6. With the power OFF, disconnect AC power cables from the auxiliary
inverter to the motor. This can be done by removing the safety brackets
from X4, X5, and X6.
Auxiliary Inverter Field Test_01.tif

LME/10880897/January 30, 2011/en
Legend:
1. AC Output 2. DC Input
7. Energize the system and verify phase-to-phase voltage in X4, X5, and
X6 terminals. If voltage is present, without motor connected, could be
a problem with the motor or motor cables.
8. Check motor and cables, if necessary.
9. Check contactors using "Offline Test".
10. Check the IGBT of the auxiliary inverter.
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Auxiliary Inverter Field Test_02.tif
11. Check terminals X4, X5, X6 for diode test against X1, X2.
12. The IGBT reading should be done using the diode mode of the DMM
and should read 0.6V for a functional IGBT.
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6.2.5 AC Drive Cooling System Motor Removal
6.2.6 Setup
Safety]
6.2.7 Procedure
The weight of the main blower is 2200 kg (4850 lb).
NOTICE
► Use the applicable lift device that can hold this weight.
To disconnect the alternator and axle box ducts,

1. Remove the nuts (7), capscrews (8), lockwashers (9), and washers
(10).
To remove the blower motor,

2. Remove the locknuts (1), capscrews (2), washers (3) and (4),
Fibromounts (6), and brace (5).
3. Remove the screws (11), lockwashers (12), washers (13), and blower
motor (14).
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04-100_000_01_AC Drive Cooling System Motor.tif

Fig. 6.2-3: AC Drive Cooling System Motor Removal
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6.2.8 AC Drive Cooling System Motor Installation
6.2.9 Setup
Safety]
6.2.10 Procedure
NOTICE
The weight of the main blower is 2200 kg (4850 lb).
To install the blower motor, do this procedure:

1. Install the blower motor (14), washers (13), lockwashers (12), and
screws (11).
2. Install the Fibromounts (6), brace (5), washers (4) and (3), capscrews
(2) and locknuts (1).
To connect the alternator and axle box ducts,

3. Install the washers (10), lockwashers (9), capscrews (8) and nuts (7).
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04-100_000_01_AC Drive Cooling System Motor.tif

Fig. 6.2-4: AC Drive System Motor Installation
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6.2.11 Main Blower Troubleshooting
MBLW1
Possible Fault How to check this fault Remedy Comment
Verify the wiring is correct
between the auxiliary inverter and
the main blower as per the
Siemens schematic.
The main blowe rmoves air in the opposite direction
Verify the wiring from the motor
winding cables to the j-box
terminal board is correct as per the
electrical specification. Correct
the wiring as necessary to retry. If
the airflow is till reversed, then the
motor winding cables are
incorrectly labeled. Swap any two
(labeled 1-3_ cables and re-label
as per rework.
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Alternator Cooling Duct
6.3 Alternator Cooling Duct
6.3.1 Alternator Cooling Duct Removal
6.3.2 Setup
Safety]
6.3.3 Procedure
1. Remove the clamps (1) and flex duct (2).
2. Remove the nuts (3), capscrews (4), lockwashers (5), washers (6),
and transition duct (7).
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04-100_000_01_Alternator Cooling Duct.tif

Fig. 6.3-1: Alternator Cooling Duct Removal
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6.3.4 Alternator Cooling Duct Installation
6.3.5 Setup
Safety]
6.3.6 Procedure
1. Install the transition duct (7), washers (6), lockwashers (5), capscrews
(4), and nuts (3).
2. Install the flex duct (2) and clamps (1).
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04-100_000_01_Alternator Cooling Duct.tif

Fig. 6.3-2: Alternator Cooling Duct Installation
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Axle Box Cooling Duct
6.4 Axle Box Cooling Duct
6.4.1 Axle Box Cooling Duct Removal
6.4.2 Setup
► Follow the haul truck safety precautions. [Reference: haul truck
Safety]
6.4.3 Procedure
NOTICE
The weight of the axle box transition duct is more than 12 kg (26 lb).
2. Remove the nuts (13), lockwashers (12), capscrews (9), washers (10),
and transition duct (11).
NOTICE
The weight of the axle box cooling duct is more than 30 kg (66 lb).
3. Remove the nuts (21), lockwashers (20), washers (19), capscrews
(17), clamps (18), and duct (16).
5. Remove the clamps (1) and flex ducts (2).
NOTICE
The weight of the axle box Y duct is more than 119 kg (262 lb).
6. Remove the locknuts (4), washers (5), capscrews (6), and Y duct (3).
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04-100_000_01_Axle Box Cooling Duct.tif

Fig. 6.4-1: Axle Box Cooling Duct Removal
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6.4.4 Axle Box Cooling Duct Installation
6.4.5 Setup
Safety]
6.4.6 Procedure
1. Install the flex ducts (2) and clamps (1).
NOTICE
The weight of the axle box transition duct is more than 12 kg (26 lb).
2. Install the Y duct (3), washers (5), capscrews (6), and locknuts (4).
NOTICE
The weight of the axle box cooling duct is more than 30 kg (66 lb).
4. Install the duct (16) and clamps (18).
5. Install the capscrews (17), washers (19), lockwashers (20), and nuts
(21).
NOTICE
The weight of the axle box Y duct is more than 119 kg (262 lb).
6. Install the transition duct (11), washers (10), capscrews (9),
lockwashers (12), and nuts (13).
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04-100_000_01_Axle Box Cooling Duct.tif

Fig. 6.4-2: Axle Box Cooling Duct Removal
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Gear Oil Cooling Condenser
6.5 Gear Oil Cooling Condenser
6.5.1 Gear Oil Cooling Condenser Removal
6.5.2 Setup
Safety]
6.5.3 Procedure
1. Disconnect the hoses.
2. Put protective covers on the hoses and open ports.
3. Remove the locknuts (1), washers (3), and capscrews (2).
05-100_000_01_Gear Oil Cooling Condenser.tif

Fig. 6.5-1: Gear Oil Cooling Condenser Removal
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Gear Oil Cooling Condenser
6.5.4 Gear Oil Cooling Condenser Installation
6.5.5 Setup
Safety]
6.5.6 Procedure
1. Install the locknuts (1), washers (3), and capscrews (2)..
2. Remove protective covers and install and reconnect the hoses.
05-100_000_01_Gear Oil Cooling Condenser.tif

Fig. 6.5-2: Gear Oil Cooling Condenser Installation
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Service Manual Electrical Power and Distribution
7 Electrical Power and Distribution 277

7.1 AC Drive System 279
7.1.2 Field Regulator 283
7.1.3 Main Rectifier 284
7.1.4 DC-DC Converter Box 285
7.1.5 Auxiliary Inverters 286
7.1.6 Inverters 287
7.1.7 Chopper 288
7.1.8 DC Link Capacitors 289
7.1.10 Grid Box 291
7.1.11 Main Blower Assembly 292
7.1.12 Cooling Pump 294
7.1.13 Pre-Heaters 295
7.1.14 Main Programmable I/O Module 296
7.1.15 Inverter Controller 297
7.1.16 Mini Programmable I/O Module 298
7.1.17 CAN Temperature Module 299
7.1.18 Independent Power Control 300
7.1.19 Touch Screen Display Panel 301
7.2 Main Rectifier Removal 302
7.3 Main Rectifier Installation 304
7.4 DC to DC Converter Box Removal 306
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7.5 DC to DC Converter Box Installation 308

7.6 Inverters Removal 310
7.7 Inverters Installation 312
7.8 Chopper Removal 314
7.9 Chopper Installation 316
7.10 DC Link Capacitor Removal 318
7.11 DC Link Capacitor Installation 320
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Electrical Power and Distribution Service Manual
7.12 Battery Disconnect Switch Box 322

7.12.1 24 VDC Battery Isolator Switch 322
7.12.2 Starter Isolator Switch 322
7.12.3 Battery Charger Receptacle 322
7.12.4 Propulsion Lockout Switch 322
7.13 24 VDC Battery Bank 323
7.13.1 Batteries Removal 324
7.13.4 Batteries Installation 326
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AC Drive System
7.1 AC Drive System
Module_02_Rev000.tif
Fig. 7.1-1: Schematic: AC Drive System
Legend:
1. Traction 6. Brake Chopper
Alternator 7. Power Stack(s)/IGBT Inverter(s)
2. Field 8. Traction Motor(s)
Regulator
9. Auxiliary Power Conversion
3. Main Rectifier
9.1. Frequency
4. Chopper Converters
Module
9.2. DC/DC Converter
5. DC Link
9.3. Main Blower
Capacitor
Assembly
9.4. Resistor Grid Box
Assembly
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AC Drive System
7.1.1 Traction Alternator
Module_15566-K_02_Rev000.tif
Fig. 7.1-2: Traction Alternator
The traction alternator produces electrical power from mechanical power

from the engine. The alternator is an AC generator that uses an interaction
of magnetic fields to produce voltage when coupled to a routing engine.
The output of the alternator is dependent on the rotational speed of the

alternator and the current supplied by the exciter field regulator.
The Traction Alternator is a brushless 3-phase, 6-wire, 8-pole synchronous

AC generator. The traction alternator is mechanically coupled to both the
diesel engine and, via the driveshaft, the hydraulic pump drive transmission.
It provides the variable AC voltage source for the electric drive system during
diesel operations. The alternator is electrically connected to the main
rectifier.
Traction Alternator Specifications Table

Rated Voltage 1872 VAC
Normal Power 2147 kW
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Apparent Power 2260 kVA

Rated Current 697 Amps
Frequency 120 Hz
RPM 1800
Table 1: Traction Alternator Specifications Table
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AC Drive System
Fig. 7.1-3: Traction Alternator Cut-Away
Legend:
1. Exciter Stator Windings 3. Exciter Rotor Windings
2. Motor Rotor Windings 4. Main Stator Windings
The brushless Traction Alternator is an electromechanical device that

converts mechanical energy from the diesel engine into AC electrical
energy.
The alternator generates electricity when the rotating magnetic field

established in the rotor windings turns within the stationary set of conductors
wound in coils on an iron core, called the stator.
The magnetic fields established in the rotor windings cuts across the
conductors in the stator windings, inducing an AC voltage in them as the
engine’s crankshaft causes the rotor to turn.
The output of the rotating exciter winding is controlled by a stationary

winding mounted on the stator called the stationary exciter field winding.
The magnetic flux (field strength) of the stationary exciter field winding is
directly proportional to the current supplied by the exciter field regulator.
The stationary exciter field magnetic field interacts with the rotating exciter
field winding to produce an AC voltage output that is then rectified by the
rotating rectifier as a DC current source for the main rotor windings.
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AC Drive System
Fig. 7.1-4: Traction Alternator Cut-Away: Rotating Rectifier Assembly
Legend:
1. Exciter Stator Windings 3. Exciter Rotor
2. Rotating Rectifier Assembly Windings
The magnitude of AC voltage generated by the alternator is dependent upon

the rotor magnetic field strength and speed of the rotor. The DC current to
produce the magnetic field in the rotor windings is supplied by the rotating
rectifier located on the rotor itself. The rotating rectifier converts the AC
voltage supplied by the rotating exciter winding into DC current.
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7.1.2 Field Regulator
Module_Field Regulator_01_Rev000.tif
Fig. 7.1-5: Field Regulator
The field regulator is located on the upper compartment of the control box
on the right side. The regulated output current Iout (for example 0 to 10A,
is proportional to the input set-point, for example 4-20mA. and constant over
the whole input voltage range, load range and temperature range. The
output voltage, for example 0-90VDC is the result of Iout and the reactance
of the field winding. The field regulator provides a feedback of 0-4VDC to
the Main Programmable I/O Module that is proportional to the output current.
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AC Drive System
7.1.3 Main Rectifier
Module_Main Rectifier_01_Rev000.tif
Fig. 7.1-6: Main Rectifier
The main rectifier is on the traction control cabinet behind the auxiliary
inverters. The unit is a non-controlled 6-pulse rectifier that produces DC bus
voltage from the 3-phase alternating current (AC) voltage from the traction
alternator. The DC output is rated at 2000V @ 1250A. AC Input is rated at
1600 V @ 900A. The unit is liquid cooled.
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AC Drive System
7.1.4 DC-DC Converter Box
532_DC_DC Converter_000_Rev000.tif
Fig. 7.1-7: DC/DC Converter
The direct current (DC)/DC Converter is located in the back of the Control
Cabinet. It uses IGBTs to convert the main DC bus (> 800VDC) to a 650
VDC supply to the auxiliary inverters. It also provides a redundant 24VDC
in case of a failure of the normal 24VDC bus. Inductors are placed in series
with the output to provide filtering. The unit is liquid cooled. Loss of cooling
flow will result in catastrophic failure.
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7.1.5 Auxiliary Inverters
532_Auxiliary Inverters_000_Rev000.tif
Fig. 7.1-8: Auxiliary Inverters
The auxiliary inverters are located in the far left compartment of the control
box. There are 3 auxiliary inverters on the haul truck.
The main blower, grid blower, and cooling pump are controlled by an
auxiliary inverter. The auxiliary inverter changes the DC input from the DC/
DC Converter to a variable frequency, three phase, AC output. The unit is
connected to the Main Programmable I/O Module, through a Controller Area
Network (CAN) bus, which monitors and controls the output. This provides
start, stopping, and speed controls. The converter can be programmed with
a wide variety of parameters. It also has a self diagnostic system which
enables the technician to quickly diagnose faults. The converters for the
main blower and grid blower are liquid cooled. The converter for the coolant
pump is air cooled.
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AC Drive System
7.1.6 Inverters
Module_Litronic Plus Control Box_02_Rev000.tif

Fig. 7.1-9: Inverters
The inverters, or power stacks (2), are in the bottom compartment of the
control box. The inverters are the electronic devices that are used to convert
DC to AC. The inverters are comprised of 6 insulated gate bipolar transistors
(IGBT). The IGBTs are used to provide 3-phase AC current for the traction
motors on the rear wheels. The control cabinet has 4 liquid cooled inverters.
Each traction motor is controlled by a Inverter Controller. The FC Controller

monitors and controls the power stack output. It will control the pulse width
modulation (PWM) on time and off time length to conduct the top IGBT and
the bottom IGBT alternately to create the AC current output, based on the
Main Programmable I/O Module torque request.
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7.1.7 Chopper
Module_Chopper Module_02_Rev000.tif
Fig. 7.1-10: Chopper
The chopper is located in the center compartment of the control box. The
chopper is installed to the left of the power stacks. The chopper controller
is included in FC1. The difference to the other FCs is an extra chopper fiber
link card on the very right side.
The chopper module is an electrical device that is used to dissipate excess

energy from the DC link in the grid resistors. The brake chopper is comprised
of four IGBTs and four diodes. This unit is controlled and monitored by the
chopper controller. Like the power stacks, the brake chopper is liquid cooled.
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Module_Chopper Module_05_Rev000.tif
Fig. 7.1-11: Chopper
Legend:
1. Brake Chopper 5. DC Bus (-)
2. Grid Box 6. TGrid Resistor
3. DC Bux (+) 7. Water Cooling
4. DC Link Capacitor
When a voltage level on the DC bus is detected to be above the desired

level, the IGBTs are gated on. The excess energy will be dissipated in the
grid resistors, causing them to heat up. When the DC Link voltage falls below
the desired level the IGBTs will be turned off.
7.1.8 DC Link Capacitors
Module_DC Link Capacitors_03_Rev000.tif

Fig. 7.1-12: DC Link Capacitors
The DC Link capacitors are connected directly to the inverters and brake
chopper as a unit. The unit is at the back of the control cabinet. A capacitor
is a passive electronic component that stores energy in the form of an
electrostatic field. The DC Link capacitors are used to minimize the ripple
voltage, which improves the operation of the IGBTs. The system has five
4mF capacitors that are labeled C5, for the brake chopper and C1 – C4
which correspond to the power stacks.
When a voltage level on the DC bus is detected to be above the desired

level, the IGBTs are gated on. The excess energy will be dissipated in the
grid resistors, causing them to heat up. When the DC Link voltage falls below
the desired level the IGBTs will be turned off.
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AC Drive System
7.1.9 Traction Motor
Traction Motor_000_01.tif
Fig. 7.1-13: Traction Motor
The traction motor is a four-pole, 6-wire, 3-phase induction motor designed

specifically to power the drive wheels on AC Drive haul trucks. Drive torque,
for both motoring (propel) and dynamic braking, is provided by the squirrel
cage AC traction motors. The motors are forced ventilated , open air cooling
circuit. The motors are independently controlled by the inverters. The
traction motor is intended for transverse mounting in the vehicle.
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7.1.10 Grid Box
532-Mosbach_Gridbox_01.tif
Fig. 7.1-14: Grid Box
The grid box is located on the main deck adjacent to the Control Cabinet
and is used to house the resistor grids and blower motor. It dissipates the
energy generated by the traction motors during dynamic braking.
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AC Drive System
532_Siemens Grid Box_000_Rev001_02.tif

Legend:
1. Resistor Grid 3. Blower Fans
2. Blower Motor
The resistor grid box is comprised of four banks of resistors which are forced
ventilated by a dual-wheel centrifugal blower system. The grid box blower
motor is controlled by an auxiliary inverter.
In the chopper, each IGBT is connected to a grid resistor bank. Of the four
grid resistor banks, two are connected to the positive DC bus and two are
connected to the negative DC bus. When a voltage level on the DC bus is
detected to be above the desired level, the IGBTs are gated on. The excess
energy will cause the resistor to heat up, thus dissipating the excess energy.
LME/10880897/January 30, 2011/en
When the DC Link voltage falls below the desired level the IGBTs will be
turned off.
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7.1.11 Main Blower Assembly
532_Main Blower Assembly_01_Rev000.tif

Fig. 7.1-16: Main Blower Assembly
Legend:
1. Axle Box 4. Main Blower
2. Control Box 5. Traction Alternator
3. Air/Water Heat Exchanger
The main blower assembly mounts under the rear portion of the control
cabinet above the traction alternator. The Main Blower Assembly provides
cooling for the traction alternator and wheel motors. Air drawn in to the main
blower through the control cabinet also cools an air/water-heat exchanger.
The 75 kW motor is connected to two fans in the main blower assembly
Blower speed is controlled by the Main Programmable I/O Module

depending on traction motor, alternator, and cooling fluid temperatures.
Should a ground fault occur, the blower is automatically run at full speed to
remove moisture out of the system which could be the cause of the ground
fault error.
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AC Drive System
7.1.12 Cooling Pump
532_Cooling Pump_000_Rev000.tif
Fig. 7.1-17: Cooling Pump
The coolant pump and air/water-heat exchanger are located in the back of
the control cabinet. The cooling system pump is run at a constant speed of
3600 RPM. Upon start up of the haul truck, the cooling pump begins to run.
The Main Programmable I/O Module monitors the flow rate in the system to
ensure proper flow to the power components. Without proper flow, the Main
Programmable I/O Module will not allow the drive system to come online. In
the event of cooling liquid loss during truck operations the Main
Programmable I/O Module will allow retarding until the truck is safely
stopped. The Main Programmable I/O Module will then inhibit the propel.
Overheating of the power components can cause a severe failure.
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7.1.13 Pre-Heaters
532_Preheaters_000_Rev000.tif
Fig. 7.1-18: Pre-Heaters
The pre-heaters are located throughout the control cabinet in various

places. While cooling of the power components is important, heating of the
power components in cold climates is equally important prior to operation.
There are seven pre-heater units installed to heat the control cabinet. They
are located at the bottom of the control cabinet and near the auxiliary
frequency controllers. The heaters are thermostatically controlled units.
They are designed for high atmospheric humidity environments. The units
are waterproof. The pre-heater system is controlled by the Main
Programmable I/O Module. The heaters are preset to turn on at
temperatures below 0 ºC (32 ºF)° for a period of 20 minutes. Each heater
controls its maximum temperature with an internal thermostat. The heaters
are only used when the truck is parked. A separate power cord is plugged
in to the truck to supply power to the heating units.
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AC Drive System
7.1.14 Main Programmable I/O Module
Module_2_Main PLC_04_Rev000.tif
Fig. 7.1-19: Main Programmable I/O Module Connection Ports
Legend:
1. USB Connections 7. Reset Button
2. LAN Connections 8. Digital Visual Interface
3. RS232 Interface 9. Four CAN Connections
4. Digital I/Os 10. CF-CARD Slot
5. Status LEDs 11. WAGO Interface Module (K-
6. Power Supply Bus)
The main programmable I/O module is located in the control cabinet behind
the inverter control rack. The main programmable I/O module is a Linux-
based programmable logic controller that combines the truck and the drive
functionality in one single unit. It can be programmed by CoDeSys including
the CoDeSys target and web visualization. It has a rugged design, which
makes it suitable for harsh environmental applications. The Main
Programmable I/O Module unit has four CAN connections. The first two are
communication connections to the inverter controllers and the CAN Modules
in the control cabinet. The second two are used to communicate with the
CAN Modules mounted on the truck
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7.1.15 Inverter Controller
532_Inverter Controller_000_Rev000.tif
Fig. 7.1-20: Inverter Controller
There are several inverter controllers in the Litronic Plus AC Drive system.
The inverter controllers are the interface between the power components
and the Main Programmable I/O Module. The inverter controllers monitor
and control the power stacks, the brake chopper, and the DC-DC converter.
Control of the power components is accomplished through fiber optic
connections.
The inverter controller is located in the upper compartment of the control

cabinet. The DC-DC Converter inverter Controller is located in the DC-DC
Converter box at the back of the control cabinet.
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AC Drive System
7.1.16 Mini Programmable I/O Module
532_Main PLC_000_Rev000.tif
Fig. 7.1-21: Mini Programmable I/O Module
The haul trucks contain several sensors. All of these components must be
controlled and monitored and the data communicated to the Main
Programmable I/O Module. Several PLCopen programmable I/O modules
provide this communication.
The programmable I/O modules have a large amount of digital / analog

inputs and digital outputs. Some of the digital outputs can be configured to
be used as digital inputs and visa versa. This PLCopen programmable (with
CoDeSys tool) module can also be used as an independent controller
because of digital and analog I/O capabilities. The programmable I/O
modules have two CAN-busses.
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7.1.17 CAN Temperature Module
532_CAN Temperature Controller_000_Rev001.tif

Fig. 7.1-22: CAN Temperature Module
There are 3 CAN Temperature Modules on the haul truck. One is located
near the traction alternator. Two are located in the axle box. Temperature
monitoring of traction motors, gear sets, and the traction alternator is crucial
to proper operation of the haul truck. Being aware that a component is
overheating enables an operator to take corrective action before
catastrophic failure occurs.
The CAN Temperature Modules are designed for applications where

temperatures are measured from a long distance. This reduces the need for
a long and expensive thermo couple wire. One module can accommodate
4 temperature sensor types J and K as well as PT100. The modules operate
on 24 VDC supplied from the truck batteries. Each module on the haul truck
is identified by a node ID which is configured by dip switches inside the unit.
The baud rate is also configured by dip switches located in the unit.
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AC Drive System
7.1.18 Independent Power Control
532_Independent PWR CTRL_000_Rev000.tif

Fig. 7.1-23: Independent Power Control
The Independent Power Control (IPC) is located in the upper compartment

of the control cabinet. The IPC functions as a signal conditioner and power
supply for the voltage sensors and current transducers. The unit also
supplies emergency chopper control and exciter disable control. The IPC
provides electromagnetic interference shielding to the signals entering and
exiting the unit. The IPC also provides for real time error monitoring of the
voltage and current sensors and the DC link to the Main Programmable I/O
Module. The LED indicators, on the front of the unit, show status of the IPC,
DC Link, sensors and emergency chopper.
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7.1.19 Touch Screen Display Panel
532_HMI_000_01.tif
Fig. 7.1-24: Touch Screen Display Panel
The touch screen display panel give the operator and the service technician
information on the operations, conditions, and performance of the haul truck.
All systems monitored by the Main Programmable I/O Module can be
programmed to be displayed on the touch screen display panel.
The information screens available to the operator will be general operating

conditions. Load weight, truck speed, and general shift statistics. Service
personnel can also access screens that will truck fault data.
Power is supplied from the 24 volt ignition circuit through a 10 amp circuit
breaker. Connection to the Main Programmable I/O Module is supplied
through an Ethernet cable.
The information screens available to the operator will be general operating
WARNING! Do not disconnect any cables from the touch screen monitor
with power ON.
► Failure to turn off the touch screen monitor through its front power
switch and to turn off the haul truck ignition can result in damage to
the monitor or to the electrical system.
► Before you remove any cables from the touch screen monitor, turn off
the front power switch, and the haul truck ignition.
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Main Rectifier Removal
7.2 Main Rectifier Removal
7.2.1 Setup
Safety]

Approved, high-voltage probe N/A Commercially available
Multi-meter N/A Commercially available
► Check the DC Link bus for voltage with an approved high voltage probe
and again with a multi-meter.
► Attach a grounding cable to make sure the DC link capacitors are
discharged.
► Remove the safety cables (to per phase) from the traction alternator
that connect to the main rectifier.
7.2.2 Procedure
1. There are six cables (1) (two per phase) from the traction alternator
that connect to the main rectifier (2 ). Disconnect the cables (1) from
the left connection (3 ) of the rectifier (2). Discard the Nord-Lock
washers (4).
– Use the bolt (5 ) and the nut to connect the two phase
connections (6) together.
– Make sure the cables are clearly marked (1).
2. At the bottom of the rectifier (2), remove the two cooling hoses (7 ).
– Pull the outer sleeve down while you simultaneously pull down
the connection (3).
3. Remove the two foundation bolts (8) from the bottom of the rectifier
(2).
– Make sure the safety grounding cable (9) is moved out of the way
when pulling the rectifier (2). Discard the Nord-Lock washers (4).
4. Remove the two bus connection bolts (10) at the top of the rectifier (2).
Discard the Nord-Lock washers (4).
5. Remove the two wall mounting bolts (11) from the back of the rectifier
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(2). These bolts are retained in the rectifier housing and will not come
out completely.
NOTICE
The weight of the main rectifier is 0 kg (0 lb).
► Damage to the air water heat exchanger can occur if the converter
box is dropped.
► Use an applicable device that can safely lift and support the
component weight.
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Main Rectifier Removal
6. Remove the rectifier (2). In a clear area, place the rectifier (2) on a flat
surface.
If the rectifier (2) is to be left out for longer than 30 minutes,
– reattach the bus connection bolts (10) and place the safety
grounding cable (9) onto the DC link bus (11).
532_Main Rectifier_100_01.tif
Fig. 7.2-1: Main Rectifier Removal
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Main Rectifier Installation
7.3 Main Rectifier Installation
7.3.1 Setup
Safety]
► Make sure the haul truck is in the same configuration from the main
rectifier removal procedure. (Ref.: Main Rectifier Removal)

► If attached, remove the safety grounding cable. Remove the bus
connection.
► Make sure the ground cable is clear and cannot get damaged when
sliding the rectifier back into the cabinet.
► Put the rectifier onto the track and carefully slide it back to the back of
the cabinet.
7.3.2 Procedure
NOTICE
The weight of the main rectifier is 0 kg (0 lb).
► Use an applicable device that can safely lift and support the
component weight.
1. Begin to tighten the two hex bolts (11) that connect the rectifier (2) to
the back wall.
– Do not tighten fully until all bolts (11) are started. You can move
the rectifier (2) slightly to align the holes.
2. Install the two foundation bolts (8) at the bottom of the rectifier (2)
– Make sure the safety ground cable (9) is connected and the
Nord-Lock washers (4) are placed on either side of the ground
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cable terminal.
– The other foundation bolt will require only one Nord-Lock washer.
3. Connect the cooling hoses (7) at the bottom of the rectifier (2).
4. Attach the traction alternator cables (1).
– Make sure the Nord-Lock washers (4) are placed on the two
sides of the connection (3).
– Start from the top terminal to connect cable L1, L2, then L3.
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Main Rectifier Installation
532_Main Rectifier_100_01.tif
Fig. 7.3-1: Main Rectifier Installation
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DC to DC Converter Box Removal
7.4 DC to DC Converter Box Removal
7.4.1 Setup
Safety]

Ply wood N/A Commercially available
► Attach a grounding cable to make sure the DC link capacitors are
discharged.
► Place a piece of plywood on top of the air water heat exchanger under
the DC to DC converter to protect the exchanger from damage.
7.4.2 Procedure
1. At the bottom of the DC to DC converter, remove the two cooling
hoses.
on the connection.
2. Remove the cover, and disconnect the ground cable from the cover.
3. Disconnect the X2 connector.
4. Disconnect the CAN cable from the master CPU card.
– Loosen the cable gland for the cable.
– Carefully pull the cable out of the converter box.
5. Disconnect the ground cable from the outside of the converter box.
Discard the Nord-Lock washers.
6. Loosen the seven cable glands at the bottom right side of the converter
box.
– Before disconnecting the input and output cables, make sure the
cables and the connection points in the cabinet are clearly
LME/10880897/January 30, 2011/en
labeled.
– Disconnect the seven input and output cables. Discard all Nord-
Lock washers.
– Carefully pull the cables out of the converter box. Cables
attached to IGBT Q1 and Q2 at connection E2 are run through a
current transducer. Carefully pull the cables through the
transducer taking care not to put unnecessary pressure on the
transducer.
– Remove the cables from the converter box.
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DC to DC Converter Box Removal
7. Remove the four mounting bolts from the top and bottom of the outside
of the converter box. Be careful to support the converter box.
532_DC to DC Converter_100_01.tif
Fig. 7.4-1: DC to DC Converter Box Removal
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DC to DC Converter Box Installation
7.5 DC to DC Converter Box Installation
7.5.1 Setup
Safety]
► Make sure the haul truck is in the same configuration from the DC to
DC converter box removal procedure. (Ref.: DC to DC Converter Box
Removal)

Plywood N/A Commercially available
► Attach a safety grounding cable to make sure the DC link capacitors
are discharged.
► Put a piece of plywood on top of the air water heat exchanger under
the DC to DC converter to protect the exchanger from damage.
7.5.2 Procedure
1. Remove the cover. Disconnect the ground cable from the cover.
2. Carefully position the converter in place to insert the mounting bolts
on the top and bottom of the outside of the converter box.
3. Insert the seven input and output cables. Cables attached to the IGBT
Q1 and Q2 at connection E2 are run through a current transducer.
Carefully pull the cables through the transducer taking care not to put
unnecessary pressure on the transducer.
– Use the provided schematics to connect the input and output
cables to the correct connection points.
– Tighten all cable glands.
4. Connect the ground cable to the outside of the converter box.
5. Carefully insert the CAN cable through the cable gland.
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– Attach the CAN cable to the master CPU card.

– Make sure the end of the line resistor is installed into the outer
CAN connection on the master CPU card.
– Tighten the cable gland.
6. Connect the X2 connector.
– Reattach the ground cable to the cover, and reinstall the cover.
7. Connect the cooling hoses at the bottom of the converter.
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DC to DC Converter Box Installation
532_DC to DC Converter_100_01.tif
Fig. 7.5-1: DC to DC Converter Box Installation
LME/10880897/January 30, 2011/en
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Inverters Removal
7.6 Inverters Removal
7.6.1 Setup
Safety]

► Attach a grounding cable.
7.6.2 Procedure
1. At the bottom of the inverter (1), remove the two cooling hoses (2).
on the connection.
2. Disconnect the fiber optic (3) connection and carefully pull the cable
through the opening of the inverter housing.
– Replace the cover on the connector to make sure it remains
clean.
– Make sure the cable is not bent and there enough cable
clearance for it to be safely pulled from the inverter without
damage.
3. Remove the insulating (4) cover from the bus bolts (5) at the top of the
inverter. Discard the Nord-Lock washers.
4. Remove the three bus bolts (5) from the top of the inverter. Discard
the Nord-Lock washers.
5. Remove the two foundation bolts (6) from the bottom of the inverter.
– Make sure the ground cable is moved out of the way when pulling
the inverter. Discard the Nord-Lock washers.
6. Loosen the eight hex bolts (7) from the back of the inverter. These
bolts are retained in the inverter housing and will not come out
completely.
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7. Remove the inverter. In a clear area, place the inverter on a flat surface
on its side. Do not leave the inverter standing upright.
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Inverters Removal
532_Inverters_100_01.tif
Fig. 7.6-1: Inverters Removal
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Inverters Installation
7.7 Inverters Installation
7.7.1 Setup
Safety]
► Make sure the haul truck is in the same configuration from the inverters
removal procedure. (Ref.: Inverters Removal)

► Make sure the fiber optic, and the ground cables are clear and cannot
get damaged when sliding the inverter into the cabinet.
► Put the inverter onto the track and carefully slide back to the capacitor.
7.7.2 Procedure
1. Begin to tighten the eight hex bolts (7) that connect the inverter to the
capacitor at the back of the inverter.
– Do not tighten fully until all bolts are started. You can move the
inverter slightly to align the holes.
– Use the alternating method by starting one bolt on one side of
the inverter then move to the other side.
– Repeat the alternating procedure until all bolts are started.
– When all bolts have been started, begin to tighten all bolts using
the alternating method.
2. Install the two foundation bolts (6) at the bottom of the inverter.
– Make sure the ground cable is connected and the Nord-Lock
washers are placed on either side of the ground cable terminal.
3. Insert the bus connection bolts (5) at the top of the inverter. The Nord-
LME/10880897/January 30, 2011/en
Lock washers will be placed on either side of the bus connection.

4. Install the insulating cover over the bus bolts (5) at the top of the
inverter.
5. Carefully pull the fiber optic connector through the hole in the side of
the inverter.
– Remove the covers from cables and inverter connection, and
attach the fiber optic connector to the inverter connection (3).
6. Attach the cooling hoses to the bottom of the inverter (2).
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Inverters Installation
532_Inverters_100_01.tif
Fig. 7.7-1: Inverters Installation
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Chopper Removal
7.8 Chopper Removal
7.8.1 Setup
Safety]

7.8.2 Procedure
1. At the bottom of the chopper (1), remove the two cooling hoses (2).
– Pull the outer sleeve down while simultaneously pulling down on
the connection.
2. Disconnect the fiber optic connection (3) and carefully pull the cable
through the opening of the chopper housing.
– Replace the cover on the connector to make sure it stays clean.
– Make sure the cable is not bent and has enough clearance from
damage when the copper is pulled out.
3. Remove the cover from the current transducer connection box located
at the bottom front of the chopper.
– Unplug the RS232 connection (4) and carefully pull the cable
through the opening of the chopper housing.
4. Remove the insulating cover (5) from the bus bolts at the top of the
chopper. Discard the Nord-Lock washers.
5. Remove the four bus bolts from the top of the chopper. Discard the
Nord-Lock washers.
6. Remove the two foundation bolts (7) from the bottom of the chopper.
– Make sure the grounding cable is moved out of the way while you
pull the chopper. Discard the Nord-Lock washers.
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7. Loosen the eight hex bolts (8) from the back of the chopper. These
bolts are retained in the chopper housing and will not come out
completely.
8. Remove the chopper. In a clear area, place the chopper on a flat
surface on its side. Do not leave the chopper standing upright.
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Chopper Removal
532_Chopper_100_01.tif
Fig. 7.8-1: Chopper Removal
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Chopper Installation
7.9 Chopper Installation
7.9.1 Setup
Safety]
► Make sure the haul truck is in the same configuration from the chopper
removal procedure. (Ref.: Chopper Removal)

► Make sure the fiber optic, an the ground cables are clear and cannot
get damaged while you slide the chopper into the cabinet.
► Place the chopper onto the track and carefully slide back to the
capacitor.
7.9.2 Procedure
1. Begin to tighten the eight hex bolts (8) that connect the chopper to the
capacitor at the back of the chopper. Start one bolt on the side of the
chopper then move to the other side.
– Do not tighten fully until all bolts are started. The chopper may
require to be moved to align the holes
the chopper then move to the other side
– Repeat this procedure until all bolts are started.
– When all bolts have been started use the alternating method to
tighten all bolts.
2. Install the two foundation bolts (7) at the bottom of the chopper.
– Make sure the ground cable is connected and the Nord-Lock
washers are placed on both sides of the ground cable terminal.
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3. Insert the grid connection bolts (6) at the top of the chopper. The Nord-
Lock washers will be placed on the two sides of the grid connection.
4. Install the insulating cover over the grid bolts (5) at the top of the
chopper.
5. Carefully pull the fiber optic connector (3) through the hole in the side
of the chopper.
6. Remove the cover from the current transducer connection box located
at the bottom front of the chopper.
– Carefully pull the RS232 cable through the chopper housing.
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Chopper Installation
– Plug the RS232 cable into the current transducer connection box
and reinstall the cover.
7. Attach the cooling hoses (4) to the bottom of the chopper.
532_Chopper_100_01.tif
Fig. 7.9-1: Chopper Installation
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DC Link Capacitor Removal
7.10 DC Link Capacitor Removal
7.10.1 Setup
Safety]

► Remove the inverter or chopper module attached to the capacitor.
Ref.: Inverter Removal, Ref.: Chopper Removal
7.10.2 Procedure
1. Remove the two foundation bolts (2) from the bottom of the capacitor.
– Make sure the grounding cable is moved out of the way when
pulling the capacitor. Discard the Nord-Lock washers.
2. Remove the two wall mounting bolts (3) from the back of the capacitor.
Discard the Nord-Lock washers.
3. Loosen the four hex bolts (4) from the bus connection at the top back
of the capacitor. These bolts are retained in the capacitor housing and
will not come out completely.
4. Remove the capacitor. In a clear area, place the capacitor on a flat
surface on its side. Do not leave the capacitor standing upright.
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DC Link Capacitor Removal
532_DC Link Capacitor_100_01.tif

Fig. 7.10-1: DC Link Capacitor Removal
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DC Link Capacitor Installation
7.11 DC Link Capacitor Installation
7.11.1 Setup
Safety]
► Make sure the haul truck is in the same configuration from the DC Link
Capacitor removal procedure. (Ref.: DC Link Capacitor Removal)

► Make sure the fiber optic, and the ground cables are clear and cannot
get damaged while sliding the capacitor into the cabinet.
► Place the capacitor onto the track and carefully slide back to the back
of the cabinet.
7.11.2 Procedure
1. Begin to tighten the four hex bolts (4) that connect the capacitor to the
DC link bus.
– Do not tighten fully tighten the bolts until all bolts are started.
– The capacitor may need to be moved slightly to align all holes.
the bus then move to the other side.
– Repeat this procedure until all bolts are started.
– When all bolts have started, begin to tighten all bolts using the
alternating method.
2. Install the two wall mounting bolts (3) from the back of the capacitor.
– Make new Nord-Lock washers are used.
3. Install the two foundation bolts (2) at the bottom of the capacitor.
– Mske sure the ground cable is connected and Nord-Lock
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washers are placed on the two sides of the ground cable

terminal.
– THe other foundation bolt will require only one Nord-Lock
washers.
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DC Link Capacitor Installation
532_DC Link Capacitor_100_01.tif

Fig. 7.11-1: DC Link Capacitor Installation
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Battery Disconnect Switch Box
7.12 Battery Disconnect Switch Box
Battery Disconnect 000_01.tif

Fig. 7.12-1: Battery Disconnect Switch Box
The battery disconnect switch box is on the left of the haul truck between
the front wheel and the bumper. The battery disconnect box has the
switches that follow:
7.12.1 24 VDC Battery Isolator Switch

The 24 VDC battery isolator switch (1) is a two-position rotary switch used
to remove the 24 VDC power from all circuits. The switch must be in the off
position when the haul truck is parked for long periods.
7.12.2 Starter Isolator Switch

The starter isolator switch (2) is a two-position rotary switch, which is used
to remove 24 VDC power from the starting circuit. This switch is used to
disable the starting circuit while allowing 24 VDC to all other circuits.
7.12.3 Battery Charger Receptacle

LME/10880897/January 30, 2011/en
The battery charger receptacle (3) is used to allow for the recharge of the
24 V batteries on the haul truck.
7.12.4 Propulsion Lockout Switch

The propulsion lockout switch (4) is used to inhibit the propulsion system
that does not permit the haul truck to move.
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24 VDC Battery Bank
7.13 24 VDC Battery Bank
07-000_000_01_Battery Bank.tif
Fig. 7.13-1: 24 VDC Battery Bank
The three series-pairs are connected in parallel to increase current capacity.

The batteries supply 24 VDC to all other systems and components. The
collective battery configuration is referred to as the 24 VDC battery bank.
During diesel operation of the haul truck, the traction alternator supplies all
drive system electrical power for the haul truck, but not the control power.
The 24 VDC battery bank supplies the control power for the traction control
unit (TCU), SBS computer, Ecomat(s), and other electrical devices.
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24 VDC Battery Bank
7.13.1 Batteries Removal
7.13.2 Setup
Safety]
► Put on protective equipment approved for this type of task.
7.13.3 Procedure
NOTICE
A Commercial 8D-size battery can weigh up to 70 kg (154 lb).
► Use an applicable device that can safely lift and support more than
this weight.
WARNING! The batteries contain dangerous acids and gasses.

► The acids in the batteries can cause injury.
► Put on approved eye, face, and hand protective equipment while you
do any procedures that includes the batteries.
► If the acid gets into the eyes, touches the skin, or clothing, immediately
get medical attention.
1. Put the battery disconnect switch to the OFF position and install a tag-
out or lockout warning device.
2. Pull out the circuit breakers in the battery disconnect box.
3. Pull out the circuit breakers in the cab on the rear of the floor mounted
center console.
4. Unlock and open the battery access doors.
5. Disconnect the negative (-) black cable (8) from the negative battery
posts.
6. Coil the cable and attach the cable to the superstructure.
7. Disconnect the positive (+) red cable from the positive battery posts.
8. Coil the cable and attach the cable to the superstructure.
9. Remove the capscrews (4), washers (5), lockwashers (6), and remove
the battery retainer bracket (11).
10. Attach a lift to each battery, carefully lift, and remove each battery (10)
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from the battery box.
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24 VDC Battery Bank
LME/10880897/January 30, 2011/en
07-100_000_01_Battery.tif
Fig. 7.13-2: Battery Removal
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24 VDC Battery Bank
7.13.4 Batteries Installation
7.13.5 Setup
Safety]
battery removal procedure. [Reference: Batteries Removal]
► Put on protective equipment approved for this type of task.
7.13.6 Procedure
NOTICE
A Commercial 8D-size battery can weigh up to 70 kg (154 lb).
this weight.
WARNING! Batteries can contain dangerous acids and gases.

► Injury can occur from battery acid or gases that touch the skin or gets
into the eyes.
► Get medical attention while you continue to flush the area if injury
occurs from the battery acids or gases.
1. Put the battery disconnect switch to the OFF position and install a tag-
out or lockout warning device.
2. Put the ignition master switch to the OFF position.
3. Pull out the circuit breakers in the battery disconnect box.
4. Pull out the circuit breakers in the cab on the rear of the floor mounted
center console.
5. Attach a lift to each battery (10) and put into the battery box (12).
6. Install the battery retainer bracket (11).
7. Install and tighten the positive (+) red cable (1) on each positive battery
post.
8. Install and tighten the negative (-) black cable (2) on each negative
battery post.
9. Use the digital multimeter to take a measure of the open circuit "no
LME/10880897/January 30, 2011/en
load" between the positive (+) and (-) battery post on the battery cables
(1), and (2).
10. Put the battery disconnect switch to the ON position.
11. Put the starter isolator switch to the ON position.
12. Use the digital multimeter, to measure approximately 5 kΩ between
the positive and negative battery posts on the battery cables.
13. Put the battery disconnect and the starter isolator switches to their OFF
positions and install a tag-out or lockout device.
14. Install the battery jumper cables (3) between the battery pairs, 1-2, 3-4,
and 5-6.
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24 VDC Battery Bank
15. Take a reading with the digital multimeter and make sure it shows 24
VDC between the positive (+) and negative (-) posts on the battery
cables (1), and (2).
16. Put the battery disconnect switch to the ON position.
17. Put the master ignition switch to the ON position.
18. Push in all circuit breakers in the battery disconnect box one at a time.
19. Push in all circuit breakers in the circuit breaker panel on the floor
mounted center console one at a time.
NOTICE
Circuit breakers must have the correct operation.
► If any of the circuit breakers remain open, check for a short circuit in
the circuit.
► The procedure is not complete unless all circuit breakers have the
correct operation.
20. Close the battery access doors.
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24 VDC Battery Bank
LME/10880897/January 30, 2011/en
07-100_000_01_Battery.tif
Fig. 7.13-3: Battery Installation
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Service Manual Hydraulic Power and Distribution
8 Hydraulic Power and Distribution 329

8.1 Drive Shaft Assembly 330
8.1.1 Pump Drive Unit 331
8.1.2 Drive Shaft 333
8.1.3 Pump Drive Unit Removal 334
8.1.5 Drive Shaft Removal 336
8.1.6 Drive Shaft Installation 338
8.1.7 Pump Drive Unit Installation 340
8.2 Hydraulic Tank 342
8.2.1 Dump System Hydraulic Tank 343
8.2.8 Brake and Steering Hydraulic Tank 347
8.2.16 Central Service Assembly 353
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Hydraulic Power and Distribution Service Manual
Drive Shaft Assembly
8.1 Drive Shaft Assembly
06-000_000_01_Drive Shaft Assembly.tif

Legend:
1. Drive Shaft Assembly 2. Pump Drive Unit
The draft shaft assembly has the following components:

• Pump Drive Unit
• Drive Shaft
The drive shaft assembly is also connected to the following systems:
• [Reference: Dump Pumps]

• [Reference: Brake and Steering Pump]
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8.1.1 Pump Drive Unit
06-000_000_01_Pump Drive Unit.tif

Fig. 8.1-2: Pump Drive Unit
Legend:
1. Hydraulic A/C Compressor 3. Pump Drive Unit
Pump 4. Brake and Steering
2. Gear Oil Pump Pumps
The pump drive unit, or pump drive, supplies the mechanical energy to turn
the shafts on the dump pumps, brake and steering pumps, gear oil cooling
pump and the hydraulically-driven A/C compressor.
The pump drive is connected to the drive shaft at one end and to the dump
pumps at the other end. The pump drive weighs 193 kg (425 lb), and has a
breather cap, oil drain plug and two oil level plugs.
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Fig. 8.1-3: Pump Drive
Legend:
1. Breather Filter Cap 3. Oil Drain and Fill Plug
2. Full Level Plug

Fig. 8.1-4: Pump Drive Gears
Legend:
1. Driven Gear 3. Spline All Gears
2. Input Gear 4. Bearing
There is a 7/8:1 speed increase on the pump drive. This 7/8:1 ratio is to
LME/10880897/January 30, 2011/en
make the hydraulic pumps increase their rotation to increase the hydraulic
oil flow from the pumps.
When the engine is at idle 700 rpm, the speed of the pump drive is 800 rpm.
When the engine is at full throttle and the hand brake set by using the dump
body override switch, the engine speed increases to 1900 rpm, which
causes the speed of the pump drive to increase to 2171 rpm.
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8.1.2 Drive Shaft
06-000_000_02_Drive Shaft Assembly.tif

Fig. 8.1-5: Drive Shaft Assembly
Legend:
1. Shaft Yoke 3. Flange Yoke
2. Slip Yoke 4. Cross and Bearing Assembly
The drive shaft supplies rotational force from the traction alternator to drive
the dump pumps, brake and steering pump, oil cooling pump and the
hydraulically-driven air conditioning compressor via the pump drive unit.
The drive shaft is covered by a protective cage to prevent damage.
The purpose of the drive shaft is to transmit torque and rotational motion at
a varying angular relationship from the traction alternator to the pump drive
unit.
The drive shaft assembly consists of two universal joints (U-joint) connected
by a solid or tubular shaft. The drive shaft weights approximately 36 kg (80
lb) and is attached to the pump drive unit and the traction alternator with 12
bolts and washers.
When the haul truck is in operation, the traction alternator turns at the same
speed as the engine. The drive shaft assembly transmits the force from the
traction alternator to the pump drive. The gears in the pump drive are
LME/10880897/January 30, 2011/en
mechanically connected to the dump pumps and provide the mechanical

energy necessary to operate the dump pumps. As the haul truck moves, the
slip yoke compensates for the movement of the frame.
The drive shaft has three grease fittings, which allows for servicing with a
grease gun.
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8.1.3 Pump Drive Unit Removal

Truck Safety].

above ground.
2. If necessary, remove the dump pumps.
8.1.4 Procedure
NOTICE
The weight of the dry pump drive unit is 193 kg (425 lb).
1. Attach an applicable lifting device to the pump drive unit.
NOTICE
The oil capacity of the pump drive unit is 8.5 L (2.3 gal).
► Make sure that you use an applicable container to catch the fluid and
to prevent leakage and contamination.
2. Drain the pump drive (5) through the connection (14)
3. Remove the hose assemblies (12) and (13) and install plastic caps on
all open ports.
4. Remove the locknuts (9).
5. Remove the capscrews (1) and lockwashers (2).
6. Remove the capscrews (7) and locknuts (6).
8. Remove the pump drive unit (5), adapters (4), and O-rings (3). LME/10880897/January 30, 2011/en
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Pump Drive Unit_01_Rev000.tif

LME/10880897/January 30, 2011/en
Fig. 8.1-6: Pump Drive Unit Removal
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8.1.5 Drive Shaft Removal

Truck Safety].

above ground.
1. Remove the capscrews (11), washers (12), and upper guard (6).
2. Remove the capscrews (8), washers (9), lockwashers (10), and lower
guard (7).
NOTICE
The weight of the drive shaft assembly is 37 kg (82 lb).
3. Attach an applicable lifting device to the drive shaft assembly (5).
5. Remove the capscrews (3), lockwashers (4), and drive shaft assembly
(5).
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Drive Shaft_100_01_Rev001.tif
Fig. 8.1-7: Drive Shaft Removal
LME/10880897/January 30, 2011/en
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8.1.6 Drive Shaft Installation

Truck Safety].

above ground.
2. Make sure that the haul truck is in the same configuration from
the drive shaft removal procedure. Drive Shaft Removal
NOTICE
The weight of the drive shaft assembly is 37 kg (82 lb).
1. Attach an applicable lifting device to the drive shaft assembly (5).
2. Install the drive shaft (5), capscrews (3), and lockwashers (4).
3. Install the capscrews (2) and locknuts (1).
4. Install the lower guard (7).
5. Install the capscrews (8), lockwashers (9), and washers (10).
6. Install the upper guard (6).
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Drive Shaft_100_01_Rev001.tif
Fig. 8.1-8: Drive Shaft Installation
LME/10880897/January 30, 2011/en
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8.1.7 Pump Drive Unit Installation

Truck Safety].

above ground.
2. Make sure that the haul truck is in the same configuration from
the pump drive unit removal procedure. Pump Drive Unit
Removal
8.1.8 Procedure
Loctite (medium grade) N/A Commercially available
NOTICE
The weight of the dry pump drive unit is 193 kg (425 lb).
1. Attach an applicable lifting device to the pump drive (5).
If the studs (8) are not installed,
– apply a medium grade Loctite to the short threaded end of the
studs (3) and install in pump drive (5).
2. Install the O-rings (3), adapters (4), and pump drive (5).
3. Install the locknuts (9) and lockwashers (12).
5. Install the capscrews (1) and lockwashers (2).
7. Remove the plastic caps from the ports and install the hose assemblies
(12) and (13).
NOTICE
The oil capacity of the pump drive unit is 8.5 L (2.3 gal).
LME/10880897/January 30, 2011/en
► Make sure that you use an applicable container to catch the fluid and
8. Make sure that the pump drive is filled to the correct level with the
shutoff valve (15).
If the dump pumps are removed,
– install the dump pumps.
– Service the pump drive unit.
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Pump Drive Unit_01_Rev000.tif

LME/10880897/January 30, 2011/en
Fig. 8.1-9: Pump Drive Unit Installation
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8.2 Hydraulic Tank
06-000_000_01_Hydraulic Power and Distribution.tif

Fig. 8.2-1: Hydraulic Tank
The hydraulic tank is on the outer side of the left frame rail. It is a fuel and
hydraulic tank.
The hydraulic tank has three sections. The forward section is for the dump
system hydraulic tank. The center section is the brake and steering hydraulic
tank and the aft section is for fuel. All three sections have access ports. The
service and maintenance personnel can access the sections of the tanks
through the access ports and clean the sections.
There are three shutoff valves for the fuel and hydraulic tank:
• brake and steering shutoff valve
• dump shutoff valve
• fuel shutoff valve
There are lift points on top of the fuel and hydraulic tank for removal and
installation of the tank.
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Hydraulic Tank
8.2.1 Dump System Hydraulic Tank

Fig. 8.2-2: Dump System Hydraulic Tank
The dump system hydraulic tank is part of the dump system. The dump
system hydraulic tank contains the hydraulic fluid for the dump system. The
dump system hydraulic tank is part of the fuel and hydraulic tank. The dump
system hydraulic tank is in the forward section of the fuel and hydraulic tank.
The hydraulic fluid from the tank flows to the dump pumps when the engine
is in operation. The dump valve returns the hydraulic fluid to the hydraulic
tank. The capacity of the dump system hydraulic tank is 1300 L (343.4
gal).
There are two hydraulic return lines on the bottom of the dump system
LME/10880897/January 30, 2011/en
hydraulic tank with a shutoff valve. The shutoff valve is on the bottom
inboard side of the fuel and hydraulic tank and is attached to the manifold.
The dump system hydraulic tank has two diffusers in the tank. The diffusers
must be set in the correct position to slow down the hydraulic oil.
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Hydraulic Tank

Fig. 8.2-3: Dump System Hydraulic Tank
There is an access panel attached to the fuel and hydraulic tank. The access
panel provides access to clean the dump system hydraulic tank.
There is a sight gauge for the dump system hydraulic tank on the outboard
side of the fuel and hydraulic tank. The filler cap is on the top of the dump
system hydraulic tank. A breather element is installed on the top of the tank.
There are two strainers in the hydraulic tank. The strainers work with the
pressure filters to clean the hydraulic oil in the dump system. The strainers
remove large pieces of contamination from the hydraulic oil in the dump
system hydraulic tank before the hydraulic oil goes to the dump pump and
other components. The service and maintenance personnel can remove,
clean, and replace the strainers. You must drain the dump system hydraulic
tank before you do servicing of the strainers.
CAUTION! The service and maintenance personnel can close the shutoff
valves for maintenance procedures.
► If you close the shutoff valves make sure you put a red tag on the
valves and the steering column and the haul truck cannot start during
maintenance.
LME/10880897/January 30, 2011/en
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Hydraulic Tank
8.2.2 Dump Section of Hydraulic Tank Drain
8.2.3 Setup
Safety]
8.2.4 Procedure
WARNING! Hydraulic fluid can cause skin irritation.

with hydraulic fluid.
NOTICE
The capacity of the dump system hydraulic tank is 1515 L (400.2 gal).
To drain the dump section of the hydraulic tank manually, do this

procedure:
1. Put an applicable container below the dump section of the hydraulic
tank.
2. Remove the plug in the bottom of the dump section of the hydraulic
tank.
3. After you remove all the hydraulic fluid, install the plug in the bottom
of the tank.
To drain the dump section of the hydraulic tank with a pump, do this
procedure:
4. Install a scavenge pump to the HYDRAULIC FILL HOIST quick
connection on the central service box.
5. Use an applicable container to drain the hydraulic fluid.
6. After the hydraulic tank is empty, disconnect the scavenge pump.
7. Know and follow all environmental regulations on how to safely discard
the hydraulic fluid.
8. Correctly discard all the hydraulic fluid from the container.
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Hydraulic Tank
8.2.5 Dump Section of the Hydraulic Tank Fill
8.2.6 Setup
Safety]

Oil (Hydraulic) N/A [Reference: Oil and Lubricant
Specifications]
8.2.7 Procedure

NOTICE
The capacity of the dump system hydraulic tank is 1515 L (400.2 gal).
1. Connect the hydraulic service cart to the HYDRAULIC FILL HOIST
quick connection on the central service box. [Reference: Central
Service Assembly]
2. Add hydraulic fluid to the dump system hydraulic tank.
3. Make sure that the hydraulic fluid is at the FULL level on the sight
gauge of the dump system hydraulic tank.
4. Loosen all four suction lines at the dump pumps.
5. Tighten each of the suction lines when the hydraulic fluid shows.
6. Add hydraulic fluid to fully fill the dump system hydraulic tank.
7. Loosen the bleeder screws on the two dump system pressure filters.
8. Tighten each of the bleeder screws when the hydraulic fluid shows.
9. Add hydraulic fluid to fully fill the dump system hydraulic tank.
10. Disconnect the hydraulic service cart from the HYDRAULIC FILL
HOIST quick connection on the central service box. [Reference:
Central Service Assembly]
LME/10880897/January 30, 2011/en
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Hydraulic Tank
8.2.8 Brake and Steering Hydraulic Tank

Fig. 8.2-4: Brake and Steering Hydraulic Tank
The brake and steering hydraulic tank is part of the fuel and hydraulic tank.
The brake and steering hydraulic tank is in the center section of the fuel and
hydraulic tank. The brake and steering hydraulic tank is part of the brake
and steering system. The brake and steering hydraulic tank contains the
hydraulic fluid for the brake and steering system. The brake and steering
pump removes hydraulic fluid from the tank when the haul truck is in
operation. During usual operation, the hydraulic fluid returns to the hydraulic
tank from these components:
• flow amplifier valve
• steering control valve
• brake pedal
• hand brake valve
• auto lube pump
There is an access panel attached to the fuel and hydraulic tank with
capscrews to clean the brake and steering hydraulic tank. There is a sight
LME/10880897/January 30, 2011/en
gauge for the brake and steering hydraulic tank on the outboard side of the
fuel and hydraulic tank. The filler cap is on the top of the brake and steering
hydraulic tank. A breather element is installed on the top of the tank. The
capacity of the brake and steering hydraulic tank is 930 L (245.7 gal).
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Hydraulic Tank

Fig. 8.2-5: Brake and Steering Hydraulic Tank
CAUTION! The service and maintenance personnel can close the shutoff
valves for maintenance procedures.
► if you close the shutoff valves make sure you put a red tag on the
valves and the steering column and the haul truck cannot start during
the maintenance.
8.2.9 Fuel Tank

Fuel System [Reference: Fuel Systems]
LME/10880897/January 30, 2011/en
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Hydraulic Tank
8.2.10 Brake and Steering Section of Hydraulic Tank

Drain
8.2.11 Setup
Safety]
8.2.12 Procedure

NOTICE
The capacity of the brake and steering hydraulic tank is 1515 L (400.2
gal).
To drain the brake and steering hydraulic tank manually,

1. Put an applicable container below the brake and steering hydraulic
tank.
2. Remove the plug in the bottom of the brake and steering hydraulic
tank.
3. After all the hydraulic fluid is removed, install the plug in the bottom of
the tank.
To drain the brake and steering hydraulic tank with a pump,

4. Install a scavenge pump to the BRAKE AND STEERING FILL quick
connection on the central service box. [Reference: Central Service
Assembly]
5. Use an applicable container to drain the hydraulic fluid into.
6. After the hydraulic tank is empty, disconnect the scavenge pump.
7. Know and follow the environmental regulation on how to safely discard
the hydraulic fluid from the container.
LME/10880897/January 30, 2011/en
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Hydraulic Tank
LME/10880897/January 30, 2011/en
06-700_000_01_Hydraulic Tank Brake and Steering Section Drain.tif

Fig. 8.2-6: Brake and Steering Section of the Hydraulic Tank Drain
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Hydraulic Tank
8.2.13 Brake and Steering Section of the Hydraulic Tank

Fill
8.2.14 Setup
Safety]
8.2.15 Procedure
WARNING! Some types of oil contain additives harmful to Buna-N (Nitrile)

and neoprene rubber compounds.
Use of incorrect fluids has an unwanted effect on the rubber components
of the brakes and master cylinder.
► Use only the recommended hydraulic oil. Never use automotive type
brake fluid in Liebherr haul trucks.

NOTICE
The capacity of the brake and steering hydraulic tank is 1515 L (400.2
gal).
1. Connect the hydraulic service cart to the BRAKE AND STEERING
FILL quick connection on the central service box. [Reference: Central
Service Assembly]
2. Add hydraulic fluid to the brake and steering hydraulic tank.
3. Make sure that the hydraulic fluid is at the FULL level on the sight
gauge of the brake and steering hydraulic tank.
LME/10880897/January 30, 2011/en
4. Loosen the suction line at the brake and steering pump.

5. Tighten the suction line when hydraulic fluid shows.
6. Add hydraulic fluid to fully fill the brake and steering hydraulic tank.
7. Loosen the bleeder screw on the brake and steering pressure filter.
8. Tighten the bleeder screw when hydraulic fluid shows.
9. Add hydraulic fluid to fully fill the brake and steering hydraulic tank.
10. Disconnect the hydraulic service cart from the BRAKE AND
STEERING FILL quick connection on the central service box.
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Hydraulic Tank
LME/10880897/January 30, 2011/en
07-705_000_01_Hyd Tank Brake Steering Fill.tif

Fig. 8.2-7: Brake and Steering Section of the Hydraulic Tank Fill
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Hydraulic Tank
8.2.16 Central Service Assembly

The central service assembly is below the fuel and hydraulic tank.
The central service assembly is used for servicing the systems of the truck.
The central oil sample points are on the left side of the haul truck near the
brake accumulators. The servicing reservoir is accomplished through the
central oil service panel that is on the bottom of the hydraulic tank.
LME/10880897/January 30, 2011/en
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Hydraulic Tank
0730000da01.tif
LME/10880897/January 30, 2011/en
Fig. 8.2-8: Central Service Assembly
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Service Manual Dump System
9 Dump System 355

9.1 Dump System 356
9.1.1 Dump System Schematic 357
9.2 Dump Pumps 358
9.3 Dump Pumps 358
9.4 Pilot Control Valve and Manifold Assembly 370
9.4.1 Pilot Control Valve Removal 371
9.4.4 Pilot Control Valve Installation 372
9.5 Dump Body Control Lever 373
9.5.1 Dump Control Lever Adjustment (Factory-Set) 374
9.5.2 Dump Body Override Switch 374
9.6 Dump Body Cylinders 375
9.6.1 Dump Body Cylinders Removal 376
9.6.4 Dump Body Cylinders Installation 380
9.7 Dump System Pressure Filters 383
9.7.1 Dump System Pressure Filters Removal 384
9.7.4 Dump System Pressure Filters Installation 386
9.8 Dump System Troubleshooting 388
LME/10880897/January 30, 2011/en
9.8.2 Observation: Dump Body will not Rise 388

9.8.3 Observation: Dump Body will not Lower 397
9.8.4 Observation: Slow slew rate 401
9.8.5 Observation: System Overheat 403
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Dump System Service Manual
Dump System
9.1 Dump System
06-000_000_01_Dump System.tif
Fig. 9.1-1: Dump System Components
LME/10880897/January 30, 2011/en
The dump system has the components that follow:

• [Reference: Dump Pumps]
• [Reference: Dump Valve]
• [Reference: Pilot Control Valve and Manifold Assembly]
• [Reference: Dump Control Lever]
• [Reference: Dump Cylinders]
• [Reference: Dump System Pressure Filters]
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Dump System
9.1.1 Dump System Schematic

LME/10880897/January 30, 2011/en
06-300_000_01_Dump System Schematic.tif

Fig. 9.1-2: Dump System Schematic
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Dump Pumps
9.2 Dump Pumps
06-000_000_01_Dump Pumps.tif
Fig. 9.2-1: Dump Pumps
There are two hydraulic pumps for the dump system of the haul truck.
The pump drive supplies the mechanical energy to operate the dump
pumps.
The dump pumps supply a flow of the hydraulic fluid to the dump system.
The pumps are fixed displacement gear pumps. The flow of the hydraulic
fluid is in proportion to the speed of the pumps. The dump pumps receive
hydraulic fluid from the dump system hydraulic tank through two suction
strainers. The dump pumps constantly supply hydraulic fluid to the dump
valve.
There are two sections to the dump pumps, a front section and a rear
section. The two sections have different capacities.
The output rate of the dump pumps is in proportion to engine speed. The
dump pumps move 1140 L (301.2 gal) per minute of hydraulic fluid oil at an
engine speed of 1900 revolutions per minute (rpm). A pump speed of 2171
LME/10880897/January 30, 2011/en
rpm gives a dump time of 20 to 30 seconds.
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Dump Pumps
9.2.1 Specifications
• Dump cycle is approximately 34 seconds UP, and 22 seconds
DOWN.
• The usual operating temperature is 50 ºC (122 ºF) to 60 ºC
(140 ºF) at 20 ºC (68 ºF) ambient temperature.
• The maximum system pressure is 207 bar (3002 psi) ±4 bar
(51 psi).
• The pump volume is 1140 L (301.2 gal) per minute at an
engine speed of 1900 and a pump speed of 2171 rpm.
LME/10880897/January 30, 2011/en
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Dump Pumps
9.2.2 Dump Pumps Removal
9.2.3 Setup
Safety]
► Close the shutoff valve for the dump system hydraulic tank .
► If the gear oil cooling pump is attached to the dump pump, remove
the gear oil cooling pump.
9.2.4 Procedure
WARNING! The hydraulic fluid can cause skin irritation.

► Put on the approved protective equipment, and clothing when you use
hydraulic fluid.
NOTICE
The weight of the dump pump is 101 kg (223 lb).
► Use a jack or a lift device that can hold the weight.
1. Put a container below the dump pump (20) or (15) to collect the
hydraulic fluid.
2. Remove the capscrews (2), washers (3), clamp halves (4), and O-rings
(21).
3. Remove the capscrews (12), washers (13), clamp halves (9), and O-
rings (10).
4. Put protective covers on the hoses (1), (11), and all open ports.
5. Remove the capscrews (19), lockwashers (18), washers (17), and
bracket (16).
6. Remove the capscrews (5), washers (6), and pump (20).
7. Remove the locknut (14), lockwashers (22), and pump (15).
8. Remove the O-rings (7) and adapter (8).
LME/10880897/January 30, 2011/en
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Dump Pumps
15-100_000_01_Dump Pump Removal.tif

LME/10880897/January 30, 2011/en
Fig. 9.2-2: Dump Pumps Removal
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Dump Pumps
9.2.5 Dump Pumps Installation
9.2.6 Setup
Safety]
dump pumps removal procedure. [Reference: Dump Pumps
Removal]
9.2.7 Procedure
WARNING! Hydraulic fluid can cause a skin irritation.

hydraulic fluid.
NOTICE
1. Install the O-rings (7) and adapter (8).
2. Install the pump (15), the locknut (14), and washers (22)
3. Install the pump (20), capscrews (5), and washers (6).
4. Install the bracket (16), capscrews (19), lockwashers (18), and
washers (17).
5. Remove the protective covers from the hoses (1), (11), and the ports.
6. Install the O-rings (10), hoses (11), capscrews (12), washers (13), and
clamp halves (9).
clamp halves (4).
8. Open the shutoff valve for the dump system hydraulic tank.
9. Install the gear oil cooling pump if it was removed.
LME/10880897/January 30, 2011/en
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Dump Pumps

LME/10880897/January 30, 2011/en
Fig. 9.2-3: Dump Pumps Installation
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Dump Pumps
9.3 Dump Pumps
06-000_000_01_Dump Pumps.tif
Fig. 9.3-1: Dump Pumps
There are two hydraulic pumps for the dump system of the haul truck.
The pump drive supplies the mechanical energy to operate the dump
pumps.
The dump pumps supply a flow of the hydraulic fluid to the dump system.
The pumps are fixed displacement gear pumps. The flow of the hydraulic
fluid is in proportion to the speed of the pumps. The dump pumps receive
hydraulic fluid from the dump system hydraulic tank through two suction
strainers. The dump pumps constantly supply hydraulic fluid to the dump
valve.
There are two sections to the dump pumps, a front section and a rear
section. The two sections have different capacities.
The output rate of the dump pumps is in proportion to engine speed. The
dump pumps move 1140 L (301.2 gal) per minute of hydraulic fluid oil at an
engine speed of 1900 revolutions per minute (rpm). A pump speed of 2171
LME/10880897/January 30, 2011/en
rpm gives a dump time of 20 to 30 seconds.
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Dump Pumps
• Dump cycle is approximately 34 seconds UP, and 22 seconds
DOWN.
• The usual operating temperature is 50 ºC (122 ºF) to 60 ºC
(140 ºF) at 20 ºC (68 ºF) ambient temperature.
• The maximum system pressure is 207 bar (3002 psi) ±4 bar
(51 psi).
• The pump volume is 1140 L (301.2 gal) per minute at an
engine speed of 1900 and a pump speed of 2171 rpm.
LME/10880897/January 30, 2011/en
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Dump Pumps
9.3.2 Dump Pumps Removal
9.3.3 Setup
Safety]
► Close the shutoff valve for the dump system hydraulic tank .
► If the gear oil cooling pump is attached to the dump pump, remove
the gear oil cooling pump.
9.3.4 Procedure

hydraulic fluid.
NOTICE
1. Put a container below the dump pump (20) or (15) to collect the
hydraulic fluid.
2. Remove the capscrews (2), washers (3), clamp halves (4), and O-rings
(21).
rings (10).
4. Put protective covers on the hoses (1), (11), and all open ports.
5. Remove the capscrews (19), lockwashers (18), washers (17), and
bracket (16).
6. Remove the capscrews (5), washers (6), and pump (20).
7. Remove the locknut (14), lockwashers (22), and pump (15).
8. Remove the O-rings (7) and adapter (8).
LME/10880897/January 30, 2011/en
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Dump Pumps

LME/10880897/January 30, 2011/en
Fig. 9.3-2: Dump Pumps Removal
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Dump Pumps
9.3.5 Dump Pumps Installation
9.3.6 Setup
Safety]
dump pumps removal procedure. [Reference: Dump Pumps
Removal]
9.3.7 Procedure
WARNING! Hydraulic fluid can cause a skin irritation.

hydraulic fluid.
NOTICE
1. Install the O-rings (7) and adapter (8).
2. Install the pump (15), the locknut (14), and washers (22)
3. Install the pump (20), capscrews (5), and washers (6).
4. Install the bracket (16), capscrews (19), lockwashers (18), and
washers (17).
5. Remove the protective covers from the hoses (1), (11), and the ports.
clamp halves (9).
clamp halves (4).
8. Open the shutoff valve for the dump system hydraulic tank.
9. Install the gear oil cooling pump if it was removed.
LME/10880897/January 30, 2011/en
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Dump Pumps

LME/10880897/January 30, 2011/en
Fig. 9.3-3: Dump Pumps Installation
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Pilot Control Valve and Manifold Assembly
9.4 Pilot Control Valve and Manifold Assembly
06-000_000_01_Pilot Control Valve.tif

Fig. 9.4-1: Pilot Control Valve Assembly
The pilot control valve assembly is installed on the inside of the right frame
rail, forward of the dump cylinder.
The pilot control valve assembly is the interface between the dump control
lever and the dump valve.
The pilot control valve has the manifold valve and the pilot control valve.
These two valves control the operation of the dump valve (raise, hold or
lowering of the dump body).
The first part of the pilot control valve assembly is the solenoid valve 7
(SOL7) also referred to as the float valve. The SOL7 receives electrical input
from the joystick in the operator cab to raise or lower the haul truck bed. The
movement of the position 4-way valve spool assembly is proportional to the
movement of the handle.
The dump valve supplies the pilot control valve with hydraulic fluid. The
dump control lever controls the two electrical, hydraulic, proportional (EHP)
valves on the manifold valve. The EHP valves control the pilot control valve.
LME/10880897/January 30, 2011/en
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9.4.1 Pilot Control Valve Removal
9.4.2 Setup
Safety]
► Disconnect all electrical power.
9.4.3 Procedure

hydraulic fluid.
1. Put a container below the pilot control valve (1) to collect the hydraulic
fluid.
2. Disconnect the tube assemblies (5) and put protective covers on the
tube assemblies and open ports.
3. Remove the four bolts (2).
4. Remove the pilot control valve (1).
LME/10880897/January 30, 2011/en

Fig. 9.4-2: Pilot Valve Removal
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9.4.4 Pilot Control Valve Installation
9.4.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the Pilot
Control Valve removal. [Reference: Pilot Control Valve Removal]
► Disconnect all electrical power.
9.4.6 Procedure

hydraulic fluid.
1. Install the pilot control valve (1).

2. Install the four bolts (2).
3. Connect the tube assemblies (5).
4. Remove the container from below the pilot valve (1) and follow the
correct local environmental waste removal procedure for any hydraulic
fluid collected.
LME/10880897/January 30, 2011/en

Fig. 9.4-3: Pilot Valve Installation
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Dump Body Control Lever
9.5 Dump Body Control Lever
06-000_000_01_Dump Control Lever.tif

Fig. 9.5-1: Dump Body Control Lever
The dump control lever sends an electrical command to the pilot control
valve. After that a hydraulic signal from the pilot control valve goes to the
dump valve. The dump valve sends the necessary quantity of hydraulic fluid
to the dump cylinders to move the dump body.
The dump body control lever is a controller with four functions. It has three
positions . The usual position if the controller is in the center.
The four functions are:

• Lower the dump body
• Raise the dump body
• Float
• Hold
The three positions are:

• Forward
• Center
LME/10880897/January 30, 2011/en
• Back
The dump body control lever operations are:
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Dump Body Control Lever
1. Push and hold the dump control lever forward to fully lower
the dump body. If the dump control lever is released before
the proximity switch engages, the dump body stops in that
position. As the dump body approaches and activates the
proximity switch, it goes automatically into the FLOAT position
against the dump body pads on the frame. The FLOAT
function prevents damage to the haul truck structure.
2. Pull the dump control lever to the BACK position to raise the
dump body.
3. Release the dump body control lever to the CENTER position
to HOLD the dump body in position. There is no HOLD
function when the dump body proximity switch is in operation.
9.5.1 Dump Control Lever Adjustment (Factory-Set)
NOTICE
The pressure set by the factory and the dump control lever should not
require adjustment when replaced.
9.5.2 Dump Body Override Switch

The function of the dump body override switch is to let the haul truck move
forward while the dump body is not completely down.
Push and hold the switch on the dump control lever to enable haul truck
movement while the dump body is not completely down.
LME/10880897/January 30, 2011/en
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Dump Body Cylinders
9.6 Dump Body Cylinders
06-000_000_01_Dump Body Cylinders.tif

Fig. 9.6-1: Dump Body Cylinders
The haul truck has two dump body cylinders that are attached to the frame
and the dump body with pivot pins.
The dump body cylinders connects to the component that follows:

• [Reference: Frame]
The dump body cylinders extend or retract with hydraulic pressure from the
dump valve. This causes the dump body to lift or lower.
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Dump Body Cylinders
9.6.1 Dump Body Cylinders Removal
9.6.2 Setup
Safety].
► For this procedure, it is necessary to have cover plates with O-rings
for the hydraulic ports.

Dump Cylinder Shipping Brackets T-193-A [Reference: Service Tools]
Fixture Dump Cylinder Extend Tool 10025660 [Reference: Service Tools]
9.6.3 Procedure
1. Start the engine .
2. Pull the dump body control lever in the UP position and lift the front of
the dump body (1) approximately 305 mm (12.01 in) above the frame.
3. Put two safety supports between the top frame rails and the dump body
beam runners.
4. Lower the dump body until it is against the safety supports.
5. Release the dump control lever to let it return to the CENTER position.
6. Stop the engine and make sure that the haul truck cannot start during
maintenance.
WARNING! The dump body can move when the pins are removed.
► Make sure that the overhead hoist is in the correct position.
7. Attach an overhead hoist to the lift points on the dump body.
8. Tighten the tension on the cables of the overhead hoist.
9. Close the supply and return line valves on the hydraulic tank.
10. Put a container below the dump cylinder (23).
11. Remove the lubrication hoses (22) and install protective caps on the
hoses and open ports.
LME/10880897/January 30, 2011/en
NOTICE
The weight of a dump body cylinder without hydraulic fluid is 2291 kg (5051
lb).
► Make sure that the lift device or support can hold the weight.
12. Attach an applicable lift device to the dump cylinder (23).

hydraulic fluid.
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Dump Body Cylinders
DANGER! The cylinder rod can move in and out of the dump cylinder if you
do not contain it.
The cylinder rod can be damaged, or cause serious injury or death.
► Make sure that you add cover plates and O-rings to the cylinder ports
to contain the cylinder rod. Make sure that there is no trapped air in
the cylinder.
13. Put a container below the dump cylinder (23) to catch the hydraulic
fluid.
WARNING! The high pressure lines for the dump system do not
automatically bleed.
► Release any system pressure at the pressure filter housing.
14. Slowly and carefully remove the bolts (19), washers (20), clamps (21),
extend and retract hydraulic hoses (17), and O-rings (18).
ATTENTION
Hydraulic fluid drains from the hydraulic lines and the cylinders.
► Use a container to catch the fluid and install cover plates and O-rings
15. Install protective covers on the hoses (17).
16. Use the tool Liebherr P/N 10025660 and an applicable bottle jack to
remove the axial force of the cylinder rod from the pin. [Reference:
Service Tools]
ATTENTION
The shipping bracket (24) is not an operational part of the haul truck.
► Make sure you remove the shipping bracket before the haul truck is
returned to service.
17. Use a chain or hand hoist to install the cylinder shipping bracket (24)
Liebherr P/N T-193-A. [Reference: Service Tools]
18. Install the capscrews (25), washers (26), and lockwashers (27).
ATTENTION
The dump cylinder (23) is not supported by the shipping bracket (24) at this
time.
► Make sure that you hold the dump cylinder (23) so that it cannot turn
around the bottom pin once the upper pin is removed.
NOTICE
LME/10880897/January 30, 2011/en
The weight of the pin (5) is 36 kg (79 lb).

21. Lift the dump cylinder (23) just enough to remove the weight of the pin
(5).
22. Remove the pin (5).
NOTICE
Usually the pin can be removed manually.
► If the pin is worn, it can be necessary to use a hydraulic pin puller.
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Dump Body Cylinders
23. Carefully and slowly turn the cylinder around the bottom pin so that it
is set against the shipping bracket.
If you do not remove the dump cylinder (23) from the haul truck,
24. Install the retainer for the shipping bracket around the dump cylinder
(23).
25. Remove the capscrews (8), washers (9), and bearing cover (10).
26. Remove the capscrews (11), lockwashers (12), and retainer plate (13).
27. Remove the lower eye of the cylinder and ball bushing (15) from the
lower pin.
28. Lower the dump cylinder (23) until it is clear of the dump body.
LME/10880897/January 30, 2011/en
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Dump Body Cylinders

LME/10880897/January 30, 2011/en
Fig. 9.6-2: Dump Body Cylinders Removal
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Dump Body Cylinders
9.6.4 Dump Body Cylinders Installation
9.6.5 Setup
Safety].
dump body cylinders removal. [Reference: Dump Body Cylinders
Removal ]

Dump Cylinder Shipping Brackets T-193-A [Reference: Service Tools]
9.6.6 Procedure
1. Attach an applicable lift device to the dump cylinder (23).
2. Lift and move the dump cylinder (23) into position.
3. Make sure that the lubrication port on the bottom eye of the dump
cylinder (23) points to the front of the haul truck.
4. Install the seals (1) and (16), retaining rings (3) and (14), and spacer
(2).
5. Put the lower ball bushing and eye (15) in position on the pin.
6. Install the retaining plate (13).
NOTICE
10. If necessary, install the tool and an applicable bottle jack to help align
the upper pin (5). [Reference: Service Tools]
LME/10880897/January 30, 2011/en

► Put on the recommended protective equipment, and clothing when
you use hydraulic fluid.
WARNING! Hydraulic fluid drains from the cylinders when the cover plates
and O-rings are removed.
► Use a container to catch the fluid.
11. Put a container below the cylinder (23).
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Dump Body Cylinders
12. Remove the protective caps from the hydraulic hoses (17).
DANGER! The cylinder rod can move in and out of the dump cylinder if you
do not contain it.
The cylinder rod can be damaged, or cause serious injury or death.
► Make sure that you prevent movement of the cylinder rod when you
remove the cover plates and O-rings. Make sure that all personnel
and equipment are away from the cylinder rod.
13. Remove the cover plates and O-rings from the hydraulic ports and
connect the extend and retract hydraulic hoses (17), bolts (19),
washers (20), clamps (21), and O-rings (18).
14. Align the upper pin hole of the cylinder (23) and install the pin (5).
15. Make sure that the lubrication port on the top eye of the dump cylinder
(23) points to the rear of the haul truck.
17. Remove the tool Liebherr P/N 10025660 , if it is installed.
18. Install the bearing cover (10), capscrews (8), and washers (9).
19. Remove the protective caps and connect the lubrication hoses (22).
20. Use a chain or hand hoist to remove the cylinder shipping brackets
(24) Liebherr P/N T-193-A, capscrews (25), washers (26), and
lockwashers (27).
21. At the hydraulic tank, open the supply and return line valves.
22. Start the engine .
23. Pull the dump control lever in the UP position and lift the front of the
dump body enough to release the safety supports.
24. Remove the safety supports from between the top frame rails and the
dump body beam runners.
25. Fully lower and then lift the dump body to release all trapped air.
26. Fully lower the dump body and stop the engine .
27. Examine the dump cylinder (23) for leaks.
28. Make sure that the dump system hydraulic fluid is at the correct level .
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Dump Body Cylinders

LME/10880897/January 30, 2011/en
Fig. 9.6-3: Dump Body Cylinders Installation
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Dump System Pressure Filters
9.7 Dump System Pressure Filters
06-000_000_01_Dump System Pressure Filters.tif

Fig. 9.7-1: Dump System Pressure Filters
The pressure filters are installed near the dump valve, downstream of the
dump pumps.
The pressure filters work together with the strainers to clean the hydraulic
fluid in the dump system.
There are elements in the pressure filters that clean the hydraulic oil. These
elements can be removed for inspection and replaced.
There is a visual indicator on the pressure filters to tell you when the element
is dirty.
Hydraulic fluid goes from the dump pumps through the pressure filters. The
clean hydraulic fluid goes from the pressure filters to the dump valve.
The pressure filter has a visual differential pressure indicator. If the red
button on the indicator shows, it is possible that the filter is clogged. If the
filter is clogged, it is necessary to replace the filter element.
LME/10880897/January 30, 2011/en
The pressure filter goes into bypass at 4 bar (51 psi). The visual indicator
pops up at 2 bar (35 psi). If the pressure differential pressure measurement
is 4 bar (51 psi) across the valve, then the hydraulic oil is going through the
bypass and not going through the pressure filter. If the red button on the
indicator pops up, the filter may be in bypass. Push the red button back down
before the haul truck is started, or while the haul truck is in operation. If the
visual indicator pops up again, replace the filter element .
If the dump system shows signs of contamination and the elements in the
pressure filters are clean, the problem is downstream of the pressure filters.
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9.7.1 Dump System Pressure Filters Removal
9.7.2 Setup
Safety].
► Drain the hydraulic fluid from the pressure filter.
9.7.3 Procedure

hydraulic fluid.
NOTICE
The weight of the pressure filter is 47 kg (104 lb).
► Make sure that the lift device can hold the weight.
1. Remove the capscrews (3), washers (4), and clamp halves (5).
2. Remove the O-ring (2) and put protective covers on the hose (1).
3. Remove the capscrews (6), flange (7), and O-ring (8).
4. Loosen the capscrews (19).
5. Loosen the clamp halves capscrews, on the dump valve side, for the
adapter (20) that connects the pressure filter to the dump valve .
ring (15).
7. Put protective covers on the open ports.
8. Remove the capscrews (19), lockwashers (18), and the pressure filter
(17).
If you must replace the pressure filter (17),

9. Remove the capscrews (9), lockwashers (10), elbow flange (11), and
O-ring (16).
10. Put protective covers on the open ports.
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LME/10880897/January 30, 2011/en
Fig. 9.7-2: Dump System Pressure Filters Removal
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9.7.4 Dump System Pressure Filters Installation
9.7.5 Setup
Safety].
dump system pressure filters removal. [Reference: Dump System
Pressure Filters Removal]
9.7.6 Procedure

hydraulic fluid.
NOTICE
1. Install the pressure filter (17).
2. Loosely install the capscrews (19) and lockwashers (18).
3. Remove the protective covers from the hoses (1) and ports.
If the elbow flange (11) is removed,

4. Install the elbow flange (11), O-ring (16), capscrews (9), and
lockwashers (10).
Continue with these steps:

5. Install the O-ring (15).
6. Loosely install the capscrews (14), washers (13), and clamp halves
(12).
7. Tighten the capscrews on the dump valve for the adapter (20) that
connects the pressure filter to the dump valve.
8. Tighten the capscrews (14).
9. Tighten the capscrews (19).
10. Install the O-ring (8), flange (7), and capscrews (6).
11. Install the O-ring (2), hose (1), clamp halves (5), capscrews (3), and
LME/10880897/January 30, 2011/en
washers (4).
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LME/10880897/January 30, 2011/en
Fig. 9.7-3: Dump System Pressure Filters Installation
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Dump System Troubleshooting
9.8 Dump System Troubleshooting
9.8.1 Setup
Safety]
Required reference documents:
► [Reference: Dump System Schematics]
► [Reference: Hydraulic Test Point Locations]
► [Reference: haul truck Test Procedure]
WARNING! Following lockout and hydraulic safety is necessary for the

procedures in this section.
► You must read, understand, and follow all requirements for haul truck
lockout, and hydraulic safety.
► If you have questions about your safety during any procedure, contact
your supervisor.
This section provides a logical process for troubleshooting the dump system
components.
General Guidance
• Read this entire procedure before starting the work.
• This procedure assumes the technician has general location
and basic knowledge of the dump system components.
• Faults have been listed in order from the easiest to diagnose
and most likely to occur, to the most difficult to diagnose and
the least likely to occur.
9.8.2 Observation: Dump Body will not Rise

Verify that the brake and steering are still functioning normally.
Fault #1 Loss of pump suction
Possible Causes:
• System oil level low
LME/10880897/January 30, 2011/en
• Isolation valve closed

• Manual lockout valve (next to the pilot valve) is in the wrong
position.
ATTENTION
The proper position for the valve handle is parallel to the ground, and is
aligned with the ports that are horizontal in the valve body.
Check:
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1. Verify hydraulic tank oil level is adequate and isolation valves

are open.
2. If no problem found, go to Fault #2.
Fault #2 Raise proportional valve, in the manifold valve,

does not supply proper pressure to the pilot valve.
Possible Causes:
• No voltage input or incorrect voltage at the manifold valve
• Contamination
• Oil improperly diverted to tank
Check:
1. Measure the pressures at PG1 and PG2 on the manifold valve
while the joystick is in the dump body raise position.
2. If the pressure at PG1 is between 28 bar (400 psi) and 31 bar
(450 psi) and PG2 is zero, go to Fault #3.
3. If pressure at PG1 is outside of above range or PG2 is above
zero, check wiring, connections, and solenoids.
Check:
1. Unplug the float solenoid. Switch the "up" and "down"
proportional valve connections on the manifold. Move the
joystick to the aft position. If the engine RPM lowers and the
engine appears to be under load, the electrical connects are
intact.
• If wiring, connections, and solenoid are intact,
switch proportional valve connections back to
the original position, and check the joystick
output.
Check:
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1. Use Section F of the Truck Test Procedure to verify power is

supplied to the joystick. [Reference: Haul Truck Test
Procedure]
2. Move the joystick to the body raise direction (aft).
3. Turn the high range potentiometer to the right to increase PG1
pressure and to the left to decrease pressure.
4. Once PG1 pressure is correct, check PG2. Place the joystick
in the body lower position and verify PG2 pressure is between
28 bar (400 psi) and 28 bar (400 psi).
• If the PG2 pressure is not within the proper
range, adjust joystick frequency potentiometer.
• If PG1 and PG2 pressure are correct and the
dump body still does not rise, it may be
necessary to adjust the frequency
potentiometer on the joystick in a clockwise
rotation one-quarter turn at a time, and moving
the joystick to the aft position after each
adjustment, to "break" the system free and raise
the dump body. If this adjustment is performed,
you must return to PG1 and PG2 to confirm the
pressures are still correct, and minor
adjustments may be needed.
• If the PG1 pressures can not be adjusted with
the potentiometers, verify the cartridge valve is
not stuck.
Check:
WARNING! The brake accumulators contains stored energy!

► Fluid under pressure can cause injury.
► Shut the haul truck down and bleed the accumulators.
1. Remove the solenoid and cartridge valve from the manifold;

place the solenoid in the end of the valve, energize the
solenoid to observe the cartridge valve movement.
• If no movement, replace the valve with a new
valve, and perform this test again for
confirmation.
• If the cartridge valve is not stuck, verify the float
valve within the manifold valve is not diverting
oil to the tank.
Check:
WARNING! Unexpected load dumping can occur.

LME/10880897/January 30, 2011/en
► Use the buddy dump system to empty the dump body, if necessary.
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1. Unplug the solenoid (SOL 7) of the float valve. Place the

joystick in the dump body raise position. Use Section F of the
Truck Test Procedure drawing, to check the joystick cams to
make sure they are in the correct position. If the cams are not
in the correct position, replace the joystick with a new joystick
and repeat this check. If the cam position is correct, continue
with the next check. [Reference: haul truck Test Procedure]
• If the dump body did not rise, check the dump
body proximity switch on the top of the cab and
on the bed of the haul truck (if installed) and the
associated connections. Use Section F of the
Truck Test Procedure to validate proper
operation [Reference: haul truck Test
Procedure], and the Dump Body Wiring
assembly drawing to verify the proper spacing
of the metal plates. Also, ensure the switch
components on top of the cab are clean, and
there are no obstructions.
Dump Body Proximiaty Switch_01.tif

LME/10880897/January 30, 2011/en
Fig. 9.8-1: Dump Body Proximity Switch

• If no problems are found with the proximity
switch and the associated connections, check
the float valve solenoid, SOL 7 on the Dump
Body Schematic. [Reference: Dump System
Schematics]
Check:
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1. Remove the solenoid from the float valve; place the solenoid
in the end of the valve, energize the solenoid and observe the
float valve movement.
• If no movement, replace the valve, and perform
this check again to verify the original float valve
was defective.
• If no problem found, go to Fault #3.
Fault #3 Pilot valve does not shift
Possible Cause:
• Contamination
Check:

1. Perform a physical displacement test.

1.1. Remove and cap the pilot line from the "B Port"
working end cap, and remove the fitting from the
port. Insert a Phillips screwdriver in the port until
if bottoms out on the pilot spool, move the
joystick to the raise body position (aft) and
observe moment of the pilot valve spool.
WARNING! Actuation of this valve is rapid

► Be careful, and use caution during the procedure that follows.
• If no movement, replace the pilot

valve with a new one, and perform
this check again to verify the
original pilot valve was defective.
• If no movement is observed, go to
Fault #4.
Fault #4 (Extend (Base) Spool in the dump valve does not
shift.
Possible Causes:
LME/10880897/January 30, 2011/en
• Damaged or Worn Spool

• Contamination
Check:
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1. Take pressure readings at the two dump valve inlet ports (DS-
G1 and DG-G2), and at the extend flange tee test port (DS-
G5).
2. With the joystick in the dump body raise position (aft), take
inlet pressures. If 207 bar (3000 psi) exists at both inlet ports,
and pressure at the extend port is 0 bar (0 psi), replace the
dump valve.
• If anything other than 0 bar (0 psi) is measured
at the extend port, proceed to Fault #5.
Fault #5 Retract (Rod) spool in the dump body does not
shift
Possible Causes:
• Damaged or worn Rod spool
• Restrictor check valve in rod spool pilot line plugged
• Various internal dump valve failures
Check:
1. Check that the check valve flow arrow points in the direction
toward the dump valve body.
2. With the joystick in the dump body raise position (aft), read the
pressure a the Retract pressure test port (DS-G6).
• If the pressure is significantly greater than 224
bar (3250 psi) then the Restrictor Check Valve
is plugged and preventing the Rod Spool from
shifting. Replace the Restrictor Check Valve
and validate by repeating this step.
• If this pressure is approximately 224 bar (3250
psi) then there is a problem internal to the dump
valve which is preventing the Rod Spool from
shifting. Replace the dump valve.
Fault #6 Dump pump low output, or 1 of the 2 flow control

valves in the dump valve does not close
Possible Causes:
• Damaged or worn pump
• One of the two flow control valves is defective
Check:
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1. Perform inlet isolation test:

1.1. Remove the float valve solenoid from the
manifold (SOL 7), check pressure at the inlet
test port for each pump (DS-G1 and DS-G2).
1.2. Make sure the dump body joystick is in the
neutral position and install a gauge (345 bar
(5000 psi) minimum) at the "Extend Pressure
Test Port", DS-G5.
1.3. Have the operator try to power down the dump
body and read the pressure.
• If the pressure is approximately
224 bar (3250 psi) then there is a
problem internal to the dump
valve which is preventing the
Base Spool from shifting.
• Replace the dump
valve.
• If the pressure is less than 172 bar
(2500 psi), then perform a Pump
Test to measure the output of the
pumps.
Check:
LME/10880897/January 30, 2011/en
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1. Unplug the float solenoid at the hoist pilot valve actuator on

the inside of the chassis.
2. Put a pressure gauge on the retract side of the hoist (DS-G6).
3. Start the haul truck; test pumps together. Without modifying
circuit, power down the dump body into chassis. Read
pressure gauge on retract side of hoist. If you have a bad
pump, the pressure will typically be less than 172 bar (2500
psi)
• If pressure is 207 bar (3000 psi) or slightly more,
there is nothing wrong with either hoist pump.
Shut off the engine.
• If the pressure is less than 172 bar (2500 psi),
complete this procedure.
4. Disconnect H3 at left inlet section of the dump valve.
Dump System Troubleshooting_01.tif

NOTE(S):
1. It will be necessary to rotate the tube about this point to cap and plug port H3 on the left inlet section.
2. Disconnect H3 at left inlet section here. Cap and plug fitting and tube assembly.
5. Start the haul truck again. Power the dump body into chassis
again. Read the gauge on retract side of hydraulics again.
LME/10880897/January 30, 2011/en
• If the pressure is 207 bar (3000 psi) (and it was

less than 172 bar (2500 psi) during [Reference:
step 3], then the failed hoist pump is on the left-
hand side and the right-hand pump is fine.
• If the retract pressure is still low, then shut off
the haul truck and proceed to the next step.
6. Reconnect H3 at the left inlet section of the dump valve. Next
disconnect H3 at the right inlet section of the dump valve.
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Dump System Troubleshooting_02.tif

NOTE(S):
3. Disconnect H3 at right inlet section of the dump valve. Cap and plug fitting and tube assembly.
4. It will be necessary to rotate the tube about this point to cap and plug port H3 on the right inlet section.
7. Start the haul truck again. Power the dump body into chassis
again.
• If the pressure is 207 bar (3000 psi) (and it was
less than 172 bar (2500 psi) when the pumps
were tested together, then the failed hoist pump
is on the opposite right-hand side. If during this
test, H3 was disconnected at the right inlet
section of the dump valve, then the failed hoist
pump is on the opposite side.
• If during this test, [Reference: step 5], and
[Reference: step 3] tests, the system pressure
is below 172 bar (2500 psi), it is possible both
hoist pumps are bad. (This should be confirmed
with proper flow test at full pressure. Although
the symptoms are beginning to indicate
bypassing hoist cylinder(s), the lines that go to
the retract ports of the cylinders can be removed
and blanked off with proper code 61 blanks to
eliminate the chance of cylinder bypass causing
LME/10880897/January 30, 2011/en
the pressure drop.
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9.8.3 Observation: Dump Body will not Lower

Fault #1 Lower proportional valve, in the manifold valve,
does not supply the proper pressure to the pilot valve.
Possible Causes:
• Contamination
• Manual lockout valve (next to the Pilot Valve) is in the wrong
position
•
ATTENTION
Check:
1. Measure the pressures at PG1 and PG2 on the manifold valve
while the joystick is in the dump body lower position.
• If the pressure at PG1 is between 28 bar (400
psi) and 31 bar (450 psi), and PG2 is zero, go
to Fault #3.
• If the pressure at PG1 is above 28 bar (400
psi) and 31 bar (450 psi) check the wiring,
connections, and solenoids.
Check:
joystick to the fwd (lower) position. If the engine is under load,
the electrical connections are intact.
check the joystick output.
Check:
LME/10880897/January 30, 2011/en
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Procedure]
2. Move the joystick in the dump body raised direction (aft).
pressure and to the left to decrease pressure.
in the dump body lower position and verify PG2 pressure is
between 28 bar (400 psi) and 31 bar (450 psi).
• If PG1 and PG2 pressure are correct, and the
dump body still does not raise, it may be
• If the PG pressure can not be adjusted with the
potentiometers, verify the cartridge valve is not
stuck.
Check:


2. If no movement, replace the valve with a new valve, and
repeat this test to confirm.
3. If the cartridge valve is not stuck, verify the float valve within
the manifold valve is not diverting oil to the tank.
Check:
LME/10880897/January 30, 2011/en

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1. Unplug the solenoid of the float valve. Place the joystick in the
dump body lower position.
• If the dump body begins to lower, use the Truck
Test Procedures to make sure the joystick cams
are in the correct position. [Reference: haul
truck Test Procedure] If the cams are not in the
correct position, replace the joystick with a new
one and repeat the check. If cam position is
correct, proceed to the next check.
• If the dump body did not lower, check the
proximity switch on the top of the cab and on the
bed of the haul truck (if installed) and associated
connections. Use Section F of the Truck Test
procedure [Reference: haul truck Test
Procedure] to validate proper operation, and
The Dump Body Proximity Wiring Assembly
drawing to verify the connections and proper
spacing of the metal plates. Also, make sure the
switch components on top of the cab are clean,
and there are no obstructions.
• If no problems were found with the proximity
switch and associated connections, check the
float valve manifold solenoid.
Check:

1. Remove the solenoid from the float valve manifold; place the
solenoid in the end of the valve, energize the solenoid and
observe the float valve movement.
• If no movement, replace the valve, and repeat
this check to verify the original float valve was
defective.
• If no problem was found, go to Fault #2.
Fault #2 Pilot Valve does not shift

Possible Cause:
• Contamination
Check: (with the haul truck running):
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1. Perform a physical displacement test:

2. Remove and cap the pilot line from the "B Port" working end
cap, and remove the fitting from the port. Insert a Phillips
screwdriver in the port until it bottoms out on the pilot spool,
move the joystick to the raise dump body position (aft) and
observe movement of the pilot valve spool.

• If no movement, replace the pilot valve with a

new valve, and repeat this step to verify the
• If movement is observed, go to Fault #4.
Fault #3 Extend (Base) Spool in the dump valve does not
shift
Possible Causes:
• Damaged or worn spool
• Contamination
Check:
G1) and DS-G2), and at the extend flange tee test port (DS-
G5). With the joystick in the raise position (aft), take the inlet
pressures. If 207 bar (3000 psi) exists at both inlet ports, and
pressure at the extend port is 0 bar (0 psi), replace the dump
valve.
• If anything other than 0 bar (0 psi) is measured
at the extend port, proceed to Fault #4.
Fault #4 Retract (Rod) spool in the dump valve does not
shift
Possible Causes:
• Damaged or worn rod spool
• Restrictor check valve in rod spool pilot line plugged
Check:
LME/10880897/January 30, 2011/en
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1. Measure pressure at extend and retract test ports.

2. Use the Hydraulic Test Procedure to make sure the restrictor
check valve flow arrow is pointing in the direction toward the
dump valve body. [Reference: Hydraulic Test Point
Locations]
3. With the joystick in the lower position (forward), read the
pressure at the extend pressure test port (DS-G5).
• If this pressure is significantly greater than 224
bar (3250 psi), then the restrictor check valve is
plugged and preventing the rod spool from
shifting.
• Replace the restrictor check valve
and repeat this step to validate.
• If the pressure is approximately 224 bar (3250
psi), then there is a problem internal to the dump
valve which prevents the rod spool from shifting.
• Replace the dump valve.
9.8.4 Observation: Slow slew rate

General hand tools and any required N/A Commercially available
safety items
Hydraulic Pressure Test Kit T-493 [Reference: Service Tools]
Fault #1 Raise proportional valve, in the manifold valve,

doe snot supply proper pressure to the pilot valve.
Possible Causes:
• Contamination
• Manual lockout valve (next to pilot valve) is in the wrong
position
ATTENTION
LME/10880897/January 30, 2011/en
Check:
1. Measure pressure at PG1 and PG2 on the manifold valve
while joystick is in the dump body raise position.
• If the pressure at PG1 is between 28 bar (400
psi) and 31 bar (450 psi) and PG2 is zero, go to
Fault #3.
• If the pressure at PG1 is outside or above range,
or PG2 is above zero, check wiring,
connections, and solenoids.
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Check:
joystick to the aft position. If the engine is under load, your
electrical connections are intact.
check the joystick output.
Check:
Procedure]
2. Move the joystick in the body raise direction (aft).
pressure and to the left to decease pressure.
in the body lower position and verify PG2 pressure is between
28 bar (400 psi) and 31 bar (450 psi).
• If the PG2 pressure is not in the proper range,
adjust joystick frequency potentiometer.
• If PG1 and PG2 pressures are correct and the
dump body still does not rise, it may be
• If the PG pressures can not be adjusted with the
potentiometers, verify the cartridge value is not
stuck.
Check:

LME/10880897/January 30, 2011/en

• If no movement, replace the valve with a new
valve, and repeat the test again to confirm.
• If the cartridge valve is not stuck, verify the float
valve within the manifold valve is not diverting
oil to the tank.
Check:
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1. Unplug the solenoid of the float valve. Place the joystick in the
body raise position.
• If the dump body does not begin to rise, use
Section F of the Truck Test Procedure to check
the joystick cams are in the correct position. If
the cams are not in the correct position, replace
the joystick with a new one and repeat this
check. If the cam position is correct, proceed to
the next check. [Reference: haul truck Test
Procedure]
• If the dump body did not rise, check proximity
switch on the top of the cab and on the bed of
the haul truck, if installed, and the associated
connections. Use Section F of the Truck Test
Procedure to validate the correct operation
[Reference: haul truck Test Procedure], and the
Dump Body Proximity Wiring Assembly to verify
the correct spacing of the metal plates. Also,
make sure the switch components on top of the
cab are clean, and there are no obstructions.
[Reference: Dump Body Proximity Wiring
Assembly]
• If no problems were found with the proximity
switch and the associated connections, check
the float valve manifold solenoid.
Check:

1. Remove the solenoid from the float valve manifold; place the
solenoid in the end of the valve, energize the solenoid and
observe the float valve moment.
• If no movement, replace the valve, and perform
this check again to verify the original float valve
was defective.
9.8.5 Observation: System Overheat

LME/10880897/January 30, 2011/en
Fault #2 Pilot Valve does not shift

Possible Causes:
• Internal Contamination
Check: (with the haul truck running)
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1. Perform a physical displacement test:

1.1. Remove and cap the pilot line from the "B Port"
working end and remove the fitting from the port.
Insert a Phillips screwdriver in the port until it
bottoms out on the pilot spool, move the joystick
to the raise dump body position (aft) and
observe movement of the pilot valve spool.

• If no movement, replace the pilot

valve with the new one, and
repeat this check to verify the
• If movement is observed, go to
Fault #4.
Fault #4 Extend (Base) Spool in the dump valve does not
shift
Possible Causes:
• Damaged or Worn Spool
• Contamination
Check:
G1 and DS-G2), and at the extend flange tee test port (DS-
G5).
2. With the joystick in the dump body raise position (aft), take
inlet pressures. If 207 bar (3000 psi) exists at both inlet ports
and pressure at the extend port is 0 bar (0 psi), replace the
dump valve.
• If anything other than 0 is measured, at the
extend port, proceed to Fault #5.
Fault #5 Retract (Rod) Spool in the dump valve does not
shift
Possible Causes:
• Damaged or worn Rod Spool
• Restrictor Check Valve in Rod Spool pilot line plugged
Check:
LME/10880897/January 30, 2011/en
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1. Make sure the restrictor check valve (see Detail J in the Dump
System Schematic flow arrow is pointing in the direction
toward the dump valve. With the joystick in the raise position
(aft), read the pressure at the retract pressure test port (DS-
G6).
• If this pressure is significantly greater than 3250,
then the restrictor check valve is plugged
therefore preventing the Rod Spool from
shifting.
• Replace the restrictor check calve
and validate by repeating this
step.
• If this pressure is approximately 224 bar (3250
psi) then there is problem internal to the dump
valve which is preventing the Rod Spool from
shifting.
• Replace the dump valve.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
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Service Manual Hydraulic Brake and Steering Systems
10 Hydraulic Brake and Steering Systems 407

10.1 Brake and Steering Pump 409
10.1.1 Pump Control 410
10.1.2 At Rest (No Rotation of Prime Mover) 411
10.1.3 Start-up (Prime Mover Running) 412
10.1.4 Pump Unloading 413
10.1.5 Loading 414
10.1.6 Brake and Steering Pump Removal 416
10.1.9 Brake and Steering Pump Installation 418
10.2 Brake and Steering Pressure Filter 420
10.2.1 Brake and Steering Pressure Filter Removal 421
10.2.4 Brake and Steering Pressure Filter Installation 423
10.3 Brake and Steering Manifold 425
10.3.1 Brake and Steering Manifold Removal 427
10.3.4 Brake and Steering Manifold Installation 429
10.4 Brake System 431
10.4.1 Brake Accumulators 434
10.4.2 Brake Accumulators Removal 435
10.4.5 Brake Accumulators Installation 437
10.4.8 Brake System Accumulator Bleed 439
10.5 Hand Brake Valve and Manifold 440
10.5.1 Hand Brake Valve and Manifold Removal 441
10.5.4 Hand Brake Valve and Manifold Installation 442
10.6 Steering System 443
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10.6.1 Steering Accumulator 444

10.6.2 Steering Accumulator Removal 445
10.6.5 Steering Accumulator Installation 447
10.6.8 Steering System Accumulator Bleed 449
10.7 Flow Amplifier Valve 450
10.7.1 Flow Amplifier Valve Removal 451
10.7.4 Flow Amplifier Valve Installation 454
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Hydraulic Brake and Steering Systems Service Manual
10.8 Steering Control Valve 457

10.8.1 Steering Control Valve Removal 458
10.8.4 Steering Control Valve Installation 460
10.9 Steering Cylinders 462
10.9.1 Steering Cylinders Removal 463
10.9.4 Steering Cylinders Installation 465
10.10 Buddy Brake and Steering Components 468
10.11 Brake and Steering Pump Unloader Valve Accumulator 470
Accumulator Removal 471
Accumulator Installation 473
Pressure Check 475
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Brake and Steering Pump
10.1 Brake and Steering Pump
06-000_000_01_Brake and Steering Pumps.tif
The brake and steering pump has the components that follow:
• Pressure Compensator
• Unloader Valve
The brake and steering pump connects to the components that follow:
• Unloader Valve Accumulator
• Check Valve for Unloader Control
There are two brake and steering pumps used in the brake and steering
system. The brake and steering pumps are installed on the front side of the
pump drive assembly and are mechanically connected to the gears of the
pump drive assembly.
The brake and steering pump takes hydraulic fluid from the brake and
steering tank. The brake and steering pump supplies a flow of hydraulic fluid
through the brake and steering pressure filter to the brake and steering
system, and the auto lube system.
LME/10880897/January 30, 2011/en
The brake and steering hydraulic pump pushes hydraulic fluid through a filter
and into the accumulators through the valves in the manifold. The brake
accumulators are charged with nitrogen gas to 124 bar (1800 psi) and the
steering accumulator to 124 bar (1800 psi). After the hydraulic fluid from the
brake and steering hydraulic pump goes into the accumulators, the nitrogen
gas is compressed more. This compressed nitrogen gas is a pressure
reserve for the brake and steering control.
There are two brake and steering pumps. The drive side pump is set to 234
bar (3400 psi), the other is set to 221 bar (3200 psi)
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The brake and steering pump is a variable displacement, in-line axial piston
pump. The angle of the swashblock determines the output volume of the
pump. The greater the swashblock angle the more fluid the pump delivers.
The swashblock in an axial piston pump acts as an inclined plane. As the
piston and shoe assemblies rotate around the face of the swashblock the
pistons travel in an inward and outward direction. As the piston travels
outward it creates a void, atmospheric pressure then forces fluid from the
hydraulic system reservoir into the pump inlet port, thus filling the void. Then
as the piston travels inward it forces oil out of the cylinder barrel/valve plate
into the hydraulic system. Pressure in the hydraulic system is resistance to
this fluid flow.
The distance the pistons travel, times the area of the piston times number
of pistons, is the displacement of the pump. The PVG-130 has a full stroke
displacement of 130 milliliters per revolution, or 7.94 cubic inches per
revolution. The output volume of the pump is determined by multiplying the
displacement of the pump (in cubic inches) times the rpm of the prime
mover, then dividing by 231 (number of cubic inches in a gallon) which
equals gallons per minute. To determine the output volume in liters, multiply
displacement in ml/rev times rpm then divide by 1000 (number of milliliters
per liter) which equals liters per minute.

Fig. 10.1-2: Brake and Steering Pump
10.1.1 Pump Control

LME/10880897/January 30, 2011/en
The mechanism used to vary the displacement of the pump is called the
control. The control is linked to the swashblock via a control pin. The control
pin engages the swashblock in the pump and control piston located in the
control housing. By changing the position of the control piston, this in turn
changes the angle of the swashblock, thus changing the output volume. The
special pressure compensator control Liebherr is using on the PVG-130
makes the pump reduce output volume to near zero at low pressure. This
occurs automatically once the accumulator system is satisfied that it is up
to operating pressure.
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Fig. 10.1-3: Pump Control
10.1.2 At Rest (No Rotation of Prime Mover)

When the prime mover is idle (not rotating), the control piston bias spring
(item 329) pushes the control piston (item 302) partially on stroke.
LME/10880897/January 30, 2011/en

Fig. 10.1-4: Brake and Steering Pump At Rest (No Rotation of Prime Mover)
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The four-way bias spring forces the four-way spool to its normally offset
position.
This connects the outlet of the pump to bias side of the control piston through
the four-way spool.
The compensator relief valve and accumulator unloading valve are offset to
their normally closed positions.

Fig. 10.1-5: Brake and Steering Relief Valve and Accumulator Unloading Valve in Closed Positions
10.1.3 Start-up (Prime Mover Running)

Fluid is pushed into the inlet port and rotating group of the pump by
atmospheric pressure acting on the fluid in the reservoir. The fluid is forced
out of the rotating group through the outlet port of the pump and into the
system past a check valve. As more fluid is forced into the system,
resistance to this fluid flow begins and pressure starts to rise. Fluid also
flows through drilled passages in the valve plate, pump housing, and control
into OP1.
Fluid out of OP1 then flows to the bias (on stroke) side of the control piston
and through OP2 to the bias (spring) side of the 4-way compensator spool.
At this point pressure has not risen sufficiently to overcome the spring
pressure in the compensator valve, so pressure rises on the bias side of the
control piston. At approximately 200 psi, the control piston is pushed to full
stroke (maximum output volume).
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Fig. 10.1-6: Brake and Steering Pump Start-up (Prime Mover Running)
10.1.4 Pump Unloading

When pressure from the system acting on the spool in the Accumulator
Unloading Valve becomes sufficient, it will overcome the spring force
holding the poppet closed, thus forcing the poppet open.
The open Accumulator Unloading poppet then allows oil to exhaust from the
bias side of the 4-way compensator spool. Because of OP2, pressure will
be slightly higher on the control side of the 4-way spool, which will cause
the 4-way to shift. This connects the outlet port of the pump through OP1 to
control (off stroke) side of the control piston. As fluid in the control piston
chamber reaches sufficient pressure, it overcomes the control piston bias
spring and the pump short strokes (compensates) at low pressure
(approximately 200 psi).
LME/10880897/January 30, 2011/en
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Fig. 10.1-7: Brake and Steering Pump Unloading
If the Accumulator Unloading Assembly fails to open, the Pressure

Compensator will open, allowing the pump to compensate at high pressure.
The Pressure Compensator should be set 150 psi higher than the
Accumulator Unloading Assembly.
10.1.5 Loading
When pressure down stream of the check drops approximately 8-10%, the
accumulator unloading valves closes. This allows the pressure to build on
the bias side of the 4-way spool, causing the 4-way to shift. This connects
the pump outlet port to the on-stroke side (bias) of the control piston, forcing
the pump on stroke (increasing the pump output volume).
The pressure compensator should be set 150 psi above the system
operating pressure. This valve will allow the pump to compensate, albeit at
high pressure, if the accumulator unloading fails to open. This prevents the
pump from exhausting over the system relief valve, which would create high
system temperatures.
LME/10880897/January 30, 2011/en
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Fig. 10.1-8: Brake and Steering Pump Unloading
LME/10880897/January 30, 2011/en
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10.1.6 Brake and Steering Pump Removal
10.1.7 Setup
Safety]
► Release the pressure from the steering system.
► Put the shutoff valve for the brake and steering tank in the closed
position.
10.1.8 Procedure

1. Put a container below the brake and steering pump (1) to collect the
hydraulic fluid.
2. Disconnect the hoses (2) and (4) and put protective covers on the open
posts.
3. Remove the capscrews (2).
4. Use an applicable lift device or support to hold the pump (14).
NOTICE
The weight of the pump without the hydraulic fluid is 50 kg (110 lb).
► Make sure that the lift device can hold this weight.
5. Remove each of the pumps from the splitter box.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
06-100_000_01_Brake and Steering Pump.tif

Fig. 10.1-9: Brake and Steering Pump Removal
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10.1.9 Brake and Steering Pump Installation
10.1.10 Setup
Safety]
10.1.11 Procedure

NOTICE
The weight of the pump without the hydraulic fluid is 50 kg (110 lb).
1. Install each of the pumps from the splitter box.
3. Remove the protective covers from the open ports and reconnect the
hoses (2) and (4).
4. Put the shutoff valve for the brake and steering tank in the open
position .
5. Do the brake and steering system pressure setup .
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
06-100_000_01_Brake and Steering Pump.tif

Fig. 10.1-10: Brake and Steering Pump Installation
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Brake and Steering Pressure Filter
10.2 Brake and Steering Pressure Filter
06-000_000_01_Brake and Steering Pressure Filter.tif

Fig. 10.2-1: Brake and Steering Pressure Filter
There is one brake and steering pressure filter to clean the hydraulic fluid in
the brake and steering system. The pressure filter is installed near the brake
and steering pump.
The pressure filter is downstream of the brake and steering pump(s).

Pressurized hydraulic fluid goes from the brake and steering pump(s)
through the pressure filter. Clean hydraulic fluid goes from the pressure filter
to the brake and steering manifold.
The pressure filter includes a visual differential pressure indicator that can
show at 3 bar (50 psi) differential and can go into bypass at 4 bar (65 psi)
differential.
LME/10880897/January 30, 2011/en
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10.2.1 Brake and Steering Pressure Filter Removal
10.2.2 Setup
Safety]
10.2.3 Procedure

1. Put a container below the pressure filter (8) to collect the hydraulic
fluid.
2. Disconnect the hose (5) and put protective covers on the hose and
open port.
NOTICE
► Make sure that the lift device that can hold this weight.
6. Remove the capscrews (2), flange (1), pressure filter (8), and O-rings
(9).
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LME/10880897/January 30, 2011/en

Fig. 10.2-2: Brake and Steering Pressure Filter Removal
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10.2.4 Brake and Steering Pressure Filter Installation
10.2.5 Setup
Safety]
10.2.6 Procedure

1. Remove all the protective caps from the pressure filter (8).
NOTICE
2. Install the O-rings (6), pressure filter (8), and capscrews (2).
3. Install the flange (1), capscrews (7) and lockwashers (6).
6. Remove the protective covers and connect the hose (5).
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LME/10880897/January 30, 2011/en

Fig. 10.2-3: Brake and Steering Pressure Filter Installation
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Brake and Steering Manifold
10.3 Brake and Steering Manifold
06-000_000_01_Brake and Steering Manifold.tif

Fig. 10.3-1: Brake and Steering Manifold
There following test ports apply hydraulic pressure:

• BS-MR1: Manual Valve to bleed Front Brake Accumulator
• BS-MR2: Manual Valve to bleed Rear Accumulator
• SOL4: Solenoid Valve with manual override to bleed Steering
Accumulator
• BS-RV1: Main Relief Valve Brake and Steering Circuit
• PG1-UP: Hoist System Raise Pilot Pressure
• PG2-Down: Hoist System Lower Pilot Pressure
• BS-G1 - Front Brake Pressure
• BS-G2 - Rear Brake Pressure
• BS-G3 - Steering Pressure
• BS-G4 - System Pressure
• BS-G5 - Park Brake Pressure
The brake and steering manifold is installed on the left side of the haul truck
on the frame forward of the hydraulic tank.
LME/10880897/January 30, 2011/en
The brake and steering manifold is an assembly of many valves, adapters,

and switches. The function of the manifold is to let pressurized hydraulic
fluid from the brake and steering pump flow to the applicable system as
necessary.
Hydraulic fluid comes from the brake and steering pump, through the
pressure filter, into the manifold. The front and rear brakes, park brake, and
steering use the hydraulic fluid as necessary to operate. Pressure switches
for the front brake, rear brake, park brake, and steering send a signal to the
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TCU. for monitoring and display. Check valves in the manifold permit one
direction of flow and do not let the accumulators bleed down if the pump or
engine fails.
The brake and steering manifold connects to the systems that follow:
• [Reference: Steering System]
• [Reference: Brake System]
• [Reference: Auto Lube System]
06-000_000_01_Brake and Steering Manifold Schematic.tif

Fig. 10.3-2: Brake and Steering Manifold Schematic
The manifold also has pressure outputs to the dump system.
The hydraulic pressure in the steering accumulator and unloader valve

accumulator bleeds automatically three to five minutes after the engine
stops. The two brake accumulators do not automatically bleed down after
engine shutdown. If necessary, there are three bleed valves to manually
make sure there is no pressure in the system.
LME/10880897/January 30, 2011/en
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10.3.1 Brake and Steering Manifold Removal
10.3.2 Setup
Safety]
► Bleed the brake accumulators.
► Bleed the steering accumulator.
10.3.3 Procedure

1. Put a container below the manifold (1) to collect the hydraulic fluid.
2. Mark and disconnect the wires (2).
3. Mark and disconnect the hoses (3) and put protective covers on the
NOTICE
The weight of the brake and steering manifold is 31 kg (68 lb).
► Use an applicable lifting device that can hold the weight.
5. Remove the capscrews (6), and lockwashers (7).
LME/10880897/January 30, 2011/en
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Fig. 10.3-3: Brake and Steering Manifold Removal
LME/10880897/January 30, 2011/en
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10.3.4 Brake and Steering Manifold Installation
10.3.5 Setup
Safety]
► Make sure the brake and steering manifold is in the same configuration
from the brake and steering manifold removal procedure. [Reference:
Brake and Steering Manifold Removal]
10.3.6 Procedure

NOTICE
The weight of the brake and steering manifold is 31 kg (68 lb).
1. Install capscrews (6), and lockwashers (7).
2. Install capscrews (4) and lockwashers (5).
3. Remove protective covers from the hoses (3) and open ports and
connect the hoses (3).
4. Connect the wires (2).
5. Remove the container from below the manifold and use the correct
procedure to dispose of the hydraulic fluid.
LME/10880897/January 30, 2011/en
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Fig. 10.3-4: Brake and Steering Manifold Installation
LME/10880897/January 30, 2011/en
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Brake System
10.4 Brake System

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12-000_000_01_Brake System.tif
Fig. 10.4-1: Brake System
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Brake System
There is one accumulator for the front brakes and one accumulator for the
rear brakes.
Hydraulic fluid from the brake accumulators is sent to the dual valve of the
brake pedal. The left side of the dual valve is for the front service brakes,
while the right side is for the rear service brakes. When the brake pedal is
pushed, hydraulic fluid from the accumulators is sent through the dual valve
to the brakes.
If the hand brake switch is the ON position, the hand brake solenoid is
energized. if the hand brake solenoid is energized, hydraulic pressure is
applied to the front and rear service brakes. A hand brake ON signal from
the pressure switch is sent to the TCU . Traction motor operation to cause
movement of the haul truck is prevented when the hand brake is ON.
The Siemens AC drive system sends a signal to the hand brake for use
during brake blending and anti-roll back.
If the park brake switch is in the APPLY position, or the master switch is
moved to the ON position, the park brake solenoid is de-energized.
Hydraulic pressure that holds the spring back from the park brake is
removed, and the park brake is applied. A signal is sent to the park brake
indicator to come on. The park brake release contactor K108 opens to
prevent haul truck movement.
if the park brake switch is in the RELEASE position, the park brake solenoid
is energized. Hydraulic pressure on the spring causes the park brake to
release. The park brake indicator in the cab goes off. The park brake release
contactor K108 closes to permit haul truck movement.
There is an alarm on the display that shows when the pressure in the brake
system goes below 172 bar (2495 psi). It is necessary to safely and quickly
stop the haul truck when this alarm shows. Use a constant pressure on the
brake pedal and do not pump the brakes when the brake pressure is low.
The brake system connect to the components that follow:

• [Reference: Brake and Steering System]
• [Reference: Front Brakes]
• [Reference: Rear Brakes]
• [Reference: Foot Pedal Controls]
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Brake System
12-000_000_02_Brake System.tif
Fig. 10.4-2: Brake System Components
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Brake System
10.4.1 Brake Accumulators
12-000_000_Brake Accumulators.tif
Fig. 10.4-3: Brake Accumulators
There are two brake accumulators for the brake system. The two brake
accumulators are installed forward of the hydraulic tank on the left side of
the haul truck. The brake accumulators have a 7.6 L (2 gal) capacity.
The brake and steering pump(s) supplies the brake accumulators with
LME/10880897/January 30, 2011/en
hydraulic fluid if there is a pump or engine failure. The accumulators supply

the brake system with sufficient pressure to apply the brakes to stop the haul
truck. There is nitrogen gas in the brake accumulators to keep a charge of
124 bar (1798 psi).
During operation, hydraulic fluid from the brake and steering pump(s) keeps
the pressure in the accumulators at 200 bar (2901 psi) to 220 bar (3191
psi). Check valves in the system do not let the accumulators bleed down if
there is an engine or a pump failure. There are two shutoff valves on the
brake and steering manifold to manually bleed the brake system .
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Brake System
10.4.2 Brake Accumulators Removal
10.4.3 Setup
Safety]
► Bleed the brake accumulators. [Reference: Brake Accumulators
Bleed]
10.4.4 Procedure

1. Put a container below the accumulator (1) to collect the hydraulic fluid.
2. Disconnect the hydraulic hoses (4) and put protective covers on the
NOTICE
The minimum weight of the empty accumulator is 39 kg (86 lb).
NOTICE
The weight of the accumulator (dry) is 39 kg (86 lb).
3. Attach an applicable lift device to the accumulator (1).
4. Remove the capscrews (2) and lockwashers (3) from the clamps.
5. Remove the accumulator (1).
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Brake System
LME/10880897/January 30, 2011/en
Fig. 10.4-4: Brake Accumulators Removal
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Brake System
10.4.5 Brake Accumulators Installation
10.4.6 Setup
Safety]
► Make sure that the haul truck is in the same condition from the brake
accumulators removal. [Reference: Brake Accumulators Removal]
10.4.7 Procedure

NOTICE
1. Attach an applicable lift device to the brake accumulator (1).
2. Install the accumulator (1) in the clamps.
5. Connect the hydraulic hoses (4) to the accumulator (1).
6. Make sure that the brake accumulator has the correct pre-charge .
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Brake System
LME/10880897/January 30, 2011/en
Fig. 10.4-5: Brake Accumulators Installation
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Brake System
10.4.8 Brake System Accumulator Bleed
10.4.9 Setup
Safety].
10.4.10 Procedure

1. Make sure the engine is stopped.

2. Manually open the valves BS-MR1 (front brake accumulator), and BS-
MR2 (rear brake accumulator) on the brake and steering manifold.
3. Make sure that no pressure remains in the system.
4. Close the valves BS-MR1 and BS-MR.
12-500_000_Brake Accumulator Bleed.tif

Fig. 10.4-6: Brake Accumulator System Bleed
LME/10880897/January 30, 2011/en
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Hand Brake Valve and Manifold
10.5 Hand Brake Valve and Manifold
12-000_000_Hand Brake Valve and Manifold.tif

Fig. 10.5-1: Hand Brake Valve and Manifold
The hand brake valve and manifold is installed below the brake pedal below
the floor of the cab.
If the hand brake is ON, the solenoid in the hand brake valve is energized.
If the hand brake solenoid is energized, hydraulic pressure is applied to the
front and rear service brakes.
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10.5.1 Hand Brake Valve and Manifold Removal
10.5.2 Setup
Safety]
► Bleed the brake accumulators. [Reference: Brake Accumulators
Bleed]
10.5.3 Procedure

1. Disconnect the hoses (1) and (5).

2. Put protective covers on the hoses (1) and (5).
3. Remove the capscrews (4), lockwashers (3), washers (2), and the
manifold assembly hand brake (6).
LME/10880897/January 30, 2011/en
12_100_000_Hand Brake Valve and Manifold.tif

Fig. 10.5-2: Hand Brake Valve and Manifold Removal
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10.5.4 Hand Brake Valve and Manifold Installation
10.5.5 Setup
Safety]
hand brake valve and manifold removal. [Reference: Hand Brake Vale
and Manifold Installation]
10.5.6 Procedure
WARNING
Hydraulic fluid can cause skin irritation.
1. Install the manifold assembly hand brake (6), capscrews (4),

lockwashers (3), and washers (2).
2. Remove the protective covers and connect the hoses (1) and (5).
LME/10880897/January 30, 2011/en
12_100_000_Hand Brake Valve and Manifold.tif

Fig. 10.5-3: Hand Brake Valve and Manifold Installation
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Steering System
10.6 Steering System

LME/10880897/January 30, 2011/en
06-000_000_01_Steering System.tif
Fig. 10.6-1: Steering System
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Steering System
The steering system has the components that follow:

• [Reference: Steering Accumulator ]
• [Reference: Flow Amplifier Valve ]
• [Reference: Steering Control Valve ]
• [Reference: Steering Cylinders]
• [Reference: Tie Rod]
• [Reference: Idler Arm Assembly ]
• [Reference: Steering Arm ]
• [Reference: Steering Stop Pads ]
The brake and steering system supplies hydraulic fluid to the steering
system through the manifold. Hydraulic fluid goes through the flow amplifier,
to the steering valve attached to the steering column. The hydraulic fluid is
blocked at the steering valve until the operator turns the steering wheel.
The steering system is hydraulically operated. There are no mechanical

connections between the steering column and the wheels of the haul truck.
There are hydraulic hoses from the steering column to the flow amplifier
valve and to the steering cylinders.
If the operator turns the steering wheel, hydraulic fluid, in proportion to the
movement of the steering wheel, is sent to the flow amplifier valve. The flow
amplifier valve increases the flow of the hydraulic fluid from the steering
column to the steering cylinders. Hydraulic pressure extends or retracts the
steering cylinders which causes the front wheels to turn.
The steering accumulator supplies the steering system with pressurized

hydraulic fluid in an emergency. If the brake and steering pump has a failure,
there is enough pressure from the accumulator to safely stop the haul truck.
There is an alarm on the display that shows when the pressure in the
steering system goes below 172 bar (2495 psi). It is necessary to safely and
quickly stop the haul truck when this alarm shows.
10.6.1 Steering Accumulator

There is one steering accumulator for the steering system. The steering
accumulator is installed on the left side of the haul truck.
The function of the steering accumulator is to supply the steering system

with hydraulic pressure if the pump or engine becomes unserviceable.
There is nitrogen gas in the steering accumulator to keep a charge of 117
bar (1697 psi). The steering accumulator has a 175 L (46.2 gal) capacity.
LME/10880897/January 30, 2011/en
During operation, hydraulic fluid from the brake and steering pump keeps
the pressure in the accumulator at 200 bar (2901 psi) to 220 bar (3191
psi). Check valves in the system do not let the accumulator bleed down if
there is an engine or a pump failure.
The steering accumulator automatically bleeds down three to five minutes

after the engine stops. There is a shutoff valve on the brake and steering
manifold to manually bleed the steering system .
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Steering System
10.6.2 Steering Accumulator Removal
10.6.3 Setup
Safety]
► Bleed the steering accumulator. [Reference: Steering System
Accumulator Bleed]
10.6.4 Procedure

2. Remove the capscrews (9), lockwashers (10), clamp halves (7), and
O-ring (6).
3. Discard the O-ring (6).
4. Put protective covers on the hose (11) and open port.
NOTICE
6. Remove the nut (5), washer (3), lockwashers (4), and the U-bolt (2).
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Steering System
LME/10880897/January 30, 2011/en
06-100_000_01_Steering Accumulator.tif
Fig. 10.6-2: Removal/Installation of the Steering Accumulator
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Steering System
10.6.5 Steering Accumulator Installation
10.6.6 Setup
Safety]
► Use a safety harness when you do maintenance above the ground.
Steering Accumulator removal. [Reference: Steering Accumulator
Removal]
10.6.7 Procedure

NOTICE
2. Put the accumulator (1) in position on the haul truck.
3. Install the U-bolt (2), nut (5), washer (3), and lockwashers (4).
4. Remove the protective covers from the hose (11) and port.
5. Install the hose (8), O-ring (6), clamp halves (7), capscrews (9), and
lockwashers (10).
6. Make sure that the steering accumulator has the correct initial charge.
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Steering System
LME/10880897/January 30, 2011/en
06-100_000_01_Steering Accumulator.tif
Fig. 10.6-3: Removal/Installation of the Steering Accumulator
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Steering System
10.6.8 Steering System Accumulator Bleed
10.6.9 Setup
Safety]
10.6.10 Procedure

1. Make sure the engine is stopped.

2. After three to five minutes, on the brake and steering manifold, push
SOL4 in and turn counter clockwise a 1/4 turn to the OUT position.
3. Make sure that no pressure remains in the system.
4. Put the SOL4 knob back to its initial position.
06-300_000_01_Steering Accumulator Bleed.tif

Fig. 10.6-4: Steering Accumulator Bleed
LME/10880897/January 30, 2011/en
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Flow Amplifier Valve
10.7 Flow Amplifier Valve
0942000da01.tif
Fig. 10.7-1: Flow Amplifier Valve
The flow amplifier valve is installed on the lower, forward crossmember on

the left side of the haul truck.
The flow amplifier valve increases the flow of the hydraulic fluid from the
steering column to the steering cylinders.
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10.7.1 Flow Amplifier Valve Removal
10.7.2 Setup
Safety]
Accumulator Bleed]
10.7.3 Procedure
1. Remove the capscrews (15), lockwashers (16), and cover (17).

2. Put a container below the flow amplifier valve (13) to collect the
hydraulic fluid.
3. Remove the capscrews (10), clamp halves (11), O-ring (12), and elbow
(9).
4. Remove the capscrews (7), clamp halves (6), and O-ring (5).
5. Remove the capscrews (2), clamp halves (3), and O-ring (4).
6. Disconnect the hoses (14).
7. Put protective covers on the hoses (1), (8), (9), (14), and all open ports.
NOTICE
The weight of the flow amplifier valve is 29 kg (64 lb).
8. Remove the capscrews (18), lockwashers (19), and flow amplifier
valve (13).
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LME/10880897/January 30, 2011/en
06-100_000_01_Flow Amplifier Valve.tif

Fig. 10.7-2: Flow Amplifier Valve Removal (Page 1 of 2)
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LME/10880897/January 30, 2011/en

Fig. 10.7-3: Flow Amplifier Valve Removal (Page 2 of 2)
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10.7.4 Flow Amplifier Valve Installation
10.7.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from the flow
amplifier valve removal. [Reference: Flow Amplifier Valve Removal]
10.7.6 Procedure

NOTICE
The weight of the flow amplifier valve is 29 kg (64 lb).
1. Install the flow amplifier valve (13), lockwashers (18), and capscrews
(19).
2. Remove the protective covers from the hoses (1), (8), (9), (14), and
ports.
3. Put the hoses (1) in position and install the O-rings (4), clamp halves
4. Put the hose (8) in position and install the O-ring (5), clamp halves (6),
and capscrews (7).
5. Put the hose (9) in position and install the O-ring (12), clamp halves
6. Connect the hoses (14).
7. Install the cover (17), lockwashers (16), and capscrews (15).
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 10.7-4: Flow Amplifier Valve Installation (Page 1 of 2)
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LME/10880897/January 30, 2011/en

Fig. 10.7-5: Flow Amplifier Valve Installation (Page 2 of 2)
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Steering Control Valve
10.8 Steering Control Valve
06-000_000_01_Steering Control Valve.tif

Fig. 10.8-1: Steering Control Valve
The steering control valve is installed on the bottom of the steering column
below the floor of the cab.
The steering control valve sends hydraulic fluid, in proportion to the

movement of the steering wheel, to the flow amplifier valve.
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10.8.1 Steering Control Valve Removal
10.8.2 Setup
Safety]
Accumulator Bleed]
10.8.3 Procedure

1. Put tags and disconnect the hoses (3) and (4).

2. Put protective covers on the hoses (3) and (4) and all open ports.
3. Remove the capscrews (1), lockwashers (2) and steering control valve
(5).
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LME/10880897/January 30, 2011/en

Fig. 10.8-2: Steering Control Valve Removal
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10.8.4 Steering Control Valve Installation
10.8.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the steering
control valve removal. [Reference: Steering Control Valve Removal]
10.8.6 Procedure

1. Put the steering control valve in the correct position to the steering
column.
2. Install the lockwashers (2) and capscrews (1).
3. Remove the protective covers from the hoses (3) and (4), and all ports.
4. Install the hoses (3) and (4), remove the identifying tags and make
sure all hoses go to the correct ports.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 10.8-3: Steering Control Valve Installation
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Steering Cylinders
10.9 Steering Cylinders
06-000_000_01_Steering Cylinders.tif
Fig. 10.9-1: Steering Cylinders
There are two steering cylinders on the haul truck that operate together to
change the direction of the front wheels.
The steering cylinders connects to the systems that follow:

• [Reference: Steering System ]
• [Reference: Idler Arm Assembly]
The steering cylinders receive hydraulic oil from the flow amplifier valve in
the steering system. The quantity and force of the hydraulic oil causes the
steering cylinders to retract or extend to change the direction of the haul
truck wheels. The steering cylinders operate in two directions. While one
steering cylinder extends and pushes on the idler arm, the opposite steering
cylinder retracts and pulls on the idler arm. The idler arm attaches to the tie
rods and steering arms.
LME/10880897/January 30, 2011/en
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Steering Cylinders
10.9.1 Steering Cylinders Removal
10.9.2 Setup
Safety]
Accumulator Bleed]
10.9.3 Procedure
1. Disconnect the hydraulic lines (1) and lubrication hoses (11).
2. Put protective caps on the hydraulic lines (1), lubrication hoses (11),
and all open ports.
NOTICE
The weight of the steering cylinder (dry) is 196 kg (432 lb).
3. Put an applicable support at the two ends of the cylinder (9).
4. Remove the lockwire from the capscrews (6).
5. Remove the lockwashers (18), locknuts (19), capscrews (13), washers
(15), and rotation stop (16).
6. Pull out the pin (17).
7. Remove the capscrews (6) and (8), cap (5), and pin (7).
8. Remove the steering cylinder (9).
9. Remove the seals (4), retainers (2), and spacers (3) and (10).
10. Remove the bushings (12).
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Steering Cylinders
LME/10880897/January 30, 2011/en
Fig. 10.9-2: Steering Cylinders Removal
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Steering Cylinders
10.9.4 Steering Cylinders Installation
10.9.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the steering
cylinders removal. [Reference: Steering Cylinder Removal]

Grease 5079-A 2.5% or more Molybdenum Disulfide
Liquid Nitrogen N/A Commercially available
Lockwire N/A Commercially available
10.9.6 Procedure
DANGER! Liquid nitrogen is a very cold liquid.

Very cold liquids can cause serious personal injury.
► Always put on protective gloves, clothing and eye protection.
1. Put the bushings (12) in an applicable container and fill with liquid
nitrogen.
2. Install the lower retainers (2).
3. Install the bushings (12) and hold in position while the bushings (12)
stabilize.
4. Install the upper retainers (2).
NOTICE
The weight of the steering cylinder without hydraulic fluid is 196 kg (432
lb).
5. Put an applicable support at the two ends of the cylinder (9).
LME/10880897/January 30, 2011/en
6. Put the steering cylinder (9) in position on the haul truck.

7. Install the spacers (3) and (10), and seals (4).
8. Carefully align the retainers (2), spacers (3) and (10), and seals (4).
9. Apply a thin coat of ant-seize to the pins (17) and (7).
10. Install the pins (17) and (7).
11. Lubricate the capscrews (8), (13) and locknut (19) with anti-seize.
12. Install the capscrews (6), (8), (13), locknut (19), lockwasher (18),
washers (15), and rotation stop (16).
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Steering Cylinders

15. Tighten the locknuts (19) to 410 N m (302 lbf ft).
16. Remove the protective caps and connect the hydraulic lines (1) and
lubrication hoses (11).
17. Lubricate the bushings (12) with grease.
LME/10880897/January 30, 2011/en
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Steering Cylinders
LME/10880897/January 30, 2011/en
Fig. 10.9-3: Steering Cylinders Installation
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Buddy Brake and Steering Components
10.10 Buddy Brake and Steering Components
LME/10880897/January 30, 2011/en
08-000_000_01_Buddy Brake and Steering Components.tif

Fig. 10.10-1: Buddy Steering and Braking Components
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Buddy Brake and Steering Components
The haul truck has hydraulic connections in the brake and steering circuit
that permit the connection of a remote hydraulic pump. The remote hydraulic
pump is for use on a haul truck with an unserviceable engine or brake and
steering pump.
The remote hydraulic pump pressurizes the brake and steering

accumulators so that the haul truck can be towed safely.
The remote hydraulic pump attaches to the pressure and suction

connections, and case drain for the buddy steering and braking system. The
remote hydraulic pump pushes hydraulic fluid from the hydraulic tank
through the pressure filter to the brake and steering system.
The remote hydraulic pump pressurizes the brake and steering system of
the haul truck so that the park brake can be released before the haul truck
is towed. The function of the buddy system is to permit usual brake and
steering operation while the haul truck is towed.
CAUTION! The buddy steering and braking system is an auxiliary system

and is for use in an emergency.
► Do not use the steering more than necessary when the buddy system
is in use, and tow the haul truck at a slow speed.
There is also a connection for the case drain line. Some remote pumps, such
as piston pumps, use this connection.
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Brake and Steering Pump Unloader Valve Accumulator
10.11 Brake and Steering Pump Unloader Valve

Accumulator
08-000_000_01_Brake and Steering Unloader Valve Accumulator.tif

Fig. 10.11-1: Brake and Steering Pump Unloader Brake Accumulator
The pump unloader valve accumulator is installed forward of the hydraulic

tank on the left side of the haul truck.
The pump unloader valve accumulator has a 7.6 L (2 gal) capacity.
The function of the pump unloader valve accumulator is to supply a pre-

charge hydraulic pressure of 124 bar (1798 psi) to the steering and brake
pump.
LME/10880897/January 30, 2011/en
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Accumulator Removal
10.11.2 Setup
Safety].
► Remove the pressure from the brake and steering pump unloader
valve accumulator by opening BS-MR1, BS-MR2, and SDL4.
10.11.3 Procedure

2. Disconnect the hydraulic hoses (4) and put protective covers on the
NOTICE
The weight of the accumulator without fluid is 36 kg (80 lb).
► Use a lift device that can hold this weight.
4. Remove the capscrews (2) and lockwashers (3) from the clamps.
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LME/10880897/January 30, 2011/en
08-100_000_01_Brake and Steering Pump Unloader Valve Acc.tif

Fig. 10.11-2: Brake and Steering Pump Unloader Valve Accumulator Removal
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Accumulator Installation
10.11.5 Setup
Safety].
brake and steering pump unloader valve accumulator removal.
[Reference: Brake and Steering Pump Unloader Valve Accumulator
Removal]
10.11.6 Procedure

NOTICE
The weight of the accumulator without fluid is 36 kg (80 lb).
► Use a lift device that can hold this weight.
2. Install the accumulator (1) in the clamps.
5. Connect the hydraulic hoses (4) to the accumulator (1).
6. Make sure that the accumulator has the correct pre-charge.
[Reference: Brake and Steering Unloader Valve Accumulator
Pressure Check]
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LME/10880897/January 30, 2011/en
08-100_000_01_Brake and Steering Pump Unloader Valve Acc.tif

Fig. 10.11-3: Brake and Steering Pump Unloader Valve Accumulator Installation
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Pressure Check
10.11.8 Setup
Safety].

Nitrogen Charge and Gauge Kit T-107-T [Reference: Service Tools]
10.11.9 Procedure
1. Make sure the hydraulic pressure is 0 bar (0 psi) before you check the
gas pre-charge.
2. Make sure the bleed valve (1) is completely in the closed position.
3. Disconnect the tank hose assembly (4) from the charge assembly (5).
4. Remove the valve cap (7) from the relief valve on the accumulator.
6. Use your hand to tighten the adapter (3) to prevent gas leakage.
DANGER! The nitrogen gas is pressurized in the Brake and Steering

Unloader Valve Accumulator.
The pressurized gas can cause injury and can remove the valve stem
assembly from the Brake and Steering Unloader Valve Accumulator if the
valve assembly is turned before the pressure is released.
► Make sure that only the small swivel nut turns.
► Always put on protective clothing, gloves, and eye shields when you
charge or discharge the system.
9. Turn the swivel nut (9) to the left two turns, or until the charge pressure
shows on the gauge (6).
LME/10880897/January 30, 2011/en
11. Turn the swivel nut (9) to the right to the completely closed position.
12. Open the bleed valve (1).
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LME/10880897/January 30, 2011/en
08-300_000_01_Brake Steering Accumulator Pressure Check.tif

Fig. 10.11-4: Brake and Steering Unloader Valve Accumulator Pressure Check
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Service Manual Hydraulic Auxiliary Systems
11 Hydraulic Auxiliary Systems 477

11.1 Auto Lube System 478
11.1.1 Auto Lube Components 480
11.1.2 Lubrication Pump 481
11.1.3 Grease Tank 481
11.1.4 Safety Unloader Valve 481
11.1.5 Vent Valve Assembly 481
11.1.6 Low Level Indicator 482
11.1.7 Pressure Switch 482
11.1.8 Injectors 483
11.1.9 Ecomat (LITES) Controller 483
11.1.10 Neutral Position Pause Function 483
11.1.11 SL-V Injector (Series B) 484
11.1.13 Stage 1 484
11.1.14 Stage 2 484
11.1.15 Stage 3 484
11.1.16 Stage 4 484
11.1.17 Spectrum Adjustment System 485
11.1.19 Hydraulic Pump 486
11.1.20 Hydraulic Pump Schematic 487
11.1.21 Hydraulic Pump Troubleshooting 488
11.2 Gear Oil Cooling System 489
11.2.1 Gear Oil Cooling Pump Removal 492
LME/10880897/January 30, 2011/en
11.2.4 Gear Oil Cooling Pump Installation 494

11.3 Hoist Cooling System 496
11.3.1 Hoist Cooling System Schematic 497
11.4 Hydraulic A/C Pump 498
11.4.1 Hydraulic A/C Pump Removal 498
11.4.4 Hydraulic A/C Pump Installation 499
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Hydraulic Auxiliary Systems Service Manual
Auto Lube System
11.1 Auto Lube System
15-000_000_01_Auto Lube Pump.tif

Fig. 11.1-1: Auto Lube System
The automatic lube system supplies grease to the pivot points on the haul
truck. One hydraulic lubrication pump pushes the grease from the grease
tank through the injectors. The injectors supply the lubrication lines to the
different pivot points.
The auto lube system connects to the systems that follow:

• Liebherr Integrated Truck Electronic System (LITES)
• [Reference: Brake and Steering System]
The lubrication pump in the auto lube system receives the hydraulic fluid
under pressure from the brake and steering system. The excess flow port
(EF) of the amplifier valve supplies the lube pump. The amplifier has a
priority valve inside that supplies hydraulic fluid to the EF. The steering has
priority over the lube pump. If the flow requirement for the steering system
is more than the pump capacity, the lube pump does not have the flow until
the pump capacity is more than the steering system requirement.
When the auto lube pump operates, 24 volts are sent to the solenoid-
operated cartridge valve on the auto lube pump assembly. Hydraulic
pressure goes to the vent valve pilot line, and the vent valve closes to let
pressure increase in the supply line. When the auto lube pump stops, the
24 volts are removed from the solenoid-operated cartridge valve. Pressure
in the vent valve pilot line decreases to 0 bar (0 psi)to let the vent valve open.
LME/10880897/January 30, 2011/en
The hydraulic lubrication pump pushes the grease from the grease tank
through hoses to the injectors. The injectors move the grease through the
supply lines to the different pivot points for lubrication.
The fault indicator on the main dash panel illuminates if the switch (end of
line) does not close after the auto lube system has operated for two cycles.
The manual lube switch is a rocker switch on the left dash panel in the
operator cab. This switch is pressed to tell the Ecomat system to start a lube
cycle. Some possible conditions for the manual start of the auto lube cycle
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Auto Lube System
is to check the hydraulic pressure at the lube pump; to check the supply line
pressure at the axle box, or to make sure that a specified set of injectors
have the correct operation. Another function for the manual lube switch is
to start a lube system test. The lube system test cycles the lube pump on
for 30 seconds and off for 30 more seconds for seven times. This interval is
set to give a maintenance technician enough time to go around the haul
truck to check the operation for each set of injectors. To start a lube system
test, the manual lube system is pressed 5 times within a two-second interval.
During the test mode, the auto lube fault indicator on the indicator panel in
the operator cab flashes. If the manual lube switch is pressed again, the test
cycle stops, but the minimum run time for the lube system test is 10 seconds.
If the test is stopped correctly, the lube fault indicator stops to flash.
NOTICE
Cold temperatures can change the lube system test results.
► Cold temperatures can change the lube system test results. 30
seconds in cold temperatures are not sufficient for the pressure to
increase in the supply lines. The injectors do not begin to move the
grease until the pressure in the supply lines increase to approximately
82.74 bar (1200 psi). If a check of the operations of a set of injectors
is necessary in very cold temperatures, use the manual lube switch
to start a lube cycle. The lube pump has 15 minutes to increase
pressure in the supply lines when the manual lube switch is activated.
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Auto Lube System
11.1.1 Auto Lube Components
15-000_000_01_Auto Lube Components.tif

Fig. 11.1-2: Auto Lube System Components
The auto lube system has the components that follow:

1. [Reference: Lubrication Pump]
1.1. Solenoid Operated Cartridge Valve
1.2. Pressure Reducing Valve
1.3. Flow Control Valve
2. [Reference: Grease Tank]
3. [Reference: Safety Unloader Valve]
4. [Reference: Vent Valve Assembly]
5. [Reference: Low Level Indicator]
The function of the auto lube system is to supply grease to the pivot points
on the haul truck.
LME/10880897/January 30, 2011/en
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Auto Lube System
11.1.2 Lubrication Pump

The lubrication pump has a flow control valve, that is set by the factory. If
the flow control valve is moved by accident, it must be set again. To set
again, turn the adjuster screw all the way in, and then turn it back out 1/2 a
turn.
The lube pump has a pressure reducing valve. This valve must be set to 24
bar (348 psi) hydraulic pressure. At low inlet pressure of 20 bar (290 psi) to
25 bar (363 psi), and low inlet flow of 7 lpm (2 gpm), the pump ratio is 9:1.
Thus, the supply line pressure can get to 217 bar (3147 psi) with the
pressure reducing valve set to 24 bar (348 psi), and the flow control valve
turned out 1/2 turn (in the event that the pressure switch did not turn off the
lube pump). The pump ratio comes near 11.0:1 at higher inlet pressure and
flow. The adjustment range of the pressure reducing valve is 12 bar (170
psi) to 31 bar (450 psi). It is very important that you set the pressure reducing
valve and do not touch it after it is set.
11.1.3 Grease Tank

The grease tank holds 54 kg (120 lb) of grease for the auto lube system.
11.1.4 Safety Unloader Valve

The Safety Unloader Valve is set to open at 259 bar (3750 psi) to 293 bar
(4250 psi) lubricant pressure. If the pressure switch fails to operate and shut
off hydraulic supply to the pump, the safety unloader valve will open at
approximately 276 bar (4000 psi) to relieve lubricant supply line pressure.
The safety unloader valve is present and cannot be adjusted.
11.1.5 Vent Valve Assembly

The vent valve assembly is on the lubrication pump. The function of the vent
valve assembly is to sense when the supply line from the lube pump to the
injectors can increase or decrease the pressure. The vent valve closes so
that pressure in the supply line can increase, and opens for the pressure to
decrease.
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Auto Lube System
11.1.6 Low Level Indicator

If this indicator pin appears to drop prematurely or water is noticeable on
top of the follower, then the indicator seal (1) can be damaged.
1. Remove the eight bolts and lockwashers which old the cover
on the reservoir.
2. Inspect the reservoir gasket seal for damage. If damage is
apparent, then replace the gasket seal.
3. Remove the entire pump, valve and follower assembly from
the reservoir.
4. Remove the retaining ring (1) from the indicator rod assembly
(4).
5. Hold the indicator plug (5) with a wrench while removing the
indicator nut (2).
6. Remove and replace the O-ring (3).
7. Reassemble in the reverse of the above procedure. Torque
the indicator nut (2) to 27 N m (20 lbf ft)
15-300_000_01_Auto Lube Low Pressure Indicator.tif

Fig. 11.1-3: Auto Lube Low Pressure Indicator
LME/10880897/January 30, 2011/en
11.1.7 Pressure Switch

The pressure switch is set to 172 bar (2495 psi) to control the maximum
supply line pressure. When the LITES® controller receives the signal from
the pressure switch at maximum pressure it turns off the lubrication pump.
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Auto Lube System
11.1.8 Injectors
The manually adjustable injectors deliver the set amount of grease to the
pivot points.
11.1.9 Ecomat (LITES) Controller

All adjustments to the time the auto lube system is in operation are done
through the LITES. The Programmable Logic Control (PLC) (Ecomat) in
LITES control the operation time and frequency of the hydraulic lubrication
pump. The LME service personnel can adjust the time for the operations
that follow:
• The time between when the haul truck starts and the auto lube
system operates;
• The time between the cycles of lubrication; and
• The maximum time the lubrication pump is energized.
At the start of the lubrication cycle, the Ecomat will output 24V to the solenoid
valve on the lube pump. The Ecomat will then wait for a maximum of 15
minutes (this time is adjustable) for an input from the pressure switch (end
of line or EOL switch). This input lets the Ecomat know that the pressure
switch is closed. At that time, the Ecomat stops the output of 24V to the
solenoid valve 2 seconds later. In the event that the Ecomat does not receive
an input from the pressure switch, the Ecomat stops output of 24V to the
solenoid valve at the end of 15 minutes.
• The first lubrication cycle occurs 5 minutes after the engine is
started.
• The frequency of lubrication cycles is every 20 minutes (this
is adjustable).
11.1.10 Neutral Position Pause Function

When the haul truck is in operation with the SHIFT SELECTOR switch in
the neutral position, the Ecomat runs one lube cycle. The lube cycle
continues when the SHIFT SELECTOR switch is moved from the neutral
position to the forward or reverse position. This operation prevents the
lubrication of the bearings while there is no haul truck movement. The
Ecomat runs a lube cycle if the manual lube switch is pushed.
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Auto Lube System
11.1.11 SL-V Injector (Series B)

The SL-V injectors are utilized on the 45 grease points located on various
locations on the haul truck utilizing injectors grouped in sets of 3 or 4 referred
to as injector blocks.
• Minimum operating pressure 128 bar (1856 psi)

• Maximum operating pressure 413 bar (5990 psi)
• Recommended operating pressure 172 bar (2495 psi)
• Maximum vent (Recharge) pressure 69 bar (1001 psi)
• Lubricant output is adjustable from 0 bar (4 psi) to 1 bar (19
psi)
11.1.13 Stage 1
The injector starts in its normal or rest position. Incoming lubricant (1.1) is
directed through the slide valve (1.2) to both sides of the piston (1.3). The
pressure of the incoming lubricant acting on both sides of the piston causes
the piston to move downward against the shoulder and fills the measuring
chamber. The injector stem (1.4) is fully retracted away from the stop of the
adjusting screw.
11.1.14 Stage 2
Further increase in pressure causes the slide valve (2.1) to move against
the force of the springs (2.2). As the slide valve moves, it closes passage 1
(2.3) and opens passage 2 (2.4) to the outlet port. The pressure of the
incoming lubricant is now acting only upon the bottom of the piston. The
incoming lubricant displaces the piston which forces the lubricant in the
measuring chamber to be dispensed through passage 2 (2.4), through the
slide valve and through the outlet port (2.5) to the lube point.
11.1.15 Stage 3
The piston (3.1) will dispense lubricant until the indicator stem (3.2) hits the
stop of the adjusting screw (3.3) . The volume of lubricant dispensed can be
adjusted by limiting the travel of the piston. The piston and slide valve (3.4)
LME/10880897/January 30, 2011/en
remain in this position until the lubricant pressure in the supply line is vented.
11.1.16 Stage 4
As the pressure in the supply line (4.1) vents to 69 bar (1001 psi), the slide
valve moves downward and closes passage 2 (4.2) and opens passage 1
(4.3). The lubricant pressure in the supply line is now acting upon both sides
of the piston causing it to move downward, a volume of lubricant flows from
the underside of the piston, past the slide valve, through passage 1 (4.3)
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Auto Lube System
and to the upper side of the piston. Since the volume on top of the piston is
greater than the volume under the piston, an additional volume of lubricant
flows from the supply line to the upper side of the piston. This volume of
lubricant leaving the supply line causes the pressure to drop very quickly.
The piston may or may not fully return to the shoulder, depending upon the
volume of lubricant in the supply line. The injector is now ready for the next
cycle.
1010000ac02.tif
Fig. 11.1-4: SL-V Injector (Series B)
11.1.17 Spectrum Adjustment System

The spectrum adjustment system consists of a set of color-coded anodized
aluminum sleeves that provide an easy way to adjust the output of the
injectors and gives a clear indication of the output setting. This allows for
easy system installation and preventative maintenance.
11.1.18 To Install A Spectrum Adjustment Sleeve

Remove and discard the locknut (2), place sleeve (3) onto adjusting screw
(1) and tighten.
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Auto Lube System
15-300_000_01_AutoLube Spectrum Adjustment Sleeve.tif
11.1.19 Hydraulic Pump

The hydraulic pump is a fully hydraulically operated grease pump. Grease
output is proportional to the hydraulic input flow. The pump is primarily
designed for centralized lubrication systems such as the single line parallel,
single line progressive and two line systems. An integrated pump control
manifold is incorporated with the motor to control input flow and pressure.
A 24-volt DC solenoid valve is also incorporated as a method to turn the
pump ON and OFF. A 24-volt DC solenoid valve with a manual override is
standard.
The pump is driven by the rotary motion of the hydraulic motor. Rotary
motion is converted to reciprocating motion through an eccentric crank
mechanism. The reciprocating action causes the pump cylinder to move up
and down. The unit is a positive displacement double acting pump as grease
output occurs during both the UP and DOWN stroke.
During the down stroke, the pump cylinder is extended into the grease.
Through the combination of shovel action and vacuum generated in the
pump cylinder chamber, the grease is forced into the pump cylinder.
Simultaneously, grease is discharged through the outlet of the pump. The
volume of grease during intake is twice the amount of grease output during
one cycle. During the upstroke, the inlet check closes, and one half of the
grease taken in during the previous stroke is transferred through the outlet
check and discharged to the outlet port.
LME/10880897/January 30, 2011/en
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11.1.20 Hydraulic Pump Schematic
15-000_000_01_Auto Lube Hydraulic Pump Schematic.tif

Fig. 11.1-6: Hydraulic Pump Schematic
LME/10880897/January 30, 2011/en
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Auto Lube System
11.1.21 Hydraulic Pump Troubleshooting
Pump becomes noisy.

No crank case oil. Add crank case oil. Remove Pipe
Plug (45) from Pump Housing
(46). Oil level should be at the
bottom of the Pipe Plug opening.
For models 85480, 85482, 85483
and 85247, add 10W30 motor oil
until the crank case is full. For
models 85610, add light weight
Mobil Arrow HFA Hydraulic Oil
until the crank case is full.
Worn wrist pin bushing (13) Check the bushing and replace, if
necessary.
Pump does not build pressure.
Foreign material holding lower Dismanle and clear check.
check open. Consider installing inlet screen
272180 before returning pump to
service.
Pump does not run.
No pressure on gauge (32)
Closed supply line shut off valve. Open shut-off valve.
No power to solenoid valve (34). Correct electrical fault.
Faulty solenoid (35). Replace solenoid (35).
Pressure Reducing Valve (38) is Reset Pressure Reducing Valve
set too low. (38).
Insufficient Hydraulic Fluid supply Check hydraulic supply for proper
pressure is low.
Pressure is shown on gauge (32).
Closed fluid outlet line. Check hydraulic supply for proper
pressure is low.
Flow control valve is fully closed. Readjust valve to 3/4 turn open.
Pump is stalled due to grease Check vent valve in system.
backpressure.
Pump is seized or damaged. Dismantle the pump and repair
defective or seized component.
See disassembly and assembly
procedure.
Pump runs, but output is low
Insufficient hydraulic supply. Check hydraulic supply and adjust
using valve (39).
Inlet pressure too low. Increase pressure using valve
(38).
Fauly inlet (25, 26, 27) or Replace faulty components.
LME/10880897/January 30, 2011/en
discharge check valve (18, 19, 20)

Pump speed up or runs erratically
Low level of grease or reservoir s Refill reservoir
empty
Follower plate is stuck and Check Follower plate and
separated from grease. container for damage.
Pump piston or checks are worn. Disassemble the pump and repair.
Weepage from housing cover 30
Cup seal (26) or O-Ring (48) worn Check the seals and replace, if
out. necessary.
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Gear Oil Cooling System
11.2 Gear Oil Cooling System

LME/10880897/January 30, 2011/en
06-000_000_01_Gear Oil Cooling Pump.tif

Fig. 11.2-1: Gear Oil Cooling
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06-000_000_01_Gear Oil FIlters.tif

Fig. 11.2-2: Gear Oil Cooling Oil Filters
LME/10880897/January 30, 2011/en
06-000_000_01_Gear Oil Cooling Manifold.tif

Fig. 11.2-3: Gear Oil Cooling Manifold
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06-000_000_01_Gear Oil Pump w Motor.tif

Fig. 11.2-4: Gear Oil Cooling Pump with Hydraulic Motor
The cooling system for the gear oil has these components:
• Gear Oil Cooling
• Gear Oil Cooling Filters
• Gear Oil Cooling Manifold
• Gear Oil Cooking Pump with Hydraulic Motor
The cooling system for the gear oil has two isolated circuits. One circuit is
for the left rear traction motor, the other circuit is for the right rear traction
motor. Each circuit has a pump, a direct acting relief valve, a filter, and an
oil cooler. The oil coolers are installed in front of the radiator. The oil filters
are installed on the inner frame near the fuel and hydraulic tank. The gear
oil cooling pump is installed on the end of the right dump pump. That pump
drives the hydraulic motor for the left and right cooling pumps.
Hydraulic fluid from the dump system goes through the gear oil cooling pump
and the hydraulic motor when the system is serviceable. The gear oil cooling
pump uses hydraulic oil from the dump system hydraulic tank.
The left and right pumps connected to the hydraulic motor are gear pumps.
The gear oil from the final drives in the traction motors flows from the final
drives to the left and right pumps. After that the gear oil goes through the oil
filters, through the oil coolers, and back to the final drive reservoirs.
The direct acting relief valve at the inlet of the two oil filters open if the inlet
pressure is more than 21 bar (300 psi) and the gear oil is released back to
LME/10880897/January 30, 2011/en
the return line. Thus, the gear oil goes around the filter and cooler and
returns to the final drive reservoirs.
The gear oil cooling pump has a relief valve set at 207 bar (2999 psi). If the
hydraulic pressure is more than 207 bar (2999 psi)the oil cooling pump does
not supply the hydraulic motor and the fluid returns directly to the hydraulic
tank. The hydraulic motor does not operate and the gear oil from the traction
motors does not go through the gear oil cooling system.
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11.2.1 Gear Oil Cooling Pump Removal
11.2.2 Setup
Safety]
► Close the dump shutoff valve.
11.2.3 Procedure

► Always put on protective clothing and eye protection when you do
procedures that involve hydraulic fluid.
1. Put a container below the oil cooling pump (5) to collect the hydraulic
fluid.
3. Put protective covers on the hoses (1) and open ports.
NOTICE
The weight of the oil cooling pump is 16 kg (35 lb).
► Use an applicable lift device or support that can hold the weight.
4. Remove the capscrews (2), washers (3), and oil cooling pump (5).
5. Remove and discard the O-ring (4).
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 11.2-5: Gear Oil Cooling Pump Removal
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11.2.4 Gear Oil Cooling Pump Installation
11.2.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the gear oil
cooling pump removal. [Reference: Gear Oil Cooling Pump
Installation]
11.2.6 Procedure
WARNING! The hydraulic fluid can irritate the skin.

► Always put on protective clothing and eye protection when you do
procedures that involve the hydraulic fluid.
1. Install the O-ring (4).
NOTICE
The weight of the oil cooling pump is 16 kg (35 lb).
► Use an applicable lift device that can hold the weight.
2. Install the oil cooling pump (5), capscrews (2), and washers (3).
5. Put the shutoff valve for the dump tank in the open position .
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 11.2-6: Gear Oil Cooling Pump Installation
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Hoist Cooling System
11.3 Hoist Cooling System
532_Hoist Cooling_01_Rev000.tif
Fig. 11.3-1: Hoist Cooling System
The Hoist Oil Cooling Circuit function is designed to cool hydraulic oil during
operation in warm ambient temperatures, and to protect the hoist oil cooler
and filter assemblies when cold temperatures would affect oil viscosity and
result in higher operating pressures.
The hoist circuit contains these components

• Gear oil cooling pump motor, mounted to the rear of the hoist
pump.
• Hoist oil cooler manifold solenoid valve, located on the
ODSright inside frame rail, forward of the hydraulic skid and
behind the gear oil cooling filters.
LME/10880897/January 30, 2011/en
• - Hoist oil cooler assyassembly, mounted on the front

ODSright bottom position of the grill
The single circuit functions by drawing oil from the hoist system hydraulic
tank with the gear oil cooling pump hydraulic motor, mounted on the rear of
the dump pump. The oil circulates through the cooler, based on the
temperature of the oil.
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Hoist Cooling System
The hoist oil cooler solenoid valve (SOL 11), hoist cooling system schematic
is a normally de-energized, solenoid operated, three-way, direct-acting
spool type, screw in cartridge valve.
When the hoist system oil temperature at the system suction rises above
45 ºC (113 ºF), the solenoid is de-energized open, allowing the oil to
circulate through the cooler.
When the hoist oil system oil temperature is below 35 ºC (95 ºF), the
solenoid is energized, which circulates the hydraulic oil back to the tank, and
does not allow it to circulate through the cooler.
11.3.1 Hoist Cooling System Schematic
532_Hoist Cooling System_Schematic 01_Rev000.tif

Fig. 11.3-2: Schematic: Hoist Cooling System
LME/10880897/January 30, 2011/en
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Hydraulic A/C Pump
11.4 Hydraulic A/C Pump
11.4.1 Hydraulic A/C Pump Removal
11.4.2 Setup
Safety]
11.4.3 Procedure
2. Put protective covers on the hoses and open ports.
3. Remove the locknuts capscrews (1), (2), (3), and (4).
15-100_000_01_Hydraulic AC Condenser.tif
Fig. 11.4-1: Hydraulic A/C Pump Removal LME/10880897/January 30, 2011/en
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Hydraulic A/C Pump
11.4.4 Hydraulic A/C Pump Installation
11.4.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the
hydraulic A/C pump removal. [Reference: Hydraulic A/C Pump
Removal]
11.4.6 Procedure
1. Install the capscrews (1), (2), (3), and (4).
2. Remove the protective covers from the hoses and open ports.
3. Reconnect the hoses (5).
15-100_000_01_Hydraulic AC Condenser.tif
Fig. 11.4-2: Hydraulic A/C Pump Installation
LME/10880897/January 30, 2011/en
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Service Manual Suspensions
12 Suspensions 501
12.1 Front Suspensions 502
12.1.1 Front Suspensions Removal 504
12.1.4 Front Suspensions Installation 506
12.1.7 Front Suspension Oil Drain 508
12.1.10 Front Suspension Oil Fill 510
12.1.12 Front Suspension Gas Discharge 511
12.1.15 Front Suspension Gas Charge 513
12.1.17 Front Suspension Pressure Check 514
12.2 Rear Suspension 516
12.2.1 Rear Suspensions Removal 518
12.2.4 Rear Suspensions Installation 520
12.2.7 Rear Suspension Oil Drain 522
12.2.10 Rear Suspension Oil Fill 524
12.2.12 Rear Suspension Gas Discharge 525
12.2.15 Rear Suspension Gas Charge 527
12.2.17 Rear Suspension Pressure Check 528
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Suspensions Service Manual
Front Suspensions
12.1 Front Suspensions
531-532_000_01_Front Suspension.tif
Fig. 12.1-1: Front Suspensions
The front suspensions are attached to the frame and to the upper control
arms. There are lubrication hoses attached to the top and bottom of the
suspensions from the auto lube system. The front suspension connects to
the assemblies that follow:
• [Reference: Control Arms]
• [Reference: Frame] LME/10880897/January 30, 2011/en
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All internal wear surfaces are lubricated with oil. The nitrogen gas
pressurizes the oil in the suspensions. When the haul truck moves along
rough ground, the check valves and ports in the suspension control the
movement of the oil.
The suspension has an elastomer rebound pad to prevent damage to the

internal parts of the suspension. If the suspension becomes defective, the
pad holds the suspension and prevents metal-to-metal contact. The pad
gives protection when the suspension is in full extension or when it is fully
compressed.
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Front Suspensions
12.1.1 Front Suspensions Removal
12.1.2 Setup
Safety]
► Remove the tire and rim assembly.
► Discharge the nitrogen gas from the front suspension.

Pin Puller T-124-C [Reference: Service Tools]
12.1.3 Procedure
NOTICE
The weight of the lower control arm is 847 kg (1867 lb).
1. Put an applicable support below the lower arm and lift the support until
the suspension slightly collapses.
WARNING! The suspension cylinder can move inward toward the frame.
► Make sure all personnel are at a safe distance away from the work
area.
NOTICE
The weight of each empty front suspension is 893 kg (1969 lb).
2. Safely attach an applicable lift device to the lift point on the suspension
(6).
3. Remove the capscrews (1), washers (2), retainer (3), and pin (4).
4. Use pin puller to remove the pin (4), if necessary.
5. Remove the suspension (6).
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LME/10880897/January 30, 2011/en
Fig. 12.1-3: Front Suspension Removal
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Front Suspensions
12.1.4 Front Suspensions Installation
12.1.5 Setup
Safety]
front suspensions removal. [Reference: Front Suspensions Removal]

Anti-seize N/A See [Reference: Oil and Lubricant
Specifications]
12.1.6 Procedure
NOTICE
The weight of each empty front suspension is 893 kg (1969 lb).
1. Attach an applicable lift device to the lift point on the suspension (6).
2. Put the suspension (6) in position.
NOTICE
The weight of the pin is 66 kg (146 lb).
3. Apply a thin layer of anti-seize to the pin (4) and install.
4. Apply a thin layer of anti-seize to the capscrews (1).
5. Install the retainer (3), washers (2), and capscrews (1).
6. Tighten the capscrews (1) to 920 N m (679 lbf ft) .
8. Put oil in the suspension. [Reference: Front Suspension Oil Fill]
9. Pressurize the suspension. [Reference: Front Suspension Gas
Charge]
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LME/10880897/January 30, 2011/en
Fig. 12.1-4: Front Suspension Installation
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Front Suspensions
12.1.7 Front Suspension Oil Drain
12.1.8 Setup
Safety]
DANGER! The nitrogen gas is pressurized in the suspension.

► The pressurized gas can cause injury.
► Make sure that the nitrogen is fully released from the suspension.
WARNING! A fully retracted suspension continues to have pressure. The

nitrogen pressure can be released, but the oil stays pressurized.
► Use a support to hold the haul truck so that it is not held by the
pressurized oil in the suspension.
► Fully release the nitrogen gas from the suspension.
12.1.9 Procedure
To drain the oil from the suspension when the suspension is on the
truck,
1. Make sure that the suspension (1) is fully extended.
2. Put an applicable container below the suspension to collect the oil.
3. Remove the drain plug (2).
4. Let the oil flow into the container.
5. Collapse suspension.
6. Replace the drain plug (2).
7. Refer to the applicable environmental regulations to know how to
safely discard the oil.
NOTICE
The minimum weight of the suspension is 66 kg (146 lb).
To drain the oil from the suspension when the suspension is removed
from the truck,
8. Make sure that the suspension (1) is in a vertical position and fully
LME/10880897/January 30, 2011/en
extended.
12. Collapse suspension.
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LME/10880897/January 30, 2011/en
Fig. 12.1-5: Front Suspension Oil Drain
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Front Suspensions
12.1.10 Front Suspension Oil Fill
12.1.11 Setup
Safety]
► Front suspension oil fill instructions are given in TI-2114-R,
[Reference: TI-2114-R (Front Suspension Test and Charge
Procedures)], which can be found in the Class Documents section of
this Service Manual. [Reference: Class Documents].
LME/10880897/January 30, 2011/en
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12.1.12 Front Suspension Gas Discharge
12.1.13 Setup
Safety]
12.1.14 Procedure
To release the pressure from the suspensions when the suspensions
are on the truck,
1. Lift the haul truck to fully extend the applicable suspensions (the
wheels must not touch the ground)
2. Turn and fully close the bleed valve (1) on the nitrogen charge and
gauge kit.
3. Disconnect the tank hose assembly (4) from the nitrogen charge
assembly (5).
4. Remove the valve cap (7) from the discharge valve on the front
suspension.

► The pressurized gas can cause injury and can remove the valve stem
assembly from the suspension if the valve assembly is turned before
► Make sure that only the small swivel nut turns and always put on
protective clothing, gloves, and face and eye shields when you charge
or discharge the system.
8. Use a 3/4 inch wrench on the swivel nut (9) and turn the swivel nut to
the left four full turns or until the charge pressure shows on the gauge
(6).
9. Carefully open and close the bleed valve (1) until the necessary
pressure is shown on the gauge.
-OR-
LME/10880897/January 30, 2011/en
Open the bleed valve (1) until all the pressure is released from the
suspension.
10. Turn the swivel nut (9) to the right to the fully closed position.
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Front Suspensions
531-532_510_01_Front Suspension Discharge.tif

Fig. 12.1-6: Front Suspension Gas Discharge
LME/10880897/January 30, 2011/en
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Front Suspensions
12.1.15 Front Suspension Gas Charge
12.1.16 Setup
Safety]
► Front suspension gas charge instructions are given in TI-2114-R,
[Reference: TI-2114-R (Front Suspension Test and Charge
Procedures)], which can be found in the Class Documents section of
this Service Manual. [Reference: Class Documents].
LME/10880897/January 30, 2011/en
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Front Suspensions
12.1.17 Front Suspension Pressure Check
12.1.18 Setup
Safety]

Nitrogen Charging and Gauging Kit T-107-T [Reference: Service Tools]
12.1.19 Procedure
To check the front suspensions when they are on the truck,
1. Lift the haul truck to fully extend the applicable suspensions (the
wheels must not touch the ground)
2. Make sure the bleed valve (1) is in the closed position.
4. Remove the valve cap (7) from the discharge valve on the rear
suspension.
6. Use your hand to correctly tighten the adapter (3) to prevent gas
leakage.
CAUTION! The nitrogen gas is pressurized in the suspension.

9. Turn the swivel nut (9) to the left four full turns, or until the charge
pressure shows on the gauge (6).
LME/10880897/January 30, 2011/en

If the front suspension pressure is not in the specified limits,

15. Pressurize the front suspension.
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Front Suspensions
531-532_605_01_Front Suspension Pressure Check.tif

Fig. 12.1-7: Front Suspension Pressure Check
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2 Rear Suspension
531-532_000_01_Rear Suspension.tif
Fig. 12.2-1: Rear Suspensions
The rear suspension is attached to the frame and to the axle box . There
are lubrication hoses attached to the top and bottom of the suspension from
the auto lube system . The rear suspension connects to these assemblies:
• [Reference: Axle Box]
• [Reference: Frame]
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Rear Suspension
Fig. 12.2-2: Rear Suspensions
The rear suspensions are tubular. There is a piston inside that operates the
suspensions. A measured quantity of nitrogen gas is pressurized into the
system. This nitrogen gas lets the suspensions absorb the vibrations.
All internal wear surfaces are lubricated with oil. The oil is pressurized from
the nitrogen gas. When the haul truck moves along rough ground, check
valves and ports in the suspension control the movement of the oil.
The suspension has an elastomer rebound pad to prevent damage to the

internal parts of the suspension. If the suspension becomes defective, the
pad holds the suspension and prevents metal-to-metal contact. The pad
gives protection when the suspension is in full extension, or if the
suspension is fully compressed.
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2.1 Rear Suspensions Removal
12.2.2 Setup
Safety]

Rear Suspension Tool T-175-A [Reference: Service Tools]
12.2.3 Procedure
WARNING! The rear suspension comes down a few inches when the
nitrogen gas is released.
► Make sure all personnel are at a safe distance.
1. Put jacks on each side of the frame below the main frame near the
lower dump cylinder anchors.
3. Lift the frame until the suspension is fully extended.
NOTICE
The minimum weight of each empty rear suspension is 722 kg (1592 lb).
4. Put a safety block below the frame.
5. Attach an applicable lift device to the suspension (1).
6. Remove the capscrews (5), washers (4), and retainer (3).
NOTICE
The minimum weight of the pin is 66 kg (146 lb).
7. Remove the pin (2) with the suspension removal tool T-175-A.
LME/10880897/January 30, 2011/en
8. Remove the suspension (1).
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Rear Suspension
Fig. 12.2-3: Rear Suspensions Removal
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2.4 Rear Suspensions Installation
12.2.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from the rear
suspension removal procedure. [Reference: Rear Suspension
Removal]

Anti-seize N/A [Reference: Oil and Lubricant
Specifications]
12.2.6 Procedure
NOTICE
The minimum weight of each empty rear suspension is 722 kg (1592 lb).
1. Attach an applicable lift device to the suspension (1).
2. Install the suspension (1).
NOTICE
The minimum weight of the pin is 66 kg (146 lb).
3. Apply a thin coat of anti-seize to the pin (2) and install.
5. Install the retainer (3), washers (4), and capscrews (5).
8. Put oil in the suspension.
9. Pressurize the suspension .
LME/10880897/January 30, 2011/en
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Rear Suspension
Fig. 12.2-4: Rear Suspension Installation
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2.7 Rear Suspension Oil Drain
12.2.8 Setup
Safety]

► The pressurized gas can cause injury.
► Make sure that the nitrogen is fully released from the suspension.
WARNING! A fully retracted suspension continues to have pressure. The

nitrogen pressure can be released, but the oil stays pressurized.
► Use a support to hold the haul truck so that it is not held by the
pressurized oil in the suspension.
► Fully release the nitrogen gas from the suspension.
12.2.9 Procedure
To drain the oil from the suspension when the suspension is on the
truck, do this procedure:
extended.
4. Slowly retract the suspension.
NOTICE
The weight of the suspension is more than 800 kg (1764 lb).
To drain the oil from the suspension when the suspension is removed
from the truck,
LME/10880897/January 30, 2011/en
extended.
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Rear Suspension
LME/10880897/January 30, 2011/en
531-532_500_01_Rear Suspension Drain.tif

Fig. 12.2-5: Rear Suspension Oil Drain
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Rear Suspension
12.2.10 Rear Suspension Oil Fill
12.2.11 Setup
Safety]
► Rear suspension oil fill instructions are given in TI-2114-P, [Reference:
TI-2114-P (Rear Suspension Test and Charge Procedures)], which
can be found in the Class Documents section of this Service Manual.
[Reference: Class Documents].
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2.12 Rear Suspension Gas Discharge
12.2.13 Setup
Safety]

Mobil Fluid 424 N/A [Reference: Oil and Lubricant
Specifications]
Type 1, Grade F Nitrogen CGA Specification G-10 or higher Commercially Available
12.2.14 Procedure
To release the pressure from the suspensions when the suspensions
are on the truck,
1. Lift the haul truck to fully extend the applicable suspensions .
2. Turn and fully close the bleed valve (1).
4. Remove the valve cap (7) from the charge valve on the rear
suspension.

LME/10880897/January 30, 2011/en
8. Use a 3/4 inch wrench on the swivel nut and turn the swivel nut to the
left four full turns or until the charge pressure shows on the gauge (6).
9. Carefully open and close the bleed valve (1) until the necessary
pressure is shown on the gauge.
- OR -
10. Open the bleed valve (1) until all the pressure is released from the
suspension.
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Rear Suspension
LME/10880897/January 30, 2011/en
531-532_510_01_Rear Suspension Discharge.tif

Fig. 12.2-6: Rear Suspension Gas Discharge
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Rear Suspension
12.2.15 Rear Suspension Gas Charge
12.2.16 Setup
Safety]
► Rear suspension gas charge instructions are given in TI-2114-P, Rear
Suspension Test and Charge Procedure., which can be found in the
Class Documents section of this Service Manual. [Reference: Class
Documents].
LME/10880897/January 30, 2011/en
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Rear Suspension
12.2.17 Rear Suspension Pressure Check
12.2.18 Setup
Safety]

Type 1, Grade F Nitrogen CGA Specification G-10 or higher Commercially Available
12.2.19 Procedure
NOTICE
The different types of suspensions have different charge pressures.
► Know the type of suspension on your truck .
To check the rear suspensions when they are on the truck,

1. Lift the haul truck to fully extend the applicable suspensions .
2. Make sure the bleed valve (1) is in the fully closed position.
4. Remove the valve cap (7) from the discharge valve on the rear
suspension.
6. Use your hand to correctly tighten the adapter (3) to prevent gas
leakage.

LME/10880897/January 30, 2011/en

9. Turn the swivel nut (9) to the left four full turns, or until the charge
pressure shows on the gauge (6).
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Rear Suspension
If the rear suspension pressure is not in the specified limits,

15. Pressurize the rear suspension .
LME/10880897/January 30, 2011/en
531-532_605_01_Rear Suspension Pressure Check.tif

Fig. 12.2-7: Rear Suspension Pressure Check
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Service Manual Wheel Assemblies
13 Wheel Assemblies 531

13.1 Front Wheel Removal (Complete) 533
13.1.3 Front Wheel (Complete) Installation 537
13.2 Front Brakes 541
13.2.1 Front Brake Bleed 543
13.2.4 Front Brake Burnish 544
13.3 Front Brake Caliper 545
13.3.1 Front Brake Caliper Removal 547
13.3.4 Front Brake Caliper Installation 549
13.4 Front Brake Disc 551
13.5 Kingpins and Spindle 552
13.5.1 Kingpins Removal 553
13.5.4 Kingpins Installation 555
13.5.7 Toe-In Check 557
13.5.10 Toe-In Adjustment 559
13.6 Steering Encoder Test 561
13.7 Tie Rods 562
13.7.1 Tie Rods Removal 562
13.7.4 Tie Rods Installation 563
13.8 Idler Arm Assembly 567
13.8.1 Idler Arm Assembly Removal 568
13.8.4 Idler Arm Assembly Installation 571
13.9 Steering Arm 574
13.9.1 Steering Arm Removal 575
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13.9.4 Steering Arm Installation 577

13.10 Steering Stop Pads 579
13.10.1 Steering Stop Pads Removal 580
13.10.4 Steering Stop Pads Installation 581
13.11 Upper and Lower Control Arms 583
13.11.2 Control Arm Removal 584
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Wheel Assemblies Service Manual
13.11.4 Control Arm Installation 586

13.12 Rear Tire and Rim Assembly 589
13.12.1 Rear Tire and Rim Assembly Removal 590
13.12.4 Tire and Rim Assembly Installation 593
13.12.7 Rear Tire Studs Replacement 596
13.13 Rear Brakes 598
13.13.1 Rear Brakes Removal 600
13.13.4 Rear Brakes Installation 603
13.13.7 Rear Brake Bleed 608
13.13.10 Rear Brake Burnish 609
13.14 Rear Disc Brake Hub 610
13.14.1 Rear Disc Brake Hub Removal 611
13.14.4 Rear Brake Disc Hub Installation 614
13.15 Park Brake (Carlisle) 617
13.15.1 Park Brake (Carlisle) Removal 619
13.15.4 Park Brake (Carlisle) Installation 622
13.16 Mechanical Release of the Park Brake 625
LME/10880897/January 30, 2011/en
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Front Wheel Removal (Complete)
13.1 Front Wheel Removal (Complete)
13.1.1 Setup
Safety]
► Make sure that the suspension is installed. [Reference: Front
Suspension Installation]
► Bleed the accumulators.
► Remove the tie rod from the steering arm.
► Drain the oil from the wheel.
13.1.2 Procedure
Lifting Bracket T-103-E [Reference: Service Tools]
NOTICE
The weight of the empty front wheel (complete) is 4168 kg (9189 lb).
1. Install the front wheel lift tool and attach an applicable lift device to the
lift tool. [Reference: Service Tools]
2. Disconnect the lubrication hoses (1) and the brake lines (18).
3. Put protective caps on the lubrication hoses (1), brake lines (18), and
open ports.
4. Remove the clamp (7).
NOTICE
The minimum weight of the lower control arm is 847 kg (1867 lb).
5. Put support blocks 250 mm (9.84 in) to 300 mm (11.81 in) below the
lower control arm.
6. Attach an applicable chain come-a-long, 3 ton or more, from the upper
LME/10880897/January 30, 2011/en
control arm to the lower control arm.
ATTENTION
The bushings, retainers, and split rings are in two pieces.
► Be careful when you remove the bushings, retainers, and split rings
and do not let the pieces fall.
NOTICE
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The minimum weight of the bushing retainer is 57 kg (126 lb).

► Be careful when you remove the bushings, retainers, and split rings
and do not let the pieces fall.
7. Attach an applicable lift device or support to the bushing retainer (13).
8. Remove two of the capscrews (11) and washers (12).
9. Insert 3/4-10NC all thread approximately 305 mm (12.01 in) long into
the two holes from where the capscrews were removed. (The thread
must also have 3/4-10NC nuts on the end to catch the busing retainer
(13) when it is removed.
10. Remove the remaining capscrews (11) and washers (12).
11. Use 3/4-10NC all-thread bolts to remove the bushing retainer (13).
12. Remove the O-rings (14).
13. Remove the bushing (15), and split ring (16).
14. Remove the set screw (9) and washer (10).
15. Use the jacking points (threaded holes) on the bushing retainer (13) if
necessary to remove the bushing retainer (13).
16. Lower the control arm until the kingpin ball is free.
CAUTION! The retainer holds the outside bushing and shims.

► The outside bushings and shims can fall when the retainer is removed.
► Do not let the outside bushing and shims fall.
17. Remove the capscrews (19, retainer (5), outside bushing (3), and
shims (4).
CAUTION! The inside bushing (2) is securely installed in the bushing

socket, but haul truck operation can loosen it.
► The inside bushing (2) can fall when the kingpin ball is free from the
upper control arm.
► Do not let the inside bushing fall.
NOTICE
The minimum weight of the inside bushing is 49 kg (108 lb).
18. Use an applicable lift device or support to hold the inside bushing (2).
19. Lower the wheel assembly (17) until the upper kingpin ball is clear of
the upper control arm and make sure that the inside bushing (2) does
not fall.
NOTICE
Freeze the inside bushing when you install the inside bushing.
► Apply pressure down to remove the inside bushing. If necessary,
LME/10880897/January 30, 2011/en
apply heat to the bushing socket.

20. Remove the inside bushing (2) with three 3/8-16NC all-thread bolts.
21. Lower the lower control arm against the support.
22. Put the wheel assembly (17) in a safe location.
23. Do a check of the kingpin.
24. Do an inspection of the kingpin ball for signs of wear or damage.
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08-100_000_Front Wheel Complete.tif

Fig. 13.1-1: Front Wheel (Complete) Removal
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13.1.3 Front Wheel (Complete) Installation
13.1.4 Setup
Safety]
front wheel removal. [Reference: Front Wheel (Complete) Removal]
13.1.5 Procedure
Grease 5079-A 2.5% or more Molybdenum Disulfide
Specifications]
Lifting Braket T-103-E [Reference: Service Tools]
NOTICE
The minimum weight of the empty front wheel (complete) is 4168 kg (9189
lb).
1. Install the front wheel lift tool and attach an applicable lift device to the
lifting tool.
NOTICE
The minimum weights of the upper control arm is 976 kg (2152 lb), and the
weight of the lower control arm is 847 kg (1867 lb).
► Use an applicable device that can safely lift and support this weights.
2. Lift the wheel assembly (17) and align the kingpin with the upper and
lower control arms.
3. Install the rubber seal (6), small end first, over the upper kingpin ball.
4. Apply grease to the upper kingpin ball.
LME/10880897/January 30, 2011/en

► Very cold liquids can cause injury.
► Put on approved protective clothing, and equipment that can protect
you when you do tasks that includes the use of liquid nitrogen.
5. Put the bushings (2) in an applicable container and fill the container
with liquid nitrogen.
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NOTICE
The minimum weights of the inside bushing is 49 kg (108 lb).
6. Install the bushings (2) into the upper control arm and hold in position
while the bushings (2) equalize.
7. Install the upper rubber seal (6) before you lift the wheel and install the
upper kingpin into the upper control arm. (You cannot install the seal
after the kingpin is in the upper control arm.)
8. Lift the wheel assembly (17) and install the kingpin ball into the upper
control arm socket.
9. Install the outside upper bushing (3) and retainer (5).
10. Lubricate the capscrews (19) with anti-seize and install.
12. Install the rubber seal (8) onto the lower kingpin (small end first).
13. Lift the lower control arm until the lower kingpin ball is through the
control arm socket.
14. Apply grease to the lower kingpin ball.
15. Install the split ring (16) into the lower control arm socket.
16. Install the bushing (15) into the lower control arm socket with the
grease groove at the bottom.
17. Install the O-rings (14)
NOTICE
The minimum weights of the bushing retainer is 57 kg (126 lb).
18. Make sure that the set screw (9) pin hole is in line for the position of
the bushing retainer (13).
19. Lower the control arm enough to lock the split ring (16) and bushing
(15) in place.
20. Lubricate the set screw (9) and the flange of the bushing retainer (13)
with anti-seize.
21. Apply grease in the bore of the bushing retainer (13).
22. Install the set screw (9), washer (10), and bushing retainer (13).
24. Use the 3/4-10NC all thread and nuts to raise the lower bushing
retainer into place and install the capscrews (11), and washers (12).
26. Put the lower rubber seal (8) into the grooves on the lower kingpin.
27. Make the upper control arm level.
28. Tighten again the capscrews (19) to 55 N m (41 lbf ft).
LME/10880897/January 30, 2011/en
29. Take four measurements 90 degrees apart of the gap between the
retainer (5) and the control arm face.
30. Get the average value of the measurements.
31. Remove the capscrews (19) and retainer (5).
32. Add shims (4) equal to the average measurement plus 0.13 mm (0.01
in).
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ATTENTION
The shim (4) must cross the two halves of the retainer (5).
► Make sure that the split in the shims is not in line with the split in the
retainer.
33. Install the retainer (5), shims (4) and capscrews (19).
35. Put the upper rubber seal (6) into the grooves on the upper kingpin.
36. Remove the protective caps and connect the lubrication hoses (1) and
brake lines (18).
37. Apply grease to all the pivot points.
38. Make sure that the grease goes out to the seals (6) and (8).
39. After 50 hours of haul truck operation, tighten the capscrews (19) to
380 N m (280 lbf ft).
40. Install the tie rod to the spindle steering arm. [Reference: Tie Rod
Installation]
41. Fill the oil in the wheel. [Reference: Front Wheel Oil Fill]
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
08-100_000_Front Wheel Complete.tif

Fig. 13.1-2: Front Wheel (Complete) Removal
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Front Brakes
13.2 Front Brakes
08-000_000_01_Front Brakes.tif
Fig. 13.2-1: Front Brakes
The front brake assembly has these components:

• [Reference: Front Brake Calipers]
• [Reference: Front Brake Disc]
The front brakes are a one disc and five caliper assembly.
The brake disc is installed on the wheel. The spindle has a flange to attach
the brake calipers. The brake calipers are installed around the brake disc,
but are attached to the spindle flange. Each caliper has two pieces.
The wheels turn when the haul truck moves. The brake disc turns with the
wheel. To stop the haul truck you must apply the brakes, the brake calipers
put pressure on the brake disc to slow the wheel and to stop the haul truck.
The brakes are hydraulically operated and the front brake accumulator
supplies hydraulic pressure to the calipers.
The routing of the hydraulic lines from the brake system control goes through
LME/10880897/January 30, 2011/en
the wheel assembly to the brake calipers.
It is recommended to burnish the front brakes after these conditions:

• you install a new brake disc
• you install a new brake lining
• The brake lining or brake disc has contamination.
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Front Brakes
Braking performance increases when the brakes are burnished. If you

burnish the brakes correctly, the temperature of the disc becomes 205 ºC
(401 ºF). Service brake operation causes heat to collect in the brake disc
and linings. The heat causes the linings and discs to change properties and
burns the unwanted material.
The front brake calipers can be removed with the wheel on the truck. You
must remove the wheel to remove the brake disc.
Use only Liebherr recommended hydraulic oil. Do not use oil that contains
additives harmful to Buna-N (Nitrile) and neoprene rubber compounds. Do
not put automotive type brake fluid in Liebherr haul trucks.
LME/10880897/January 30, 2011/en
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Front Brakes
13.2.1 Front Brake Bleed
13.2.2 Setup
Safety]
► Make sure that all of the hydraulic connections and fittings are correctly
tightened.
► Two maintenance personnel are necessary to do the bleed procedure.
13.2.3 Procedure

1. Loosen the highest bleeder screw on the caliper.
WARNING! The brake linings and discs must be clean and free from
contamination to operate correctly.
► Do not get hydraulic fluid on the brake linings or disc.
2. Put a small rubber tube on the bleed screws to change the direction
of the fluid away from the brakes and into an applicable container.
4. Apply the service or hand brake to bleed all the air from the brakes.
WARNING! Air in the system can cause the incorrect operation of the
brakes.
Incorrect brake function can result in personal injury or serious damage to
equipment.
► Make sure that all the air is removed from the brake system.
5. Close the bleeder screw when there are no air bubbles in the fluid.
6. Tighten the bleeder screw to 11 N m (8 lbf ft) to 20 N m (15 lbf ft).
7. Repeat this procedure for all the caliper pieces.
8. Make sure that there are no hydraulic leaks.
LME/10880897/January 30, 2011/en
9. Correctly discard all the hydraulic fluid collected from the bleed
procedure. Follow the environmental regulations when you discard the
fluid.
10. Make sure that the brake and steering hydraulic tank is at a serviceable
level.
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Front Brakes
13.2.4 Front Brake Burnish
13.2.5 Setup
Safety]
WARNING! Disc brake components can become very hot and cause a fire
or injury to personnel.
► Be very careful when you do work around the brakes. Make sure that
four to six fire extinguishers are available.
► Make sure that all the brakes operate correctly and the system
pressure is 205 bar (2973 psi).
► Move the haul truck to a safe area.
► Remove the hub caps, if applicable.
► Disconnect the rear brake line, SVB, at the axle box, and install
protective covers on the brake line and open ports.
13.2.6 Procedure
1. Press the override switch on the dump control lever during the time
the service brake is applied.
2. Drive the haul truck. 12.87 km/h (8 mph) to 24.14 for approximately
135 m (442.91 ft) and at the same time apply the service brakes at
30-50% effort.
3. Stop the haul truck and measure the temperature of the disc.
If the disc temperature is less than 205 ºC (401 ºF),

4. Repeat the procedure.
If the disc temperature is equal to or more than 205 ºC (401 ºF),

5. Let the disc become cool to 125 ºC (257 ºF).
6. Put the haul truck on a level surface.
7. Set the parking brake and release the service brake pedal prior to
letting the brake disc cool. There is a possibility that the brake pad can
become stuck to the brake disc if allowed to cool while touching the
brake disc.
8. Inspect for leaks or other unsatisfactory conditions.
LME/10880897/January 30, 2011/en
9. Connect the rear brake line, SVB, in the axle box.

10. Install the hub caps.
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Front Brake Caliper
13.3 Front Brake Caliper
08-000_000_01_Front Brake Caliper.tif

Fig. 13.3-1: Front Brake Caliper
The front brake caliper has two pieces attached together. The front brake
caliper is attached to the brake flange with bolts. The brake caliper can be
referred as the brake housing in this manual.
The front brake caliper has these components:

• Brake lining (brake pads)
• End plates
• Pistons
• O-rings
• Backup Rings
• Dust Boots
• Bleeder valves
• Elbow Fitting
• Tee-Fitting
Each caliper piece has a brake lining that moves freely between the end
LME/10880897/January 30, 2011/en
plates.
Each caliper piece has three pistons that are hydraulically-operated. The
pistons are installed in the bores of the caliper housing with the O-rings,
backup rings, and dust boots.
There are three caliper ports on each caliper piece. These ports are
interchangeable with the bleeder valves, elbow fittings and tee-fitting. There
are two bleeder valves on each caliper piece.
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Front Brake Caliper
If you apply the service brakes, hydraulic fluid from the accumulator goes
to the calipers through hydraulic lines. The pressure of the hydraulic fluid
causes the pistons to move. The pistons push on the brake linings and
cause them to close against the brake disc.
WARNING! Compressed air can remove a piston with a dangerous force.

► Do not use compressed air to remove pistons from the caliper
housing.
LME/10880897/January 30, 2011/en
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Front Brake Caliper
13.3.1 Front Brake Caliper Removal
13.3.2 Setup
Safety]
► Bleed the brake accumulators.
13.3.3 Procedure

1. Bleed the oil from the bleeder valves (3) on all five calipers.
2. Disconnect the hydraulic supply (12) and jumper lines (7).
3. Remove the hex nuts (1) and hardened washers (2) from the brake
caliper to be removed.
4. Correctly hold the inboard caliper piece (4).
NOTICE
The weight of the front brake caliper is 122 kg (269 lb).
5. Attach an applicable lift device to the inboard caliper half (4).
6. Move in the inboard caliper piece (4) on the capscrews (11)
approximately 50 mm (1.97 in) to 70 mm (2.76 in).
7. Carefully remove the inboard brake lining (5) from behind the caliper
piece (4) .
8. Do not let the brake lining (5) fall.
9. Remove the inboard caliper piece (4).
10. Correctly hold the outboard caliper piece (8) and attach an applicable
lift device to the caliper piece (8).
11. Remove the capscrews (11) and hardened washers (10).
ATTENTION
The outboard brake lining comes out when the outboard caliper is removed.
LME/10880897/January 30, 2011/en
► Be careful when you remove the capscrews and hold the outboard
brake lining.
12. Remove the outboard caliper piece (7) and the outboard brake lining
(6).
13. Do not let the outboard brake lining (6) fall.
14. Inspect the brake lining.
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Front Brake Caliper

LME/10880897/January 30, 2011/en
Fig. 13.3-2: Front Brake Caliper Removal
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Front Brake Caliper
13.3.4 Front Brake Caliper Installation
13.3.5 Setup
Safety]
front brake caliper removal. .

13.3.6 Procedure
NOTICE
The weight of the front brake caliper is 122 kg (269 lb).
1. If the end plates need to be installed, apply Loctite® 271 threadlocker
or equivalent to the threads of the end plate bolts (apply several drops
to the three end threads on each bolt and apply several drops down
one side of each female threaded hole). Tighten the bolts to 515 N m
(380 lbf ft) to 624 N m (460 lbf ft).
2. Correctly hold the outboard caliper piece (8) and attach an applicable
lift device.
3. Install the outboard caliper piece (8) and outboard brake lining (6) onto
the brake disc.
4. Install the shims, as necessary, between the brake disc and flange to
align the caliper to the center over the brake disc ±1.5 mm (0.06 in).
NOTICE
The bolts (11) for the upper brake caliper cannot be installed from the
kingpin side.
► Install the bolts (11) for the upper brake caliper from the wheel side.
► Install the bolts (11) for the other four brake calipers from the kingpin
LME/10880897/January 30, 2011/en
side.
5. Install the capscrews (11) and hardened washers (10).
6. Correctly hold the inboard caliper piece (4) and attach an applicable
lift device.
7. Put the inboard caliper piece (4) onto the capscrews (11).
8. Install the inboard brake lining (5).
9. Lubricate the hex nuts (1) and hardened washers (2) with anti-seize.
10. Install all the hex nuts (1) and hardened washers (2) onto the
capscrews (11).
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Front Brake Caliper
11. Tighten the hex nuts (1) to 1005 N m (741 lbf ft).
12. Tighten the bleeder screws (3) to 11 N m (8 lbf ft) to 20 N m (15 lbf
ft).
13. Connect the hydraulic supply (12) and jumper lines (7).
14. Bleed the brakes.
15. Install the tire and rim assembly.
LME/10880897/January 30, 2011/en

Fig. 13.3-3: Front Brake Caliper Installation
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Front Brake Disc
13.4 Front Brake Disc
08-000_000_01_Front Brake Disc.tif

Fig. 13.4-1: Front Brake Disc
The front brake disc is a one wheel speed disc and is installed on the wheel.
The front brake disc attaches to the inboard side of the wheel with
capscrews. Five brake calipers are in position around the brake disc. The
brake calipers close against the brake disc to stop the haul truck when the
operator applies service brakes.
You must burnish the brakes when you install a new brake disc.
LME/10880897/January 30, 2011/en
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Kingpins and Spindle
13.5 Kingpins and Spindle
08-000_000_01_Kingpins and Spindle.tif

Fig. 13.5-1: Upper and Lower King Pins and Spindle
The king pin and spindle connects to these assemblies:

• Steering Arm
• Upper and Lower Control Arms
• Front Wheel Assembly
The upper and lower king pins and spindle are attached together as a
complete unit to supply support and steering to the wheel.
The king pins attach to the upper and lower control arms. The steering arm
attaches to the spindle. Movement of the steering arm causes the king pins
and spindle to turn in the applicable direction.
LME/10880897/January 30, 2011/en
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13.5.1 Kingpins Removal
13.5.2 Setup
Safety]
13.5.3 Procedure
Lift devices N/A See applicable weight warnings
Eye bolt N/A Commercially available
1. Carefully rotate the spindle so that the lower king pin (4) is at the top
of the spindle.
NOTICE
2. Attach the eyebolt (2) to the lower kingpin (4).
3. Attach an applicable lifting device to the eyebolt (2).
5. Lift the lower king pin (4) from the spindle.
6. Carefully rotate the spindle 180º to remove the upper king pin (3).
NOTICE
The weight of the upper king pin is 238 kg (525 lb).
7. Attach the eyebolt (2) to the upper king pin (3).
8. Remove the capscrews and carefully lift the upper king pin from the
spindle.
LME/10880897/January 30, 2011/en
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King Pin_100_01.tif
Fig. 13.5-2: Kingpins Removal
LME/10880897/January 30, 2011/en
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13.5.4 Kingpins Installation
13.5.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the king pin
removal procedure. [Reference: Kingpins Removal]
13.5.6 Procedure
Lift devices N/A See applicable weight warnings
Eye bolt N/A Commercially available
Specifications]
NOTICE
1. Install the eye bolt into lower king pin (3), and attach a suitable lifting
device that can support the weight of the lower king pin (3).
2. Make sure the contact surface between the lower king pin (3) and
spindle is clean, dry and smooth.
3. Set the lower king pin (3) onto the spindle.
4. Carefully turn the spindle 180 degrees, and hold in an upright position.
ATTENTION
The contact surface between the lower king pin (3) and spindle is clean,
dry, smooth, and free of any pint.
► Make sure no paint is under the head of the fasteners.
5. Set the lower king pin (3) on the spindle.
6. Install 20, new 12 pt. cap screws (1) with anti-seize on the bottom
LME/10880897/January 30, 2011/en
threads (12.7 mm (0.5 in) to 25.4 mm (1 in)) only, and install hand tight.
7. Use a cross pattern to tighten the cap screws to 793 N m (585 lbf ft).
8. Use the same cross pattern and increase to a final torque of 1058 N
m (780 lbf ft), and tighten.
9. Remove the eyebolt.
10. Carefully rotate the spindle 180º and secure in place.
NOTICE
The combined weight of the upper kingpin and the spindle is 3374 kg (7438
lb).
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11. Install the eye bolt into upper kingpin (4) and attach appropriate lifting
device that can support the weight of the upper king pin (4).
12. Set the upper king pin (4) on the spindle.
13. Install 24, new 12 pt. cap screws (1) with anti-seize on the bottom
threads (12.7 mm (0.5 in) to 25.4 mm (1 in)) only, and install hand tight.
14. Use a cross pattern to tighten the cap screws to 793 N m (585 lbf ft).
15. Use the same cross pattern and increase to a final torque of 1058 N
m (780 lbf ft), and tighten.
16. Remove the eye bolt.
17. Carefully rotate the spindle 180º and secure in place.
King Pin_100_01.tif
Fig. 13.5-3: Kingpins Installation
LME/10880897/January 30, 2011/en
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13.5.7 Toe-In Check
13.5.8 Setup
Safety]
► Make sure that the suspensions are set to the parameters in the
suspension inspection check.
► Make sure that the haul truck is empty.
► Park the haul truck on a level surface and put chocks on the rear tires.
13.5.9 Procedure
1. Adjust the steering to the center so that the idler arm is parallel with
the center line of the main frame.
- OR -
2. So that the distance from the two sides of the idler arm to the steering
stop pads is the same.
3. Lift the front of the haul truck until the front tires are off the ground a
small distance.
4. Measure the pin to pin lengths of the two tie rods and record.
5. Take a measurement of (X) and (Y).
If (X) is equal to 254 mm (10 in) less than (Y), and the pin to pin lengths
of the two tie rods are the same,
6. Toe-in is correct.
- OR -
If (X) is not equal to 254 mm (10 in) less than (Y), and the pin to pin
lengths of the two tie rods are the same,
7. Do a toe-in adjustment. [Reference: Toe-In Adjustment]
LME/10880897/January 30, 2011/en
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06-400_000_01_Toe In Check.tif
Fig. 13.5-4: Toe-In Check
LME/10880897/January 30, 2011/en
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13.5.10 Toe-In Adjustment
13.5.11 Setup
Safety]
► Make sure that the suspensions are set to the parameters in the
suspension inspection check.
► Make sure that the haul truck is empty.
► Park the haul truck on a level surface and put chocks on the rear tires.
13.5.12 Procedure
or
2. So that the distance from the two sides of the idler arm to the steering
stop pads is the same.
3. Lift the front of the haul truck until the front tires are off the ground a
small distance .
4. Loosen the tie rod clamps.
5. Turn the tie rods with a pipe wrench to adjust their length with this
procedure:
NOTICE
The tie rods have opposite threads at opposite ends.
► Turn the tie rods in the applicable direction to adjust their length.
– Adjust the length so that (X) is 254 mm (10 in) less than (Y).
6. Align the joint of the tie rod clamp with the compression relief of the tie
rod tube.
7. Tighten the bolts of the rod clamps to 245 N m (181 lbf ft).
8. Completely lower the front of the haul truck and remove the lift device.
9. Put a load in the haul truck.
10. Park the haul truck on a level surface and put chocks on the rear tires
12. Take a measurement of (X) and (Y).
LME/10880897/January 30, 2011/en
13. Calculate (Z) = (Y) - (X).
If (Z) is between zero and ±25,

14. The toe-in is correct.
If (Z) is not between zero and ±25,

15. Adjust the toe-in.
If the toe-in cannot be adjusted correctly,

16. See your Liebherr service representative.
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06-500_000_01_Toe In Adjustment.tif
Fig. 13.5-5: Toe-In Adjustment
LME/10880897/January 30, 2011/en
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Steering Encoder Test
13.6 Steering Encoder Test
13.6.1 Setup
Safety]
► Take a measurement of both left and right steering cylinder rods and
adjust the front wheels to the center.
13.6.2 Procedure
1. Connect the computer to the Siemens communication port on the
dash.
2. Start the monitor program version 2.40 and make sure that you have
communication.
To do the test with the values shown continuously, do this procedure:

3. Make the selection APPLICATION-OBSERVER from the pull-down
menu and push ENTER.
4. Use the keyboard to add the data "$WST".
5. Push the ENTER button continually until the values start to scroll down
the screen.
6. Push CONTROL C to stop the scrolling.
7. Move the steering control fully left or fully right and repeat the test.
To do the test without the values shown continuously, do this

procedure:
8. Make the selection APPLICATION-CONNECTOR from the pull-down
menu (do not push ENTER).
9. Use the keyboard to add the data "$WST" AND PUSH enter.
10. Move the steering control fully left or fully right and repeat the test.
To do a check of the voltage of the steering encoder, do this procedure:

11. Use a voltmeter to measure the voltage at 1XT-56, or Con B-89, or at
the steering encoder.
LME/10880897/January 30, 2011/en
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Tie Rods
13.7 Tie Rods
13.7.1 Tie Rods Removal
13.7.2 Setup
Safety]
13.7.3 Procedure
WARNING! The tie rods prevent side to side wheel movement.

► Use a restraint to hold the wheel in position before you remove the tie
rod.
1. Disconnect the lubrication hoses (15) and install protective caps on

the hoses (15) and open ports.
NOTICE
The weight of the tie rod is 184 kg (406 lb).
2. Put a support at the two ends of the tie rod (7).
3. Remove the lockwashers (13), locknut (14), capscrews (9), washers
(11), and rotation stop (12).
NOTICE
4. Pull out the pins (6).
5. Remove the tie rod (7).
6. Remove the seals (5), capscrews (3), retainers (2), and spacers (4)
and (8).
7. Remove the bushings (1).
LME/10880897/January 30, 2011/en
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Tie Rods
LME/10880897/January 30, 2011/en
06-100_000_01_Tie Rods.tif
Fig. 13.7-1: Tie Rods Removal
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Tie Rods
13.7.4 Tie Rods Installation
13.7.5 Setup
Safety]
► Make sure the haul truck is in the same configuration from the tie rods
removal. [Reference: Tie Rods Removal]

Permatex® anti-seize N/A [Reference: Oil and Lubricant
Specifications]
Grease 5079-A [Reference: Oil and Lubricant
Specifications]
13.7.6 Procedure

Very cold liquids can cause serious personal injury.
► Always put on protective gloves, clothing and eye protection.
1. Put the bushings (1) in an applicable container and fill with liquid
nitrogen.
2. Install the lower retainers (2).
3. Install the bushings (1) and hold in position while the bushings (1)
stabilize.
4. Install the upper retainers (2).
NOTICE
The weight of the tie rod is 184 kg (406 lb).
6. Put an applicable support below the tie rod (7).
LME/10880897/January 30, 2011/en
7. Put the tie rod (7) in position.

8. Install the spacers (8) and (4), and the seals (5).
10. Carefully align the spacers (4) and (8), seals (5), and bushings (1) with
the tie rod (7).
NOTICE
11. Install the pins (6).
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Tie Rods
12. Lubricate the capscrews (9) and locknuts (14) with anti-seize.
13. Install the capscrews (9) and the locknuts (14).
14. Install the lockwashers (13), washers (11), and rotation stop (12).
15. Tighten the locknuts (14) to 410 N m (302 lbf ft).
16. Bend the tab of the lockwasher (13) into the slot of the locknut (14).
19. Lubricate the bushings (1) with grease.
LME/10880897/January 30, 2011/en
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Tie Rods
LME/10880897/January 30, 2011/en
06-100_000_01_Tie Rods.tif
Fig. 13.7-2: Tie Rods Installation
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Idler Arm Assembly
13.8 Idler Arm Assembly
06-000_000_01_Idler Arm Assembly.tif

Fig. 13.8-1: Idler Arm Assembly
The idler arm assembly interfaces with the assemblies that follow:
• Tie Rods
• Steering Cylinders
• Frame
• Steering Stop Pads
The idler arm is attached to the front cross member of the frame with a large
vertical pin and two roller bearings.
The steering cylinders extend and retract which causes the idler arm to
move. When the idler arm moves, it pushes on one of the tie rods and pulls
on the other. When the steering is fully turned in one direction or the other,
the idler arm moves against the steering stop pads.
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Idler Arm Assembly
13.8.1 Idler Arm Assembly Removal
13.8.2 Setup
Safety]
► Put an applicable support below the idler arm assembly.
► Remove the tie rods.
► Remove the steering cylinders. [Reference: Steering Cylinder
Removal]
13.8.3 Procedure
1. Disconnect the lubrication hoses (25).
2. Disconnect the steering encoder cable (7).
3. Remove the screws (5) and the retaining bracket (8).
4. Remove the capscrews (13), the lockwashers (14), and the drive plate
(15).
5. Carefully remove the steering encoder (6) and the coupling (1).
NOTICE
The weight of the idler arm assembly is 376 kg (829 lb).
6. Put an applicable support below the idler arm assembly (22).
ATTENTION
The retainer holds the upper bearing in position.
The upper bearing may come out with the retainer.
► Do not let the bearing fall.
7. Remove the capscrews (4), washers (3), retainer (9), upper bearing
(10), and shims (2).
ATTENTION
The retainer holds the lower bearing in position.
The lower bearing can come out with the retainer.
► Do not let the bearing fall.
ATTENTION
The retainer holds the pin in position.
LME/10880897/January 30, 2011/en
The pin can fall when the retainer is removed.

► Support the pin if necessary.
NOTICE
► Make sure that you are prepared to hold the weight.
9. Remove the key (21), and pin (16).
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Idler Arm Assembly
If the lower bearing (19) is not removed with the retainer (20),
10. Remove the lower bearing (19).
11. Move the idler arm assembly (22) to the rear of the haul truck and out
of the crossmember.
12. Remove the seals (11) and (18), and the spacers (12) and (17).
13. Do an inspection of the pins and bearings.
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Idler Arm Assembly
LME/10880897/January 30, 2011/en

Fig. 13.8-2: Idler Arm Assembly Removal
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Idler Arm Assembly
13.8.4 Idler Arm Assembly Installation
13.8.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration as the idler
arm removal. [Reference: Idler Arm Assembly Removal].

Specifications]
Loctite 277 N/A Commercially available
Grease 5079-A 2.5 % or more Molybdenum
Disulfide [Reference: Oil and
Lubricant Specifications]
13.8.6 Procedure
If the bearing (19) is removed from the retainer (20),
1. Put the bearing (19) into the retainer (20).
2. Put an applicable support below the idler arm assembly (22).
3. Move the idler arm assembly (22) into position on the crossmember.
4. Align the pin boss with the upper and lower bearing ports in the frame.
NOTICE
► Make sure that you are prepared to hold the weight.
5. Install the pin (16) in the hole so that it is centered from top to bottom.
6. Turn the pin (16) and install the key (21).
7. Install the lower spacer (17) and the lower seal (18).
8. Make sure the lower seal (18) is square with the crossmember bore
and flush with the top surface of the bottom of the crossmember.
9. Install the bearing (19) and retainer (20).
LME/10880897/January 30, 2011/en

13. Install the upper spacer (12) and the upper seal (11).
14. Make sure the upper seal (11) is square with the crossmember bore
and flush with the bottom surface of the top boss of the crossmember.
15. Install the drive plate (15) and coupling (1).
17. Install the bearing (10) and the retainer (9).
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Idler Arm Assembly
18. Lubricate the capscrews (4) with Permatex® anti-seize. [Reference:

Oil and Lubricant Specifications]
19. Install four of the capscrews (4) and washers (3).
20. Evenly, tighten the capscrews (4) to 53 N m (39 lbf ft).
21. Loosen the capscrews (4) and then tighten to 14 N m (10 lbf ft).
22. Measure the gap between the retainer (9) and the top surface of the
upper crossmember boss with a feeler gauge.
23. Take the average of the measurements and remove 0.25 mm (0.01
in) to determine the amount of shim necessary.
25. Install the necessary shims (2).
26. Install the retainer (9) and washers (3).
27. Apply Loctite 277 to the capscrews (4) and install.
29. Connect the auto-lube supply hoses (25).
30. Lubricate the bearings (10) and (19) with grease and make sure that
the hole is fully filled with grease.
31. Install the steering encoder (6), retaining bracket (8), and screws (5).
32. Connect the steering encoder cable (7).
33. Install the steering cylinders.[Reference: Steering Cylinders
Installation]
34. Install the tie rods. [Reference: Tie Rods Installation]
35. Lubricate all the pivot points of the front end with grease.
LME/10880897/January 30, 2011/en
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Idler Arm Assembly
LME/10880897/January 30, 2011/en

Fig. 13.8-3: Idler Arm Assembly Installation
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Steering Arm
13.9 Steering Arm
06-000_000_01_Steering Arm.tif
Fig. 13.9-1: Steering Arm
The steering arm connects to the assemblies that follow:

• Tie Rod
• King Pins and Spindle
The steering arm is attached to the spindle.
The tie rods push and pull on the steering arm which causes the wheels to
change directions.
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Steering Arm
13.9.1 Steering Arm Removal
13.9.2 Setup
Safety]
► Remove the tie rod from the steering arm.
13.9.3 Procedure
NOTICE
The weight of the steering arm is 201 kg (443 lb).
1. Attach an applicable lift device to the steering arm (3).
ATTENTION
The steering arm capscrews must not be installed again after loosened from
full torque.
► If you loosen the capscrews (1) and (5), you must replace them with
new capscrews.
2. Remove and discard the capscrews (1).
3. Remove the spacers (2).
4. Remove and discard the capscrews (5).
5. Remove the washers (4).
6. Remove the steering arm (6).
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Steering Arm
LME/10880897/January 30, 2011/en
Fig. 13.9-2: Steering Arm Removal
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Steering Arm
13.9.4 Steering Arm Installation
13.9.5 Setup
Safety]
steering arm removal. [Reference: Steering Arm Removal]
13.9.6 Procedure
Specifications]
NOTICE
The weight of the steering arm is 201 kg (443 lb).
1. Using a press, install new bushing (3) into steering arm (6). Make sure
the grease port is aligned correctly, and the bearing is fully engaged
into the arm bore.
2. Set the retaining ring (7) into steering arm (6).
3. Screw in 8, 12 pt. capscrews (8) with anti-seize on the threads and
tighten them to 110 N m (81 lbf ft).
NOTICE
Steering arm and spindle contact faces must be free of dirt, scale,
lubricants, anti-seizes, or surface irregularities.
4. [Reference: Oil and Lubricant Specifications]
5. Attach steering arm (3) and torque fasteners (1), and (5) to 3300 N m
(2434 lbf ft).
6. Install the tie rod to the steering arm.
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Steering Arm
LME/10880897/January 30, 2011/en
Fig. 13.9-3: Steering Arm Installation
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Steering Stop Pads
13.10 Steering Stop Pads
06-000_000_01_Steering Stop Pads.tif

Fig. 13.10-1: Steering Stop Pads
The steering stop pads interface with the assemblies that follow:
• Frame
• Idler Arm Assembly
The steering stop pads are attached to the rear of the lower front
crossmember of the frame on the two sides of the idler arm.
Maximum movement of the steering is controlled with the steering stop

pads. When the steering is fully turned in one direction or the other, the idler
arm moves against the steering stop pads. The steering stop pads can have
shims installed to get the correct steering limits.
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Steering Stop Pads
13.10.1 Steering Stop Pads Removal
13.10.2 Setup
Safety]
13.10.3 Procedure
2. Remove the stop pad (3).
4. Remove the plate (2) and shim (5).
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Steering Stop Pads
13.10.4 Steering Stop Pads Installation
13.10.5 Setup
Safety]
► Make sure the haul truck is in the same configuration as the steering
stop pads removal. [Reference: Steering Stop Pads Removal]

Specifications]
13.10.6 Procedure
1. Install the shim (5).
2. Install the plate (2).
5. Install the stop pad (3).
6. Install the capscrews (4).
LME/10880897/January 30, 2011/en
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Steering Stop Pads
LME/10880897/January 30, 2011/en
06-100_000_01_Steering Stop Pad.tif

Fig. 13.10-2: Steering Stop Pads Installation
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Upper and Lower Control Arms
13.11 Upper and Lower Control Arms
Front Control Arm_01_Rev000.tif

Fig. 13.11-1: Upper and Lower Control Arm
13.11.1 System Description and Function

The control arms are attached to the frame and to the kingpin. The front
suspension is attached to the upper control arm. When the haul truck moves
along the ground, the control arms permit the front wheel assemblies to
move vertically.
LME/10880897/January 30, 2011/en
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13.11.2 Control Arm Removal

1. Follow the haul truck safety precautions. [Reference: Haul truck
Safety]
CAUTION
Fall prevention!
applicable anchor tie-off point when you do any tasks from above
ground.
2. Remove the front wheel assembly.
3. Remove the front suspension.
13.11.3 Procedure
Tools and Materials Liebherr Part Number Note
Pin Puller T-075-B [Reference: Service Tools]
Dead blow hammer N/A Commercially available
1. Disconnect the lubrication hoses (12) and put protective caps on the
hose ends (12) and all open ports.
NOTICE
The minimum weight of the upper control arm is 976 kg (2152 lb), and the
lower control arm is 847 kg (1867 lb).
► Use an applicable device that can safely lift and support these
weights.
2. Attach an applicable lifting device to the upper control arm (11).
3. Put an applicable support below the lower control arm (10).
4. Loosen and remove the capscrews (1). See torque specification table.
5. Remove the washers (2), retaining plates (3), bearing washers (5),
shims (4), and dowel pins (14) and (15).
6. Remove and discard the O-rings (13).
7. Pull the pins (7) with the spacers (6) using a pin puller (Liebherr P/N
T-075-B. [Reference: Service Tools]
8. Remove the shims (8) and the bearing washers (9).
9. Remove the control arms (10) and (11).
LME/10880897/January 30, 2011/en
10. Examine the bushings, pins (7), dowel pins (14) and (15), and pivot
points.
11. Replace the parts that are worn or show signs of damage.
12. Fully clean the bores in the frame.
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531_Front Control Arms_100_01.tif

LME/10880897/January 30, 2011/en
Fig. 13.11-2: Control Arms Removal
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13.11.4 Control Arm Installation

Safety]
CAUTION
Fall prevention!
applicable anchor tie-off point when you do any tasks from above
ground.
2. Make sure that the haul truck is in the same configuration from the
control arm removal procedure. [Reference: Control Arm Removal]
13.11.5 Procedure
Liquid nitrogen N/A Commercially available
Micrometer or dial calipers N/A Commercially available

1 8135 N m (6000 lbf ft)
NOTICE
The minimum weight of the upper control arm is 976 kg (2152 lb).
ATTENTION
Only one control arm must be installed at a time!
► Fully install one of the control arms, and then the other.
LME/10880897/January 30, 2011/en
1. Move the control arms (10) or (11) into position on the frame.
2. Align the pin holes.
3. Install the bearing washers (9).
4. Push the control arm (10) or (11) fully against the frame in one
direction.
5. Measure the gap between the bearing washer (9) and the frame.
6. Divide the measurement by two to get the quantity of shims necessary
for both ends of the control arm.
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7. Add shims (8) equally, on both ends of the control arm, to center the
control arm to ± 1 mm (0.04 in) in relation to the frame.
– The control arm is permitted to move up and down, but not
forward or rearward.
8. Put the shims (8) between the bearing washer (9) and the control arm
(10) and (11).
9. Make sure that the gap between the bearing washer (9) and the frame
is equal to or less than 1 mm (0.04 in).
DANGER
Liquid nitrogen is a very cold liquid!
► Very cold liquids can cause serious injury.
► Always put on protective clothing and equipment when you do
procedures that include liquid nitrogen.
10. Put the pins (7) in an applicable container and fill with liquid nitrogen.
11. Loosely, cover the container.
12. Let the pins (7) stay in the liquid nitrogen until they stabilize, or the
liquid nitrogen stops bubbling.
13. Install the pins (7) through the control arms (10) or (11) and into the
frame.
If the pins (7) do not install easily into the control arm,
– put the pins (7) in the liquid nitrogen again and apply heat to the
boss in the frame.
ATTENTION
The pins can be damaged if you use too much force to push the pins in
position.
► The pins may be tapped with a dead blow hammer, but do not use a
dead blow hammer if the pin is stuck.
14. Make sure that the pins (7) are fully seated against the retainer plate
inside the frame.
15. Install the spacers (6).
– Align the center grease groove on the spacer (6) with the grease
port in the control arms (10) or (11).
16. Install the bearing washers (5) and the dowel pins (14) and (15).
17. Take a measurement from the outer face of the bearing washer (5) to
the end face of the pin (7) using one of the following procedures:
Using a depth micrometer or dial calipers,
– take measurement (X) from the outer face of the bearing washer
(5) to the end face of the pin (7).
(X) plus 0.13 mm (0.01 in) is equal to the amount of shims
necessary.
LME/10880897/January 30, 2011/en
18. Install the shim pack (4).

19. Install the retainer plates (3), new O-rings (13), and washers (2).
20. Lubricate the screws (1) with anti seize and install.
21. Torque the capscrews (1) to the specified torque shown in the torque
specification table. [Reference: Torque Specification Table]
22. Make sure that the control arms (1) and (11) move up and down
without interference.
24. Install the front suspensions.
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25. Install the front wheel assembly (complete).

area.
LME/10880897/January 30, 2011/en
531_Front Control Arms_100_01.tif

Fig. 13.11-3: Control Arms Installation
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Rear Tire and Rim Assembly
13.12 Rear Tire and Rim Assembly
08-000_000_Rear Tire and Rim.tif

Fig. 13.12-1: Rear Tire and Rim Assembly
The tires initially installed on the haul truck are 55/80-R63 E3R (41 x 63 in.
rims). For more information refer to the tire manufacturer maintenance guide
or see your local Liebherr service representative.
The weight of the tire and rim assembly is 7750 kg (17086 lb), and has a
height of 3.91 m (12.83 ft), and a width of 1.4 m (55.12 in) .
The larger tires can have a weight of 7938 kg (17500 lb).
DANGER! Fatigue fractures can occur in areas that are outside the air
chamber.
► If the air in tire is not released, the assembly can break apart when
you remove the nuts with enough force to cause injury or death.
► Make sure that you release the air from the tire before you do
maintenance.
LME/10880897/January 30, 2011/en
Fatigue fractures can occur in areas that are outside the air chamber. For
example in the lock ring groove in the rim base. This type of fatigue fracture
do not cause a decrease of air pressure in the tire, and there is no indication
of a fatigue fracture until you remove the nuts.
If the air is not released from the tire, the assembly can break apart when
you remove the nuts. The quantity of force when the assembly breaks is
enough to cause injury or death.
If you change the tire size you must change the setting in the electronic
control. See your Liebherr service representative.
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13.12.1 Rear Tire and Rim Assembly Removal
13.12.2 Setup
Safety]
► Park the haul truck on a level surface and put chocks on the tires that
are not to be removed.
13.12.3 Procedure
1. Put the jack in position at the jacking point near the tire that you
remove.
2. Lift the tire a small distance off the ground.
DANGER! Fatigue fractures can occur in areas that are outside the air
chamber and can be held together by the clamps.
► If you do not deflate the tire the assembly can break apart when you
remove the clamp nut with enough force to cause injury or death.
► Deflate the air from the tire before maintenance.
3. Remove the valve core and deflate the inboard (8) and outboard (2)
tire, as necessary, to approximately 69 kPa (10 psi) to 103 kPa (15
psi).
NOTICE
It is necessary to keep some pressure in the tire so that the bead seal does
not break.
► Keep approximately 69 kPa (10 psi) to 103 kPa (15 psi) pressure in
the tire.
4. Lift the jack until the tire is clear of the ground.
NOTICE
The minimum weight rear tire and rim assembly is 7750 kg (17086 lb).
► Use an applicable tire handler that can hold this weight. See the
instructions of the manufacturer for the correct tools.
5. Move the tire machine into position and hold the outboard tire (2).
6. Remove the inner circle of nuts (3).
LME/10880897/January 30, 2011/en
ATTENTION
The diffuser valve can be damaged during the removal of the tire and rim
assembly.
► Be careful when you remove the tire and rim assembly.
7. Remove the outboard tire and rim (2) from the wheel assembly.
8. Remove the capscrews (5), lockwashers (6), and hose guard (7).
9. Remove the nuts (9).
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ATTENTION
The valve stem and diffuser valve can be damaged during the removal of
the tire and rim assembly.
► Be careful when you remove the tire and rim assembly.
10. Remove the inboard tire and rim (8) from the wheel assembly.
If necessary to remove the rim adapter (4):

11. Remove the nuts (1) and the rim adapter (4).
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
08-100_000_Tire and Rim.tif

Fig. 13.12-2: Rear Tire and Rim Assembly Removal
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13.12.4 Tire and Rim Assembly Installation
13.12.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from the tire
and rim assembly removal.
13.12.6 Procedure
Oil N/A [Reference: Oil and Lubricant
Specifications]
1. Clean the rim and the area on the wheel where the rim and wheel
touch.
NOTICE
The minimum weight of the tire and rim assembly is 7750 kg (17086 lb).
► Dirt, dust, and unwanted material can collect on this component and
change its weight.
2. Move the inboard tire and rim (8) carefully into position.
ATTENTION
The valve stem extension and diffuser valve can be damaged during
installation of the tire and rim assembly.
► Be careful when you install the tire and rim assembly.
3. Align the valve stem with the extension hose guard, and the diffuser
valve with the notch in the wheel assembly.
4. Lubricate the threads of the nuts (9) with a small quantity of anti-seize.
5. Install the nuts (9).
6. Make sure that the rim is fully against the circumference of the wheel
LME/10880897/January 30, 2011/en
and gradually tighten all the nuts (9).

7. Tighten the nuts (9) to 1850 N m (1364 lbf ft).
8. Align the extension hose for the valve stem of the inboard tire in
position between the mounting brackets for the hose guard.
9. Install the hose guard (7), capscrews (5), and lockwashers (6).
If the rim adapter (4) is removed,

11. Align the slot of the rim adapter (4) with the extension hose from the
inboard tire and rim (8), and do as follows:
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– Lubricate the threads of the nuts (3) with a small quantity of anti-
seize.
– Install the rim adapter (4).
– Install the nuts (3).
– Tighten the nuts (3) to 1850 N m (1364 lbf ft).
ATTENTION
The extension hose for the valve stem of the inboard rim and the diffuser
valve for the outboard rim can be damaged during installation of the tire and
rim assembly.
► Be careful when you install the outboard tire and rim assembly.
12. Align the diffuser valve of the outboard rim with the adapter slot
opposite the slot for the extension hose for the valve stem of the
inboard rim.
13. Move the outboard tire and rim (2) into position.
14. Put the extension hose for the valve stem of the inboard rim through
the clearance hole of the outboard rim.
15. Lubricate the threads of the nuts (1) with a small quantity of anti-seize.
16. Install the nuts (1).
17. Make sure that the rim is fully against the circumference of the wheel
and gradually tighten the nuts (1).
18. Tighten the nuts (1) to 1850 N m (1364 lbf ft).
19. Refer to the recommendations of the tire manufacturer for proper tire
maintenance and inflation.
WARNING! A tire that blows apart can cause damage to equipment and
injury to personnel.
► Do not stand near a tire when it is inflated. Always use a clip-on air
chuck with remote controls. Use a safety cage if the unit is removed
from the hauler.
20. Inflate the tires.
WARNING! Movement of the haul truck with a load can cause the rim nuts
to loosen.
► It is necessary that you tighten the rim nuts again after the haul truck
does one load.
21. Make sure that the next operation of the haul truck is not longer than
one hour and then tighten all the nuts (1), (3), and (9) to 1850 N m
(1364 lbf ft).
22. Repeat the previous step three to four times, or until all the nuts keep
a torque value of 1850 N m (1364 lbf ft).
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 13.12-3: Tire and Rim Installation
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13.12.7 Rear Tire Studs Replacement
13.12.8 Setup
Safety]
► Remove the rear tire and rim assembly.
13.12.9 Procedure
Loctite, medium duty N/A Commercially available
To replace the rim adapter studs, do this procedure:

1. Push out the applicable stud (1) and discard the stud.
2. Push the new stud (1) into the rim adapter.
To replace the rear inboard studs, do this procedure:

3. Push out the applicable stud (2) and discard the stud.
4. Push the new stud (2) into the mounting flange on the rear wheel
assembly.
To replace the rear inboard bolts, do this procedure:

5. Loosen and remove the bolts (3), and discard the bolts.
6. Apply a medium duty Loctite to the bolts (3), and install the bolts.
7. Tighten the bolts (3) to 922 N m (680 lbf ft). LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en

Fig. 13.12-4: Rear Tire Studs Replacement
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Rear Brakes
13.13 Rear Brakes
08-000_000_01_Rear Brakes.tif
Fig. 13.13-1: Rear Brakes
The rear brake assembly is installed on this component:

• Rear Disc Brake Hub
The rear brake assembly has the components that follow:

• Brake Calipers
• Brake Discs
The rear brakes are a two disc assembly. Each of the discs has one service
brake caliper and one hand brake caliper. The calipers are attached to the
traction motor assembly. The discs are installed on the disc brake hub. The
disc brake hub is installed on the inboard end of the armature shaft of the
traction motor inside the axle box.
When the armature shaft of the traction motor turns, the discs turn. When
you apply the brakes the calipers close against the discs to help to stop the
haul truck.
LME/10880897/January 30, 2011/en
The brakes operate with hydraulic oil and the rear brake accumulators
supply hydraulic pressure to the calipers.
It is necessary to burnish the rear brakes if you have these conditions:

• You install a new brake disc
• You install a new brake lining
• The brake lining or brake disc has contamination.
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Rear Brakes
The brake linings adjust to the correct position and the contamination is
removed from the brake linings and discs when you burnish the brakes. It
is necessary to burnish the brakes to make sure that the full brake
performance is available. A disc temperature of 205 ºC (401 ºF) is necessary
to burn off the unwanted material from the linings and discs. The service
brake transmits the heat from the brake disc to the linings and calipers when
you apply the service brake.
The rear brakes can be removed only in pieces and not as a unit.
Use only Liebherr recommended hydraulic oil. Do not use oil that contains
additives harmful to Buna-N (Nitrile) and neoprene rubber compounds. Do
not put automotive type brake fluid in Liebherr haul trucks.
LME/10880897/January 30, 2011/en
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Rear Brakes
13.13.1 Rear Brakes Removal
13.13.2 Setup
Safety]
► Bleed the brake system.
► To remove the brake discs, you must remove the park brakes.
► Open the access panel on the axle box.
13.13.3 Procedure

1. Bleed the oil from the bleeder valves (17) on the calipers. The upper
brake caliper has bleeder valves in the top of the caliper. The lower
brake caliper has the bleeder valves (20) located on the rear of the
caliper half.
2. Disconnect the hydraulic supply (18) and jumper lines (19) and install
protective covers.
NOTICE
The weight of the caliper is 42 kg (93 lb).
3. Remove two of the capscrews (7) and washers (6) and install two
temporary alignment studs 350 mm (13.78 in) long.
4. Hold the inboard piece of the inboard caliper (5) with an applicable lift
device.
5. Remove the remaining capscrews (7) and washers (6).
ATTENTION
The brake lining can fall when you remove the caliper piece.
► Do not let the brake lining fall.
6. Carefully move the inboard caliper piece of the inboard caliper (5) off
the alignment studs.
LME/10880897/January 30, 2011/en
NOTICE
The weight of the brake disc is 127 kg (280 lb).
7. Securely hold the inboard brake disc (8).
9. Remove the inboard brake disc (8).
10. Securely hold the outboard caliper piece of the inboard caliper (5).
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Rear Brakes
11. Remove the outboard caliper piece of the inboard caliper (5) and the
shims (3).
12. Remove the capscrews (11) and the disc adapter (4).
13. Remove two of the capscrews (12) and washers (13) and install two
temporary alignment studs 350 mm (13.78 in) long.
14. Hold the inboard piece of the outboard caliper (5) with an applicable
lift device.
15. Remove the remaining capscrews (12), the washers (13), and the
adapter (14).
ATTENTION
The brake lining can fall when you remove the caliper piece.
► Do not let the brake lining fall.
16. Carefully move the inboard caliper piece of the outboard caliper (5) off
the alignment studs.
17. Securely hold the outboard brake disc (8).
19. Remove the outboard brake disc (8).
20. Remove the outboard caliper piece of the outboard caliper (5) and the
shims (3).
21. Remove the temporary alignment studs.
If access to the traction motor is necessary, do this procedure to

remove the remaining parts:
22. Remove the capscrews (1) and (15) and the adapters (2) and (16).
23. Inspect the brake lining.
24. Inspect the brake disc.
LME/10880897/January 30, 2011/en
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Rear Brakes
LME/10880897/January 30, 2011/en
08-100_000_01_Rear Brakes Removal.tif

Fig. 13.13-2: Rear Brakes Removal
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Rear Brakes
13.13.4 Rear Brakes Installation
13.13.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration as the rear
brakes removal. [Reference: Rear Brakes Removal]
13.13.6 Procedure
1. If the end plates need to be installed, apply Loctite® 271 threadlocker
or equivalent to the threads of the end plate bolts (apply several drops
to the three end threads on each bolt and apply several drops down
one side of each female threaded hole). Tighten the bolts to 515 N m
(380 lbf ft) to 624 N m (460 lbf ft).
3. Install the adapter (16) and capscrews (15).
NOTICE
The weight of the brake disc is 127 kg (280 lb).
5. Install the outboard brake disc (8).
7. Install four of the capscrews (10) and washers (9) at every 90 degrees.
8. Measure the dimension (X) from the inboard face of the lower adapter
(16) to the inboard face of the disc (8).
9. Shim thickness is equal to (X) subtract 152 mm (5.98 in)±15 mm (0.59
in).
10. Remove the capscrews (10), washers (9), and the disc (8).
LME/10880897/January 30, 2011/en
11. Install the applicable shims (3).

12. Install two alignment studs in the location for the capscrews (12) for
the outboard caliper (5).
NOTICE
The weight of the caliper is 42 kg (93 lb).
NOTICE
The two calipers are different.
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Rear Brakes
► Make sure you install the correct caliper in the correct position and
location.
13. Install the outboard caliper piece of the outboard caliper (5) on the
alignment studs.
14. Install the outboard brake disc (8).
15. Install the capscrews (10) and the washers (9).
17. Install the inboard caliper piece of the outboard caliper (5) on the
alignment studs.
19. Install the adapter (2) and the capscrews (1).
20. Install shims (3) to center the adapter (2) over the disc (8) to 0.25 mm
(0.01 in).
23. Install the park brake adapter (14) and four of the capscrews (12) and
washers (13).
25. Install the disc adapter (4) and capscrews (11).
27. Install the inboard brake disc (8).
28. Install four of the capscrews (10) and washers (9) at every 90 degrees.
29. Measure the dimension (Y) from the inboard face of the caliper adapter
(2) to the inboard face of the disc (8).
30. Shim thickness is equal to (Y) subtract 152 mm (5.98 in)±15 mm (0.59
in).
31. Remove the capscrews (10), washers (9), and the disc (8).
32. Install the applicable shims (3).
33. Install two alignment studs in the location for the capscrews (7) for the
inboard caliper (5).
34. Install the outboard caliper half of the inboard caliper (5) on the
alignment studs.
35. Install the inboard brake disc (8).
37. Install the capscrews (10) and the washers (9).
39. Install the inboard caliper half of the inboard caliper (5).
41. Install four of the capscrews (7) and washers (6).
42. Remove the alignment studs and lubricate and install the capscrews
LME/10880897/January 30, 2011/en
(7) and washers (6) that remain.

44. Install shims (3) to center the adapter (14) over the disc (8) to 0.25 mm
(0.01 in).
46. Remove the alignment studs and install all the capscrews (12) and
washers (13).
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Rear Brakes

48. Remove the protective covers and connect the hydraulic supply (18)
and jumper lines (19).
49. Tighten the bleeder valves (17) to 11 N m (8 lbf ft) to 20 N m (15 lbf
ft).
50. If applicable, install the park brakes.
52. Close the access panel on the axle box.
53. If you install a new brake disc or brake lining, burnish the brakes.
LME/10880897/January 30, 2011/en
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Rear Brakes
LME/10880897/January 30, 2011/en

Fig. 13.13-3: Rear Brakes Installation (Page 1 of 2)
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Rear Brakes
LME/10880897/January 30, 2011/en

Fig. 13.13-4: Rear Brakes Installation (Page 2 of 2)
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Rear Brakes
13.13.7 Rear Brake Bleed
13.13.8 Setup
Safety]
► Make sure that all of the hydraulic connections and fittings are correctly
tightened.
► Two maintenance personnel are necessary to do the bleed procedure.
13.13.9 Procedure

1. Loosen the highest bleeder screw on the park brakes.
WARNING! It is necessary that the brake linings and discs are clean and
free from contamination to operate correctly.
► Do not get brake fluid on the brake linings or discs.
2. Put a small rubber tube on the bleed screws to point the fluid away
from the brakes and into an applicable container.
4. Apply and release the park brake to pressurize the park brake.
WARNING! Air in the system can prevent the correct operation of the
brakes.
Incorrect brake function can cause personal injury or damage to equipment.
► Make sure that there is no air in the brake system.
7. Loosen the highest bleeder screw on the service brake calipers.
8. Put a small rubber tube on the bleed valves to point the fluid away from
the brakes.
LME/10880897/January 30, 2011/en
9. Apply the service brakes to bleed all the air from the brakes.
WARNING! Air in the system can prevent the correct operation of the
brakes.
Incorrect brake function can cause personal injury or damage to equipment.
► Remove all air from the brake system.
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Rear Brakes
12. Apply the park brake and at the same time fully apply the service
brakes.
This will automatically supply the correct adjustment and setup the parking
brake.
13. Make sure that there are no hydraulic leaks.
14. Correctly discard all the hydraulic fluid collected from the bleed
procedure. Follow the environmental regulations.
15. Make sure that the brake and steering hydraulic tank is at a serviceable
level.
13.13.10 Rear Brake Burnish
13.13.11 Setup
Safety]
WARNING! Disc brake components can become very hot and cause a fire
or injury to personnel.
► Be very careful when you do work around the brakes. Make sure that
four to six fire extinguishers are available.
► Follow the applicable haul truck safety precautions .
► Make sure that the axle box is free of unwanted material, oil, and dirt.
► Make sure that all the brakes operate correctly and the system
pressure is correct.
► Move the haul truck to a safe area.
13.13.12 Procedure
1. Drive the haul truck 12.87 km/h (8 mph) to 24.14 for approximately
135 m (442.91 ft) and at the same time apply the service brakes at
30-50% effort.
2. Press the override switch on the dump control lever during the time
the service brake is applied.
3. Stop the haul truck and measure the temperature of the disc.
4. Monitor the rear brakes.
If the disc temperature is less than 205 ºC (401 ºF),

LME/10880897/January 30, 2011/en
5. Repeat the procedure.
If the disc temperature is equal to or more than 205 ºC (401 ºF),

6. Let the disc to become cool to 125 ºC (257 ºF).
7. Put the haul truck on a level surface.
8. Release the service and park brakes and repeat the procedure one
time.
9. Inspect for leaks or other unsatisfactory conditions.
area.
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Rear Disc Brake Hub
13.14 Rear Disc Brake Hub
08-000_000_01_Rear Disc Brake Hub.tif

Fig. 13.14-1: Rear Disc Brake Hub
The rear disc brake hub connects to this assembly:

• Rear Brakes
The rear disc brake hub is installed on the shaft of the rear traction motor.
The rear disc brake hub turns when the traction motor shaft turns. The rear
brake discs are attached to the brake hub and turn when the motor shaft
turns.
LME/10880897/January 30, 2011/en
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Rear Disc Brake Hub
13.14.1 Rear Disc Brake Hub Removal
13.14.2 Setup
Safety]
► Remove the rear brakes.
13.14.3 Procedure
Rear Brake Disc Hub Puller T-504-A [Reference: Service Tools]
1. Remove the capscrews (3) and washer (4).
2. Remove the capscrews (5), lockwashers (6), and cap plate (2).
NOTICE
The weight of the hub is 75 kg (165 lb).
3. Use the disc brake hub puller tool Liebherr P/N T-504-A .
4. Install six Grade 8 rods with a thread, at equally space, in the hub (1).
5. Make sure that you install the rods with a thread a minimum of 25 mm
(0.98 in) deep into the hub (1).
6. Install the mount puller plate onto the rods with a thread.
7. Install the 3/4-10 inch nuts onto the rods with a thread.
8. Install a 30 ton hydraulic ram between the traction motor shaft and the
puller plate.
9. Make sure that the ram base is clear of the hub (1).
10. Evenly tighten the nuts until the puller plate is against the hydraulic
ram.
11. Apply pressure with the ram while you apply heat, quickly and equally,
to the hub (1).
ATTENTION
If the motor shaft becomes hot, it expands and prevents the removal of the
LME/10880897/January 30, 2011/en
brake hub.
► Apply heat quickly to the brake hub and make sure that the motor shaft
does not become hot.
If the motor shaft becomes hot and expands,

12. Let the motor shaft and brake hub become cool and then do the
procedure again.
13. Increase the pressure with the ram until the hub (1) breaks free.
14. Examine the hub (1) and replace it if there is a damage to the hub.
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Rear Disc Brake Hub
08-1--_000_01_Rear Disc Brake Hub.tif

LME/10880897/January 30, 2011/en
Fig. 13.14-2: Rear Disc Brake Hub Removal (Page 1 of 2)
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Rear Disc Brake Hub

LME/10880897/January 30, 2011/en
Fig. 13.14-3: Rear Disc Brake Hub Removal (Page 2 of 2)
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Rear Disc Brake Hub
13.14.4 Rear Brake Disc Hub Installation
13.14.5 Setup
Safety]
disc brake hub removal.
13.14.6 Procedure
Anti-seize compound 5080-B [Reference: Oil and Lubricant
Specifications]
1. Clean and examine the traction motor shaft.
2. Apply anti-seize compound to the motor shaft.
WARNING! Parts that are hot can burn your skin if you touch the hot part
directly.
► Make sure that you put on protective clothing and hand protection
when you work with high temperatures.
3. Evenly apply heat to the disc brake hub (1) to 175 ºC (347 ºF).
NOTICE
The weight of the hub is 75 kg (165 lb).
4. Install the hub (1) onto the traction motor shaft.
5. Make sure that the hub (1) is flush with the traction motor shaft.
7. Install the cap plate (2), lockwashers (6), and capscrews (5).
LME/10880897/January 30, 2011/en

12. Install the rear brakes.
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Rear Disc Brake Hub

LME/10880897/January 30, 2011/en
Fig. 13.14-4: Rear Disc Brake Hub Installation (Page 1 of 2)
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Rear Disc Brake Hub

LME/10880897/January 30, 2011/en
Fig. 13.14-5: Rear Disc Brake Hub Installation (Page 2 of 2)
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Park Brake (Carlisle)
13.15 Park Brake (Carlisle)
08-000_000_01_Park Brake Carlisle.tif

Fig. 13.15-1: Park Brake (Carlisle)
The park brake is in the axle box. There is one park brake caliper attached
to each of the rear brake discs. Access to the park brake is through the axle
box access panel or when the rear wheel assembly is removed.
The park brake caliper has these components:

• Lining and Carrier Assembly
• Cap
• Springs
• Pistons
• Backup rings
• Packings
• Bleeder Valve
• Piston Housings
The park brake engages with a spring and disengages by hydraulics. The
park brake caliper has two pieces. Each piece of the brake caliper has a
LME/10880897/January 30, 2011/en
spring loaded piston. The spring loaded piston is installed in the caliper bore
and is held there by a cap. The cap attaches to the caliper with screws and
washers. The lining and carrier assembly attaches to the piston with screws.
Epoxy adhesive is applied to the threads to lock the screws in place.
Packings and backup rings are seated in the grooves in the caliper bores.
The packing and backup rings supply a seal to prevent hydraulic fluid leaks.
A bleeder screw is installed in two of the three inlet ports located on the ends
of the caliper. The bleeder screws and the inlet fluid line connection are
interchangeable between all three inlet ports.
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The park brake must be applied in order for the engine to start.
With the master switch in the ON position, the park brake switch in the OFF
position and the brake system fully pressurized, the park brake is in the
release mode.
With the master switch in the ON position, the park brake switch in the ON
position and the brake system fully pressurized, oil pressure is released from
the pressure chamber of the park brake. The springs are no longer
contained and the park brakes are set.
With the master switch in the OFF position, hydraulic pressure is released
from the pressure chamber of the park brake and the park brakes are set
with the springs.
The park brake mechanically engages when the pressure in the brake
system decreases below the necessary level. If you must move the haul
truck after the brake pressure decreases, you must mechanically release
the park brake.
IF the hydraulic pressure decreases the parking brake will not engage.
There is a check valve in the circuit to prevent loss of pressure in the parking
brake.
LME/10880897/January 30, 2011/en
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13.15.1 Park Brake (Carlisle) Removal
13.15.2 Setup
Safety]
13.15.3 Procedure

1. Disconnect the hydraulic supply lines (4) and install protective covers.
NOTICE
The weight of the park brake caliper is 48 kg (106 lb).
2. Remove the capscrews (2), washers (1), calipers (3), and shims (5).
3. Inspect the brake disc.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
Fig. 13.15-2: Park Brake (Carlisle) Removal (Page 1 of 2)
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LME/10880897/January 30, 2011/en
Fig. 13.15-3: Park Brake (Carlisle) Removal (Page 2 of 2)
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13.15.4 Park Brake (Carlisle) Installation
13.15.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from the park
brake (Carlisle) removal.
13.15.6 Procedure
1. Connect the hydraulic supply lines (4) to the ports with a thread of the
two piston housings.
2. Pressurize the hydraulic supply lines (4) to 103 bar (1494 psi) to 207
bar (3002 psi)to retract the pistons.
3. Keep the hydraulic supply lines (4) pressurized during the installation.
NOTICE
The weight of the park brake caliper is 48 kg (106 lb).
4. Install the calipers (3), capscrews (2), and washers (1).
5. Install three shims (4) between the adapter and caliper on the two
sides.
6. Measure the distance between the carrier lining assembly to the brake
disc.
7. Add or remove shims (4) to supply 0.5 mm (0.02 in) to 1.25 mm (0.05
in)between the carrier lining assembly and the disc.
8. Tighten the capscrews (2) to 515 N m (380 lbf ft) to 530 N m (391 lbf
ft).
9. Measure the distance between the carrier lining assembly to the brake
disc.
10. Add or remove shims (5) to supply 0.5 mm (0.02 in) to 1.25 mm (0.05
in)between the carrier lining assembly and the disc.
12. Close the access panel on the axle box.
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
Fig. 13.15-4: Park Brake (Carlisle) Installation (Page 1 of 2)
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LME/10880897/January 30, 2011/en
Fig. 13.15-5: Park Brake (Carlisle) Installation (Page 2 of 2)
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Mechanical Release of the Park Brake
13.16 Mechanical Release of the Park Brake
13.16.1 Setup
Safety]
13.16.2 Procedure
1. Gradually loosen all of the capscrews (1) one turn at a time until the
lining and carrier is free from the disc.
You can tow the haul truck.

2. Gradually tighten all of the capscrews (1) one turn at a time.
13.16.3 Closeout
► Start the engine of the haul truck to pressurize the hydraulic supply
lines to the park brake.
After the hydraulic system is repaired and hydraulic pressure is back,

do this procedure:
► Start the engine of the haul truck to pressurize the hydraulic supply
lines to the park brake.
► Tighten the capscrews (1) to 515 N m (380 lbf ft) to 530 N m (391 lbf
ft).
► Stop the engine and apply the hand and park brakes.
► Close the access panel on the axle box.
► Remove all tools, equipment, and unwanted materials from the work
area.
LME/10880897/January 30, 2011/en
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08-300_000_01_Park Brake Mechanical Release.tif

LME/10880897/January 30, 2011/en
Fig. 13.16-1: Mechanical Release of the Park Brake
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08-300_000_02_Park Brake Mechanical Release.tif

LME/10880897/January 30, 2011/en
Fig. 13.16-2: Mechanical Release of the Park Brake
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LME/10880897/January 30, 2011/en
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Service Manual Frame, Dump Body and Structures
14 Frame, Dump Body and Structures 629

14.1 Frame 631
14.1.1 Frame Welding and Repairs 631
14.2 Dump Body 632
14.2.1 Dump Body Welding and Repairs 632
14.2.2 Dump Body Removal 633
14.2.5 Dump Body Installation and Alignment 635
14.2.9 Dump Body Guides Installation and Alignment 638
14.2.12 Dump Body Lift or Lower for Service (Hydraulically) 641
14.2.15 Dump Body Lift or Lower for Service (Manually) 642
14.3 Dump Body Pivot Pins 643
14.3.1 Dump Body Pivot Pins and Bearing Removal 644
14.3.4 Dump Body Pivot Pins and Bearing Installation and
Alignment 646
14.4 Dump Body Pads 649
14.4.1 Dump Body Pads Removal 650
14.4.4 Dump Body Pads Installation 652
14.5 Rock Knocker 655
14.5.1 Rock Knocker Removal 656
14.5.4 Rock Knocker Installation 658
14.6 Superstructure 660
14.7 Hood and Grill 661
14.7.1 Hood Removal 661
14.7.4 Hood Installation 661
14.7.7 Grill Removal 665
LME/10880897/January 30, 2011/en
14.7.10 Grill Installation 669

14.8 Battery Boxes 674
14.8.1 Battery Boxes Removal 674
14.8.4 Battery Boxes Installation 675
14.9 Axle Box 678
14.9.1 Axle Box: Rear Door Removal 679
14.9.4 Axle Box: Rear Door Installation 680
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Frame, Dump Body and Structures Service Manual
14.9.7 Axle Box: Front Door Removal 681

14.9.10 Axle Box: Front Door Installation 683
14.10 Drag Links 685
14.10.1 Drag Links Removal 686
14.10.4 Drag Links Installation 688
14.11 Rear Control A-Arm (Rear Control Arm Axle Box) 690
14.11.1 Rear Control A-Arm Removal 691
14.11.4 Rear Control A-Arm Installation 693
LME/10880897/January 30, 2011/en
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Frame
14.1 Frame
09-000_000_531_02_Frame.tif
Fig. 14.1-1: Frame
The frame is transmits the weight of the dump body to the wheels through
the suspensions and the axle box.
The frame is the primary support for the components that follow:
• [Reference: Dump Body]
• [Reference: Superstructure]
• Front Control Arms Pivot with Bushings
• [Reference: Fuel], and [Reference: Hydraulic Tank]
• [Reference: Front Suspensions]
• [Reference: Drag Links]
• [Reference: Rear Control A-Arm]
14.1.1 Frame Welding and Repairs

LME/10880897/January 30, 2011/en
The A-710 steel on the frame is readily weldable. Before you do any repairs
to the frame, refer to the Welding Procedures shown in this manual. The
maintenance and service of the frame includes scheduled inspections, for
cracks and structural damage. Refer to the Preventive Maintenance
Schedule to know the specified intervals for the frame and weld structure
inspections.
• [Reference: Welding Procedures]
• [Reference: Preventive Maintenance Master Schedule]
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Dump Body
14.2 Dump Body
09-000_000_Dump Body.tif
Fig. 14.2-1: Dump Body
The dump body is assembled from A-656 alloy steel. The dump body has a
flat floor plate and a front vertical plate. To prevent the dump body from
damage during load operations, the front plate is installed at a 90-degree
angle to the floor.
The dump body has the components that follow:

• [Reference: Dump Body Pivot Pins]
• [Reference: Dump Body Pads]
• [Reference: Rock Knockers]
• cylinder mounts
The dump body is attached to the frame with dump body pivot pins. The
dump body lifts and rotates on the dump body pivot pins when the dump
cylinders extend. After the dump cylinders retract and the dump body is in
the lowered position, the dump body rests on the dump body pads on the
frame.
LME/10880897/January 30, 2011/en
14.2.1 Dump Body Welding and Repairs

Without specified welding information from the dump body OEM, follow the
recommended welding specifications shown in this manual with the site
requirements for personal protective equipment, the haul truck isolation
procedures, work permits and vehicle safety regulations.
• [Reference: Preventive Maintenance Master Schedule]
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Dump Body
14.2.2 Dump Body Removal
14.2.3 Setup
► Follow the haul truck safety precautions.[Reference: Haul Truck
Safety]
► If necessary, remove the dump body exhaust.

Lift devices and supports, for N/A See applicable weight warnings
example, overhead hoist, crane(s)
14.2.4 Procedure
NOTICE
The minimum weight of the dump body is 42000 kg (92594 lb).
► Unwanted material can collect on this component and change its
weight.
1. Use the engine power to lift the front of the dump body approximately
300 mm (11.81 in) above the frame.
Put safety blocks between the top fame rails and the dump body beam
runners.
2. Use the FLOAT function to lower the dump body to the safety blocks.
3. Manually activate the proximity switch to put the dump body lever to
the FLOAT position. (This action can make the upper pins of the dump
cylinders easier to remove).
4. Make sure all hydraulic pressure is released.
5. Disconnect all wires and grease lines from the dump body.
6. Install protective caps on the grease lines.
7. Attach the overhead hoist or crane(s) to the lift points (1) on the dump
body.
8. Increase the tension on the cables of the overhead hoist or crane(s).
LME/10880897/January 30, 2011/en
9. Remove the dump body pivot pints.

10. Carefully lift the dump body from the haul truck.
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Dump Body
13-100-B_Rev000.tif
Fig. 14.2-2: Dump Body Removal
LME/10880897/January 30, 2011/en
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Dump Body
14.2.5 Dump Body Installation and Alignment
14.2.6 Setup
Safety]
► Make sure that the haul truck is in the same configuration from dump
body removal procedure. [Reference: Dump Body Removal]

10 Capacity Hydraulic Cylinder N/A Commercially available
14.2.7 Dump Body Installation

NOTICE
weight.
1. Remove the dump body pads. [Reference: Ref: Dump Body Pads
Removal]
2. Align the rear pivot pin ports and install the dump body pins.
3. Slowly lower the dump body while you align the dump cylinders.
4. Use the Fixture Dump Cylinder Extend Tool and an applicable
hydraulic cylinder to extend the dump cylinder enough to align the
holes. [Reference: Service Tools]
CAUTION! The cylinder extension tools are not strong enough to hold the
weight of the dump body.
► Use the Fixture Dump Cylinder Extend Tool and the hydraulic cylinder
only to extend the dump cylinders.
LME/10880897/January 30, 2011/en
5. Install the dump cylinder upper pins.
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Dump Body
14.2.8 Dump Body Alignment

1. Slowly lower the dump body (1).
2. Monitor the toes of the dump body main beams to make sure the dump
cylinders stop at the same time. When you monitor the toes of the
dump body main beams, you get a better visual to see if the two dump
cylinders stop at the same time.
NOTICE
The two dump cylinders must stop to retract at the same time.
► When the two dump cylinders do not stop to retract together, incorrect
alignment of the dump body guides, pads, and pivot pins can occur.
► If the dump cylinders do not stop at the same time, see your Liebherr
Service Specialist before you continue this procedure.
3. Align the toes of the dump body main beams with the main frame rails.
If the toes are not exactly in line with the main frame rails:
• Make sure the overhang is equal on all sides.
• Make sure the overhang is square and within 6.35 mm
(0.25 in).
The dump body guides and the pivot pin shim stacks are removable. If you
cannot align the toes of the dump body main beams with the main frame
rails,
• Remove the dump body guides and the pivot pin shim
stacks.
4. Align the pivot pins.
5. Align the dump body guides.
6. Install the dump body pads.
7. Install the dump body exhaust if it was removed.
LME/10880897/January 30, 2011/en
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Dump Body
13-100-B_Rev000.tif
Fig. 14.2-3: Dump Body Installation and Alignment
LME/10880897/January 30, 2011/en
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Dump Body
14.2.9 Dump Body Guides Installation and Alignment
14.2.10 Setup
Safety]
► Make sure the dump body installation is complete.
► Make sure the dump body pivot pins and bearings installation is
complete.
► Lower the dump body completely. , or
14.2.11 Procedure
NOTICE
weight.
1. Measure the "X" dimensions on both sides of the haul truck.
The "X" measurement is from the frame wear plates and the dump body
guides.
All measurements must be accurate to:
3 mm (0.12 in)
2. Make sure that each of the "X" dimensions is equal to:
10 mm (0.39 in) ± 3 mm (0.12 in)
If the X dimensions are not equal to:
10 mm (0.39 in) ± 3 mm (0.12 in)
3. Calculate the total thickness of the spacers necessary to decrease the

LME/10880897/January 30, 2011/en
X dimensions to:
10 mm (0.39 in) ± 3 mm (0.12 in)
4. Weld the four areas with the necessary amount of dump body guide
shim plates to the frame to decrease the dimension D to 10 mm (0.39
in) ± 3 mm (0.12 in)
5. Follow the welding symbol (8) (WP-G880725-2, 4X) to weld the
necessary amount of spacers (1), (2), (3), (4), and (5).
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Dump Body
NOTICE
The spacers have different thicknesses.
► Weld the thickest spacer next to the frame wear plates and the
thinnest spacers next to the dump body guides.
6. Do a quality check to make sure the spacers are welded correctly. The
spacers must be level at the top and the sides of the dump body.
7. Install the dump body pivot pins, and locknuts.
LME/10880897/January 30, 2011/en
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Dump Body
LME/10880897/January 30, 2011/en
09-200-300_000_Dump Body Guides.tif

Fig. 14.2-4: Dump Body Removal
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Dump Body
14.2.12 Dump Body Lift or Lower for Service

(Hydraulically)
14.2.13 Setup
Safety]
14.2.14 Procedure
WARNING! The dump system remains under pressure when the dump
body is raised even if the engine is not in operation.
► Make sure the two safety cables or bars are anchored.
1. Move or lift the dump body to decrease the tension in the safety bars
or cables.
2. Remove the safety bars or cables from the anchors.
4. Put the dump control lever to the DOWN position and fully lower the
dump body.
5. Stop the engine.
LME/10880897/January 30, 2011/en
13-500-B_000_Rev000.tif
Fig. 14.2-5: Dump Body Lowered After Maintenance
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Dump Body
14.2.15 Dump Body Lift or Lower for Service (Manually)
14.2.16 Setup
Safety]
► If the engine power is not available, use this procedure to lower the
dump body.
14.2.17 Procedure
WARNING! The dump system remains under pressure when the dump
body is raised even if the engine is not in operation.
► Make sure the two safety cables or bars are anchored.
1. Make one or two turns to loosen the jam nut (1).

2. Attach an Allen wrench to the end of the adjustment screw (2) and
slowly turn the adjustment screw (2) left. The dump body lowers as the
flow is released.
3. To stop the dump body lower movement, turn the adjustment screw
(2) right.
4. When the dump body is lowered completely, turn the adjustment screw
(2) and to tighten the top nut (1).
LME/10880897/January 30, 2011/en
13-505-B_Rev000.tif
Fig. 14.2-6: Dump Body Manual Bypass Valve
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Dump Body Pivot Pins
14.3 Dump Body Pivot Pins
09-000_000_Dump Body Pivot Pins.tif

Fig. 14.3-1: Dump Body Pivot Pins
There are two dump body pivot pins on the haul truck. The dump body pivot
pins are installed on the frame through the rails of the frame.
The pivot pins supply the pivot points for the dump body. The dump body
pivot pins turn against the bearing sleeves and not the frame. Because the
bearing sleeves can absorb the wear, the bearing sleeves are replacement
parts.
LME/10880897/January 30, 2011/en
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14.3.1 Dump Body Pivot Pins and Bearing Removal
14.3.2 Setup
Safety]
► Disconnect the top of the dump cylinder, if necessary.
14.3.3 Procedure
Lift devices and supports, for N/A See applicable weight warnings.
Hydraulic puller N/A
NOTICE
► Unwanted material can increase the weight of the dump body.
1. Attach an applicable lift device that can safely lift and support the
weight of dump body.
2. Remove the lubrication hoses and install protective caps on the hoses
and open ports.
NOTICE
The weight of each pivot pin is 88 kg (194 lb).
3. Lift the rear of the dump body until all the weight is removed from the
pivot pins.
4. Remove the retaining capscrew and locknut from both pins.
5. Move the dump body pivot pin toward the outside of the frame.
NOTE: Each dump body pivot pin has a threaded puller hole (1 1/2"-6 NC).
LME/10880897/January 30, 2011/en
6. Lift the dump body until the pivots are clear from the bearing area.
7. Install safety bars, cables, or applicable supports strong enough to
hold the weight of the rear of the dump body.
8. Lower the dump body to the safety supports.
9. Remove the dump body pivot bearing with a hydraulic puller.
10. Remove the dump body pivot pin bearing spacer.
11. Examine each dump body pivot pin bearing. Reference the wear limits
shown in the recommended maximum wear limits table.
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12. If the dump body pivot pin or the dump body pivot pin bearing show
wear or damage, replace the items.
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14.3.4 Dump Body Pivot Pins and Bearing Installation

and Alignment
Safety]
► Make sure the haul truck is in the same configuration as the dump body
pivot pins and bearing removal procedure.
14.3.5 Installation
NOTICE
► Unwanted material can increase the weight of the dump body.
the minimum weight.
1. Clean the bores on the frame.
2. Make sure that the bores for the dump body pivot pin are clean and
smooth.
3. Make sure that the new bearing sleeves (1) are clean and smooth.
LME/10880897/January 30, 2011/en
13-200-B1_Rev000.tif
4. Measure the dimension (X) of the outside diameter of the new bearing
sleeve (1).
5. Measure the dimension (Y) of the inside diameter of the bore ports.
6. Make sure that (X) is larger than (Y).
DANGER! Liquid nitrogen can cause injury!
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► Always make sure you put on approved protective equipment when

do procedures that include liquid nitrogen.
7. Freeze the bearing sleeves (1).
8. Install the bearing sleeves (1) and spacer (7) into bores.
9. Move the safety supports as necessary and lower the dump body until
you align the pivot pin holes.
10. Make sure the two safety supports are between the top frame rails and
the dump body beam runners.
NOTICE
The minimum weight of the pivot pin is 19 kg (42 lb).
the minimum weight.
14.3.6 Alignment (Shim)

1. Remove the dump body pads from the frame.
2. Lower the dump body while you monitor the toe, or front tip, of the
dump body beams.
NOTICE
The two main beam toes must stop at the same time while the hoist
cylinders reach the low point.
► If one main beam toe stops and the other main beam continues
to drop, immediately contact the Liebherr service person before
you continue this procedure.
3. Center the dump body left to right so that the front toe of the main body
rails aligns with the main frame rails. The main frame overhang must
be equal and symmetrical to the haul truck center-line on both sides
within 6 mm (0.24 in).
NOTICE
The haul truck has removable pivot pin shim stacks and dump body guides.
► The removal of the pivot pin shim stacks and the dump body
guides can be necessary to get the necessary measurements.
4. When you have the dump body aligned with the frame, get four
measurements between each of the dump body pivot ears and the
main frame castings.
5. If any measurement you get from the previous steps are more than
1.5 mm (0.06 in), a shim pack is necessary to decrease the space to
1.5 mm (0.06 in). The minimum space for each pin is 1.5 mm (0.06
in), and the maximum is 3 mm (0.12 in).
6. Remove the main pivot pins and reinstall the same pivot pins with the
LME/10880897/January 30, 2011/en
shim packs made in the previous steps, if necessary.

7. Use the tolerances shown in the recommended wear limits table.
• Check the total space for each pin as specified in step 5
of this procedure.
• If the tolerance is not correct, repeat the necessary steps
until you get the correct tolerance.
8. Replace the capscrew (10), and locknut (4).
9. When you have the dump body aligned with the frame, get four
measurements between each of the dump body pivot ears and the
main frame castings.
copyright by
T282C-532-Y06435 to 06436 647
10. Weld the four areas with the necessary amount of the shim plates to
the frame to decrease the dimension D to 10 mm (0.39 in) ± .3 mm
(0.12 in)
If you must stack the shims, the thickest shim is to the frame, and the
thinnest shim is to the dump body pivot.
11. Install the dump body pivot pins and locknuts (4).
12. If necessary, connect the top of the dump cylinder.
LME/10880897/January 30, 2011/en
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Dump Body Pads
14.4 Dump Body Pads
09-000_000_Dump Body Pads.tif

Fig. 14.4-1: Dump Body Pads
The dump body has five dump body pads for each of its sides. The dump
body pads are installed on the frame. The dump body lowers against the
dump body pads and provides level surfaces on which the dump body can
rest. The dump body pads can absorb the vibrations, and shocks from the
dump body.
LME/10880897/January 30, 2011/en
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Dump Body Pads
14.4.1 Dump Body Pads Removal
14.4.2 Setup
Safety]
14.4.3 Procedure
NOTICE
Pads must be equal.
► Pads that are not equal can cause stress to the dump body and the
frame.
► Do not only replace the pads on one side of the frame.
► Replace the dump body pads on both sides of the frame.
1. Remove the capscrews (1), flat washers (2), and locknuts (3).
2. Remove the dump body pads (5), and (6), and the shims.
3. Replace the dump body pads.
LME/10880897/January 30, 2011/en
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Dump Body Pads
LME/10880897/January 30, 2011/en
13-200-B2_Rev000.tif
Fig. 14.4-2: Dump Body Pads Removal
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Dump Body Pads
14.4.4 Dump Body Pads Installation
14.4.5 Setup
Safety]
► The dump body is installed.
► The dump body pivot pins and bearings are installed.
► The dump body guides are installed.
► The dump body has the correct alignment.
► Make sure that the haul truck is in the same configuration from dump
body pads removal procedure.
14.4.6 Procedure
NOTICE
Pads must be equal.
► Pads that are not equal can cause stress to the dump body and the
frame.
► Do not only replace the pads on one side of the frame.
► Replace the dump body pads on both sides of the frame.
1. Measure the height of all of the dump body pads.
NOTICE
The usual thickness of the dump body pad is 44.5 mm (1.75 in).
► The shims with thicknesses of 50.8 mm (2 in) are permitted if the shim
thickness necessary below the pad is more than 6.35 mm (0.25 in).
► Remove 6.35 mm (0.25 in) of the 50.8 mm (2 in) necessary shims to
give a smooth and level surface to the adjacent 44.5 mm (1.75 in)
pads.
2. Make sure that the thickness of each pad is 44.5 mm (1.75 in).
3. Lower the dump body.
4. Measure the dimension (D) on the operator cab side.
5. Use the formula below to calculate (T) of the shims necessary below
the lowest dump body pad:
LME/10880897/January 30, 2011/en
(T) = (D) - 15.9 mm (0.63 in)
If (T) is a negative number:
Do not install shim below the lowest dump body pad.
6. Measure the dimension (F) on the operator cab side.
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Dump Body Pads
7. Use the formula below to calculate the thickness (T) of the shims
necessary below the highest dump body pad:
(T) = (F) - 30.2 mm (1.19 in)
If (F) is a negative number:
Do not install shim below the highest dump body pad.
8. Measure the dimensions (D) and (F) on the side opposite the operator
cab and calculate the thickness (T).
NOTICE
The result of the thickness (T) can be different for the two sides of the haul
truck.
► Make sure to calculate the thickness (T) correctly and install the
necessary shims on the correct side of the haul truck.
9. Record all measurements.
10. Put a straight edge across the lowest and the highest pads.
The measurements must be accurate within 1.5 mm (0.06 in).

11. Measure the dimensions between the bottom of the straight edge and
the top of the main frame rail for the other locations for the remaining
three pads.
12. Use the formula below to calculate the thickness (T) of the shims
necessary below the three remaining pads:
(T) = to the measurements - 44.5 mm (1.75 in).
13. Repeat the procedure to calculate the thickness of the shims

necessary for the side opposite the operator cab.
14. Lower the dump body.
LME/10880897/January 30, 2011/en
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Dump Body Pads
LME/10880897/January 30, 2011/en
13-200-B2_Rev000.tif
Fig. 14.4-3: Dump Body Pads Installation
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Rock Knocker
14.5 Rock Knocker
09-000_000_Rock Knockers.tif
Fig. 14.5-1: Rock Knockers
There are two rock knockers installed on the dump body. The rock knockers
are steel bars attached to the dump body above the rear wheels. The
function of each rock knocker is to remove rocks that become lodged
between the two rear tires.
LME/10880897/January 30, 2011/en
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T282C-532-Y06435 to 06436 655
Rock Knocker
14.5.1 Rock Knocker Removal
14.5.2 Setup
Safety]

Lift devices and supports N/A See applicable weight warnings
14.5.3 Procedure
NOTICE
The minimum weight of the rock knocker is 83 kg (183 lb).
weight.
1. Attach an applicable lift device that can support the weight of the rock
knockers (3).
2. Remove the cotter pins (4), washers (5), and carefully remove the rock
knocker pins (2)) from the dump body.
LME/10880897/January 30, 2011/en
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Rock Knocker
LME/10880897/January 30, 2011/en
13-100-B3_Rev000.tif
Fig. 14.5-2: Rock Knocker Removal
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Rock Knocker
14.5.4 Rock Knocker Installation
14.5.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from rock
knocker removal procedure. [Reference: Rock Knocker Removal]

Lift devices and supports N/A See applicable weight warnings
14.5.6 Procedure
NOTICE
The minimum weight of the rock knocker is 83 kg (183 lb).
► Dirt, dust, and unwanted material can collect on this component and
change its weight.
1. Attach an applicable lift device that can support the weight of the rock
knocker (3).
2. Put the rock knocker (3) in position.
3. Install the rock knocker pins (2), cotter pins (4), and washers (5).
LME/10880897/January 30, 2011/en
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Rock Knocker
LME/10880897/January 30, 2011/en
13-100-B3_Rev000.tif
Fig. 14.5-3: Rock Knocker Installation
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Superstructure
14.6 Superstructure
09-000_000_Superstructure.tif
Fig. 14.6-1: Superstructure
The superstructure is the platform installed on the top of the frame at the
front of the haul truck. The superstructure is the work platform for the
electronic control box cabinet, grid box, and access platform to the operator
cab. The superstructure is the support for many components. The
components attached to the superstructure follow:
• electronic control box
• operator cab
• grid box
• battery boxes
• ladders and handrails
• hood and grill
• engine air cleaners
LME/10880897/January 30, 2011/en
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Hood and Grill
14.7 Hood and Grill
14.7.1 Hood Removal
14.7.2 Setup
Safety]
► Remove the diagonal ladder platform, and supports, and handrails.
► Disconnect all applicable electrical wiring, and remove the ladder.
14.7.3 Procedure
NOTICE
► Use an applicable device that can safely lift this weight.
1. Attach an approved lift that can support the weight of the hood.
2. Remove the capscrews (6), flat washers (5), and lockwashers (4) from
the grill.
3. Remove the capscrews (10), locknuts (7), and flat washers (6) from
the superstructure.
4. Remove the capscrews (3), washers (9), and lockwashers (8) from the
superstructure crossmember.
5. Carefully lift the hood from the grill and superstructure, and move the
hood to a safe location.
14.7.4 Hood Installation
14.7.5 Setup
Safety]
► Install the grill insert assembly, and connect all applicable wiring.
LME/10880897/January 30, 2011/en

Lift devices and supports, for N/A See applicable weight warnings.
copyright by
T282C-532-Y06435 to 06436 661
Hood and Grill
14.7.6 Procedure
NOTICE
1. Carefully attach a lift device to safely hold and move the hood in
position to the grill, and superstructure.
2. Install the flat washers (7), lockwashers (9), and capscrews (8).
3. Install the flat washers (6), locknuts (7), and capscrews (10) to the
superstructure.
4. Install the lockwashers (5), flat washers (4), and capscrews (6) to the
grill.
LME/10880897/January 30, 2011/en
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_01.tif
Fig. 14.7-1: Hood and Grill Removal (Page 1 of 3)
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_02.tif
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_03.tif
14.7.7 Grill Removal
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Hood and Grill
14.7.8 Setup
Safety]
► Remove the diagonal ladder platform, and supports, and handrails.
► Disconnect all applicable electrical wiring.
► Disconnect baffles from radiator sides.
14.7.9 Procedure
NOTICE
The weight of the grill is 318 kg (701 lb).
1. Attach an applicable lift device that can safely lift and support the
weight of the grill.
2. Remove the capscrews (1), lockwashers (2), and flat washers (3) from
the two sides of the bumper connection.
3. Carefully lift the grill from the haul truck and move the grill to a safe
area.
LME/10880897/January 30, 2011/en
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_01.tif
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_02.tif
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_03.tif
14.7.10 Grill Installation
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Hood and Grill
14.7.11
14.7.12 Setup
Safety]
► Connect all applicable electrical wiring.
► Connect and install the radiator sight gauge to the left grill post.
14.7.13 Procedure
NOTICE
The weight of the grill is 318 kg (701 lb).
1. Carefully attach a lift device to safely hold and move the grill in position
to the superstructure.
2. Install the capscrews (1), lockwashers (2), and flat washers (3) to the
two sides of the bumper connection.
3. Remove the lift device from the grill.
LME/10880897/January 30, 2011/en
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_01.tif
Fig. 14.7-7: Hood and Grill Installation (Page 1 of 3)
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_02.tif
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Hood and Grill
LME/10880897/January 30, 2011/en
13-100-C1_Rev000_03.tif
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Battery Boxes
14.8 Battery Boxes
14.8.1 Battery Boxes Removal
14.8.2 Setup
Safety]
► Remove the batteries.
14.8.3 Procedure
NOTICE
The weight of each battery box is 34 kg (75 lb).
1. Disconnect the drain hoses.
2. Remove the capscrews (4), lockwashers (6), flat washers (5), and star
washers (5).
3. Remove the stainless steel battery boxes (12). LME/10880897/January 30, 2011/en
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Battery Boxes
LME/10880897/January 30, 2011/en
13-100-C3_Rev000.tif
Fig. 14.8-1: Battery Boxes Removal
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Battery Boxes
14.8.4 Battery Boxes Installation
14.8.5 Setup
Safety]

Hose Drain -5120-R 11 m (36.09 ft)
Clamps 10404-G
14.8.6 Procedure
NOTICE
The weight of each battery box is 34 kg (75 lb).
1. Install the stainless steel battery boxes (12).
2. Install the star washers (14), flat washers (5), lockwashers (6), and
capscrews (4).
3. Attach the drain hoses.
LME/10880897/January 30, 2011/en
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Battery Boxes
LME/10880897/January 30, 2011/en
13-100-C3_Rev000.tif
Fig. 14.8-2: Battery Boxes Installation
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Axle Box
14.9 Axle Box
09-000_000_Axle Box.tif
Fig. 14.9-1: Axle Box
The axle box is to the aft of the haul truck. The axle box provides several
functions for the haul truck. The axle box attaches to the rear control A-arm,
the drag links, and the rear wheel assemblies. The planetary gear box and
traction motor assemblies are also attached to the axle box. The main
blower air duct holes are attached to the axle box for air flow to decrease
the temperature of the motors. The AC drive cooling system sends the air
to the axle box. There is an entry door with a seal on the axle box. The rear
service and parking brake components are found in the axle box. The axle
box housing remains under pressure while the haul truck is in operation.
The axle box, control arms, drag links, and suspensions primary function is
to make the loads stable, and decrease the stress to the main frame. If the
haul truck has a heavy load, the drag links and control arm with their position
to the frame and the suspensions, absorb the loads before the force reaches
the frame.
LME/10880897/January 30, 2011/en
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Axle Box
14.9.1 Axle Box: Rear Door Removal
14.9.2 Setup
Safety]
14.9.3 Procedure
NOTICE
The minimum weight of the axle box door is 41 kg (90 lb).
► Unwanted material can increase the weight of the axle box access
door.
► Install an applicable device that can safely lift and hold the minimum
weight of the component.
1. Put the lift device to lift and support the axle box door after its removal.
2. Remove capscrews (3), lockwashers (2), and washers (1).
3. Remove the axle box door.
LME/10880897/January 30, 2011/en
09-100_000_Axle Box Rear Door.tif

Fig. 14.9-2: Axle Box Rear Door Removal
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Axle Box
14.9.4 Axle Box: Rear Door Installation
14.9.5 Setup
Safety]
► Make sure the axle box is in the same configuration from the axle box
rear door removal.
14.9.6 Procedure
NOTICE
The minimum weight of the axle box door is 41 kg (90 lb).
door.
1. Use a lift device to put the axle box door in position to the axle box.
2. Install the washers (1), lockwashers, (2), and capscrews (3).
LME/10880897/January 30, 2011/en
09-100_000_Axle Box Rear Door.tif

Fig. 14.9-3: Axle Box Rear Door Installation
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Axle Box
14.9.7 Axle Box: Front Door Removal
14.9.8 Setup
Safety]
14.9.9 Procedure
NOTICE
The minimum weight of the axle box front door is 47 kg (104 lb).
door.
1. Install a lift device to lift and support the axle box door (3) after its
removal.
2. Remove the locknut (1).
3. Remove the hex screws (2).
4. Remove the gasket (4).
5. Remove the safety pins.
6. Remove the axle box front door (3).
LME/10880897/January 30, 2011/en
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Axle Box
09-100_000_Axle Box Front Door.tif

Fig. 14.9-4: Axle Box Front Door Removal
LME/10880897/January 30, 2011/en
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Axle Box
14.9.10 Axle Box: Front Door Installation
14.9.11 Setup
Safety]
► Make sure the axle box is in the same configuration from the axle box
front door removal.
14.9.12 Procedure
Loctite® 242® N/A Commercially available
NOTICE
The minimum weight of the axle box front door is 47 kg (104 lb).
► Unwanted material can increase the component weight.
1. Install a lift device to lift and support the axle box front door (3) and
move it into the correct position to the axle box.
2. Install the gasket (4), and the washers (1).
3. Apply Loctite® 242® to the hex screws and install the hex screws (4).
4. Tighten the hex screws (4) to 380 N m (280 lbf ft).
5. Install the safety pins.
LME/10880897/January 30, 2011/en
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Axle Box
09-100_000_Axle Box Front Door.tif

Fig. 14.9-5: Axle Box Front Door Installation
LME/10880897/January 30, 2011/en
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Drag Links
14.10 Drag Links
09-000_000_Drag Links.tif
Fig. 14.10-1: Drag Links
There are two drag links on the haul truck. The drag links attach to the frame
and the bottom of the axle box. The drag links absorb loads or shock before
the force reaches the frame. The drag links supplies support for the axle
box.
LME/10880897/January 30, 2011/en
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Drag Links
14.10.1 Drag Links Removal
14.10.2 Setup
Safety]
14.10.3 Procedure
Required Tools and Material
Puller Pin Drag Link T282 T-124-B [Reference: Service Tools]
Table 1: Required Tools and Material
NOTICE
The weight of the drag link (27) is 345 kg (761 lb).
this weight.
To remove the drag link from the axle box:

1. Disconnect the lubrication hoses and cover the hoses with protective
covers.
2. Attach, to the end of the drag link (8), an applicable lift device that can
support its weight.
3. Put a hydraulic jack directly in line with the pin being removed.
4. Remove the lockwire, capscrews (2), washers (3) and (4), and left rear
drag link BRNG cover (5).
WARNING! The drag links can move suddenly when the machine pin (9)
is removed.
► Put on approved protective equipment that can protect from objects
that suddenly move and make sure the area is without other personnel
during the pin removal procedure.
LME/10880897/January 30, 2011/en
NOTICE
The weight of the machine pin (9) is 66 kg (146 lb).
this weight.
5. Use the drag link pin puller (Liebherr P/N T-124-B) puller to remove
the machine pin (9).
To remove the end of the drag link from the frame:

6. Remove the safety lockwire from the capscrews (10).
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Drag Links
7. Remove the capscrews (10), washers (11) and (14), and retainer pin
(12).
WARNING! The drag links can move suddenly when the machine pin (13)
is removed.
NOTICE
The weight of the machine pin is 66 kg (146 lb).
8. Use the drag link pin puller (Liebherr P/N T-124-B) to remove the
machine pin (9).
After the drag link is removed:

9. Examine all bushings spherical bushing 160 mm (16), retainer ring 260
mm (DIN 472) (15), frame bores, and surfaces of the machine pin (13)
for damage and wear.
10. Discard and replace the pin if the machine pin (13) is damaged, scored
or cracked.
09-100_000_01_Drag Link.tif
Fig. 14.10-2: Drag Links Removal
LME/10880897/January 30, 2011/en
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Drag Links
14.10.4 Drag Links Installation
14.10.5 Setup
Safety]
► Make sure that the haul truck is in the same configuration from drag
link removal procedure. [Reference: Drag Link Removal]
14.10.6 Drag Links to Axle Box Installation

Anti seize N/A Commercially available
Hydraulic lift N/A Commercially available
Puller Pin Drag Link T282 T-124-B [Reference: Service Tools]
Machine oil N/A [Reference: Oil and Lubricant
Specifications]
NOTICE
The weight of the drag link is 345 kg (761 lb).
component weight.
1. Align the drag link (8) bores with the axle box bores .
2. Securely put the machine pin (9) on a hydraulic jack, or similar device,
and align the machine pin (9) with the bottom of the bore and spherical
bushing (7).
3. Slowly lift the device and push the machine pin (24) until the head is
flat against the bottom face of the lower boss.
4. If necessary, lubricate the capscrews (10) with machine oil.
[Reference: Oil and Lubricant Specifications]
5. Install the retainer plate (5), washers (3) and (4), and capscrews (2).
LME/10880897/January 30, 2011/en
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Drag Links
14.10.7 Drag Links to Frame Installation

NOTICE
The weight of the drag link (8) is 345 kg (761 lb).
component weight.
1. Align the drag link (8) bores with the frame bores.
NOTICE
The weight of the machine pin (13) is 66 kg (146 lb).
component weight.
2. Securely put the machine pin (13) on a hydraulic jack, or similar, and
align the machine pin with the outboard side of the bore and spherical
bushing (16).
3. Slowly push the machine pin (13) until the head of the machine pin is
flat against the face of the outboard boss.
4. Install the retainer plate (12), washers (10) and (11), and capscrews
(4).
After installation of the two ends of the drag link:
Tighten the capscrews (10) to 925 N m (682 lbf ft).

5. Install the right rear drag link cover (4), or left rear drag link cover (3)
without tension to let the drag link move.
6. Install the washers (23), and capscrews (17).
7. Install the worm clamp (5).
8. Remove the protective covers and connect the lubrication hoses.
LME/10880897/January 30, 2011/en
09-100_000_01_Drag Link.tif
Fig. 14.10-3: Drag Links Installation
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Rear Control A-Arm (Rear Control Arm Axle Box)
14.11 Rear Control A-Arm (Rear Control Arm Axle

Box)
09-000_000_Rear Control A-Arm.tif

Fig. 14.11-1: Rear Control A-Arm (Rear Control Arm Axle Box)
The rear control A-arm attaches to the frame and to the top of the axle box.
The rear control A-arm is in a position to absorb the loads, or shocks before
the force reaches the frame. The rear control A-arm supplies support for the
axle box.
LME/10880897/January 30, 2011/en
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14.11.1 Rear Control A-Arm Removal
14.11.2 Setup
Safety]
14.11.3 Procedure
Tool Liebherr Part Number Notes
Sling N/A See applicable weight warnings
NOTICE
The weight of the control A-arm (26) is 936 kg (2064 lb).
component weight.
To remove pin from axle box:

1. Attach a sling and an applicable lift device that can support the weight
of the axle box control arm.
2. Remove the safety lock wire from capscrews (7).
WARNING! The control A-arm (26) can move suddenly when the pin is
removed.
NOTICE
LME/10880897/January 30, 2011/en
component weight.
4. Remove the machine pin (2).
NOTICE
The weight of the upper boss pin is 94 kg (207 lb).
component weight.
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To remove the pin from the main frame:

5. Remove the safety lock wire, capscrews (15), washers (14), and
retainer (16).
6. Remove the capscrews (17), washers (18) and retainer (19).
7. Remove the capscrews (11) and (12), washers (7) and (6), retainer
(13), and the necessary shims (8), (9), (10), (24), or (25).
8. Remove the capscrews (20), washers (12), and machine retainer
bushing (21).
WARNING! The control A-arm (26) can move suddenly when the pin is
removed.
NOTICE
component weight.
9. Pull the rear control A-arm pin (1).
10. Remove the axle box control arm (26).
11. Examine the spherical bushing (23) for damage.
NOTICE
The weight of the bushing is 29 kg (64 lb).
component weight.
Replace the spherical bushing (23) if damaged. LME/10880897/January 30, 2011/en
09-100_000_01_Rear Control A Arm.tif

Fig. 14.11-2: Rear Control A-Arm Removal
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14.11.4 Rear Control A-Arm Installation
14.11.5 Setup
Safety]
control A-Arm removal procedure. [Reference: Rear Control Arm (A-
Arm) Removal]
► Install the rear suspension and the drag links. [Reference: Rear
Suspension Installation], and [Reference: Drag Link Installation]
14.11.6 Procedure
Tool Liebherr Part Number Notes
Sling N/A See applicable weight warnings
Feeler gauges N/A Commercially available
Fit-up pins N/A Minimum clearance; and marked
"For Side Clearance Measurement
Only"
Machine Oil N/A [Reference: Oil and Lubricant
Specifications]
NOTICE
The weight of the spherical bushing (23) is 29 kg (64 lb).
component weight.
1. Install the spherical bushing (23) if it was removed, if not, continue with
the next step.
2. Attach a sling and an applicable lift device that can support the weight
of the axle box control arm (26).
LME/10880897/January 30, 2011/en
3. Move the axle box control arm (26) into position.
NOTICE
Instead of a rear control arm (A-arm) pin, a pair of fit-up pins can be used
to install the axle box control arm (26).
► The pins require minimum clearance for easier installation or removal
and are marked "For Side Clearance Measurement Only".
4. Align the pin holes and install the fit-up pins through the frame
bushings and the spherical bushing (23).
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5. Hit the pins until their inboard ends are flush with the inboard surface
of the spherical bushing (23).
6. Move the spherical bushing (23) completely to the applicable left, or
right.
7. Use a feeler gauge and measure the dimension (X) of the distance
between the frame and the spherical bushing (23).
NOTICE
component weight.
8. Replace the fit-up pins, one at a time, with the rear control arm (A-arm)
pin (1).
9. Install the necessary shims (2), (3), retainer pin (22), washers (6), and
capscrews (7).
If more than one shim is necessary:
Install one shim (8), (9), (10), retainer (22), washers (6) and (11), and
capscrews (7) and (12).
10. Follow Control Arm Shimming Procedure.
09-100_000_01_Rear Control A Arm.tif

Fig. 14.11-3: Rear Control A-Arm Installation
LME/10880897/January 30, 2011/en
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Service Manual Operator Cab
15 Operator Cab 695

15.1 Operator Cab Glass 696
15.1.1 Operator Cab Glass Replacement 697
15.2 Foot Pedal Controls 701
15.2.2 (1) Service Brake Pedal 701
15.2.3 (2) Dynamic Braking Pedal 701
15.2.4 (3) Accelerator Pedal 702
15.3 Steering Column and Controls 703
15.3.1 Tilt and Telescopic Lever 703
Switch 703
15.3.3 Hazard Flasher 704
15.3.4 Horn Button 704
15.3.5 Steering Column Turn Signal Replacement 705
15.3.16 Steering Column Trough Cover Replacement 709
15.3.21 Steering Column Wire Harness Replacement 711
15.3.26 Steering Column Knob Kit Replacement 713
15.4 Access Panels and Miscellaneous Items 714
LME/10880897/January 30, 2011/en
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Operator Cab Service Manual
Operator Cab Glass
15.1 Operator Cab Glass
The glass on the haul truck is the windshield and the side and rear windows.
The glass lets the operator and passenger see out of the haul truck.
The glass is made from safety plate glass and protects the interior of the
cab from weather and unwanted material. The windows on the driver and
passenger doors are electrically operated.
LME/10880897/January 30, 2011/en
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Operator Cab Glass
15.1.1 Operator Cab Glass Replacement
15.1.2 Setup
Safety]
15.1.3 Procedure
1. Find the end of the locking seal (3).
2. Use the applicable tool to pull some of the locking seal (3) out of the
rubber moulding (2).
3. Manually pull the remaining locking seal (3) out of the rubber moulding
(2).
4. Carefully push out on the glass (1) and remove.
5. Examine the rubber moulding (2) and replace if necessary.
If the rubber moulding (2) was removed,

6. Install the rubber moulding (2) in the window frame and make sure that
the two ends of the moulding touch at the bottom.
7. Put the bottom edge of the glass (1) in position in the rubber moulding
(2).
8. Gradually push the glass (1) into the rubber moulding (2) around the
frame.
9. Use a locking seal (3) insert tool (7) to install the locking seal (3).
10. Put one end of the locking seal (3) into the rubber moulding (2) at the
bottom center of the frame.
11. Carefully install the locking seal (3) into the rubber moulding (2) around
the frame, and do not stretch the seal.
12. Make sure the locking seal (3) is fully installed into the rubber moulding
(2).
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Operator Cab Glass
532_Glass_01_Rev000.tif
Fig. 15.1-1: Operator Cab Glass Replacement
Legend:
1. Glass 5. Finishing Pin
2. Rubber Moulding 6. Tool Handle
3. Locking Seal 7. Inserter
4. Cab Panel 8. Channel Spreader
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Operator Cab Glass
532_Glass Front_01_Rev001.tif
Fig. 15.1-2: Operator Cab Front Glass Dimensions
LME/10880897/January 30, 2011/en
532_Glass Front Side_01_Rev000.tif

Fig. 15.1-3: Operator Cab Front Side Glass Dimensions
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Operator Cab Glass
532_Glass Rear Side_01_Rev000.tif

Fig. 15.1-4: Operator Cab Rear Glass Dimensions
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Foot Pedal Controls
15.2 Foot Pedal Controls
16-000_000_01_Foot Pedal Controls.tif

Fig. 15.2-1: Foot Pedal Controls
15.2.1 System Description and Function
The foot pedal controls are:

1. Service Brake Pedal
2. Dynamic Braking Pedal
3. Accelerator Pedal
15.2.2 (1) Service Brake Pedal

The brake pedal is the pedal on the left. The brake pedal controls the service
brakes. If the operator pushes on the brake pedal, the hydraulic pressure
through the brake system operates the brake calipers to decrease the speed
of the brake discs. The red stop lights on the rear of the axle box illuminate
when the brake pedal is pushed.
The brake pedal has a dual valve. The left side of the dual valve is for the
front brakes. The right side of the dual valve is for the rear brakes.
LME/10880897/January 30, 2011/en
The brake pedal interfaces with the system that follows:

• Brake System [Reference: Brake System]
• Front Brakes [Reference: Front Brakes]
• Rear Brakes [Reference: Rear Brakes]
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Foot Pedal Controls
15.2.3 (2) Dynamic Braking Pedal

The dynamic braking pedal is the center pedal. If the operator pushes on
the dynamic braking pedal, the speed of the haul truck decreases. The
dynamic braking pedal is part of the Siemens AC Drive System. The function
of the dynamic braking pedal is to stop the haul truck electrically. The AC
drive system can supply a high force to fully stop the haul truck and hold the
haul truck in that position, but the service brakes automatically get applied
just before the haul truck comes to a full stop.
During the time when the operator pushes on the dynamic braking pedal
and the speed of haul truck decreases, the traction control unit (TCU) in the
AC drive system gradually applies the service brakes. The quantity that the
service brake is applied is increased at the same time the quantity of the
electricity from the dynamic braking system is decreased. This function is
referred to as a "blended service holding brake" and causes the haul truck
to smoothly stop without pushing on the brake pedal.
The amber brake lights on the rear of the axle box illuminate when the
dynamic braking pedal is pushed.
For more information on the AC drive system, refer to the Siemens manual.
The dynamic braking pedal interfaces with the system that follows:
• Brake System [Reference: Brake System]
• Rear Brakes [Reference: Rear Brakes]
• AC Drive System [Reference: AC Drive System]
15.2.4 (3) Accelerator Pedal

The accelerator pedal is the pedal on the right. If the operator pushes on
the accelerator, the signal goes to the traction control unit (TCU) in the AC
drive system. The TCU uses this signal and a signal from the shift selector
switch to calculate the speed and direction (forward or reverse) for the haul
truck. The TCU uses this calculation and tells the applicable components to
energize the rear wheel motors. This causes the haul truck to move in
proportion to the accelerator pedal movement, and in relation to the shift
selector switch.
The accelerator pedal also supplies a signal to the TCU to control the engine
RPM.
For more information on the AC drive system, see the Siemens manual.
The accelerator pedal interfaces with the system that follows:

• AC Drive System [Reference: AC Drive System]
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Steering Column and Controls
15.3 Steering Column and Controls
16-000_000_01_Steering Column.tif
Fig. 15.3-1: Steering Column
The steering column has the components that follow:

• Tilt and Telescope Lever
• Left and Right Turn Signals Lever, and Dimmer Switch
• Hazard Flasher
• Horn Button
15.3.1 Tilt and Telescopic Lever
To tilt the steering, pull and hold the tilt and telescopic lever up to unlock.
Move the steering column up or down. Release the tilt and telescopic lever
to lock the steering column into the necessary position.
To extend or retract the steering column, push the tilt and telescopic lever
LME/10880897/January 30, 2011/en
down to unlock.
Pull or push the steering wheel as necessary and then pull the tilt and
telescopic lever to lock in position.
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Switch
The left and right turn signals lever switch moves up to signal a right turn,
and down to signal a left turn.
To make a high or low headlight selection, pull and release the dimmer
switch lever.
15.3.3 Hazard Flasher

The hazard flasher is a pull on, push off button. if the hazard flasher is pulled
the headlights flash every second. To turn off the hazard lights, the hazard
flasher button is pushed.
15.3.4 Horn Button

The horn button is in the center of the steering wheel. Push the horn button
to operate.
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15.3.5 Steering Column Turn Signal Replacement
15.3.6 Setup
Safety].
15.3.7 Upper and Lower Steering Column Cover Removal

1. Remove the upper and lower covers that snap around the column.
2. Telescope the steering column all of the way up (toward the front of
the operator cab).
3. Hold the upper cover at the bottom closest to the dash and remove it
by pulling up on it.
4. Remove the lower cover by tilting the steering column all of the way
up (toward the front glass).
5. Hold it at the bottom or closest to the dash and pull down on it.
532_Steering Upper and Lower Cover_100_01_Rev000.tif

Fig. 15.3-2: Steering Column Upper and Lower Cover Removal
15.3.8 Turn Signal Switch Removal

1. Use a Phillips head screwdriver to remove the two screws from the
turn signal mounting bracket.
2. Cut the wires as close to the turn signal switch as possible.
3. Discard the old turn signal switch. Tape the terminal block on the new
turn signal switch to the old turn signal switch wire that protrudes from
the steering column.
4. Disconnect the old terminal block where the harness from the old
switch plugged into the module.
5. Use the old harness wiring to pull the new harness down through the
steering column.
6. Take the tape off and discard the old harness.
LME/10880897/January 30, 2011/en
532_Turn Signal Wire_100_01_Rev000.tif

Fig. 15.3-3: Turn Signal Switch Wire Removal
15.3.9 Turn Signal Switch Replacement

1. Plug the new harness into the module.
2. Use the Phillips head screwdriver to install the new turn signal switch
to the bracket that attaches to the steering column.
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15.3.10 Upper and Lower Steering Column Cover

Installation
1. Install the lower cover by tilting the steering column all the way up
(toward the front glass), hold it at the bottom or closest to the dash and
push up on it.
2. Hold the upper cover at the bottom closest to the dash and install it by
pushing up on it.
3. Telescope the steering column all the way up (toward the front of the
operator cab), then tilt the steering column all the way up (toward the
cab ceiling).
532_Steering Upper and Lower Cover_100_01_Rev000.tif

15.3.11 Steering Column Turn Signal Cancel Cam

Inspection
1. Position the steering wheel and steer tires in the straight forward
position.
2. Star the engine.
3. Active the turn signal switch to the right as if to turn right.
4. Turn the steering wheel to the right counting the rotations. At 3/4 turn,
reverse the rotation and check when the right turn signal indication
stops. The right turn signal indication must stop before the steering
wheel is half way back to the center position.
5. Repeat steps 1 to 4 for a left turn indication.
If the turn signal cancels within approximately 3/4 turn in both
directions, the mechanical part of this inspection has passed.
15.3.12 Critical Checking Procedure

1. Secure the haul truck to make sure the haul truck cannot move.
2. Activate the turn signal switch. With the turn signal ON to indicate a
right, or left turn, walk around the haul truck to make sure the correct
front and rear external lights flash to signal a left or right turn. Do the
walk around to check both signal indicators.)
3. Activate the hazard button. With the hazard button in operation, walk
LME/10880897/January 30, 2011/en
around the haul truck to make sure the correct front and rear external
lights flash to indicate a hazard warning.
4. Turn and push the signal switch to operate the wiper and washer.
Make sure the wipers operate, and the washer fluid flows correctly.
5. Turn the steering wheel from full left to full right, lock to lock, to make
sure the steering column rotates freely and does not lock at any
position during rotation. While the steering wheel is being rotated, feel
for any catches or binding. Also listen for any unusual noises, like
snapping, cracking or popping.
6. tilt the steering column and verify that it locks.
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7. Telescope the steering column to all the positions and verify the
steering column locks at all positions.
8. Push the horn button to make sure it operates correctly.
WARNING! The tilt signal kit must pass all critical checks!
► Do not operate the haul truck if any of the critical checks have failed.
► Replace the steering column and/or the steering shaft before
operating the haul truck if any of the critical checks have failed.
15.3.13 Remove the Turn Signal Lever and Dimmer Switch

1. Remove the turn signal switch lever by pulling straight out.
2. Remove the turn signal switch by removing the two screws.
16-100_000_02_Steering Column_Upper Lower Column.tif

Fig. 15.3-5: Steering Column and Controls Turn Signal Lever and Dimmer Switch Removal
3. Carefully lift the snap tabs (4 places) on the harness connected and
remove the wire harness from the back of the turn signal switch.
15.3.14 Steering Column Turn Signal Switch Replacement

► Snap in the harness connector to the new switch. Make sure the
connector is fully engaged and the snap tabs are fully seated.
► Place the switch back against the housing and align the screw holes.
► Install the screws and torque to 4 N m (3 lbf ft) to 5 N m (3 lbf ft).
► Reinstall the turn signal switch lever. Make sure the lever is fully seated
and snapped into location.
► Reinstall the upper and lower covers.
LME/10880897/January 30, 2011/en
15.3.15 Critical Turn Signal Switch Installation Check

Procedure
► Tilt and telescope the steering column to ensure it continues to operate
correctly.
► Check to make sure that all the turn signal functions are correct.
► Apply the hazard lights and check that the service brakes lights over
the flashing hazard function.
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► Turn the steering wheel from full left to full right, lock to lock, to make
sure the steering column rotates freely. While rotating the steering
wheel, feel for any catches, binding or abnormalities.
WARNING! Abnormalities felt as the steering wheel turns can cause

continuous damage.
► Do not return the haul truck to service if the steering wheel operates
incorrectly, or if you feel abnormalities after the replacement.
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15.3.16 Steering Column Trough Cover Replacement
15.3.17 Setup
Safety].
15.3.18 Procedure
1. Remove the column after removing the mounting bolts (these bolts
mount the column to the haul truck).
2. Remove the 4 bolts and locking bolts and washers.
3. Remove the mounting bracket.
4. Remove the trough cover.
16-100_000_01_Trough Cover.tif
Fig. 15.3-6: Steering Column Trough Cover Removal
LME/10880897/January 30, 2011/en
15.3.19 Steering Trough Cover Replacement

► Replace the trough cover (2).
► Reinstall the bracket and install the lock washers (1) along with the
bolts and torque to 23 N m (17 lbf ft) to 31 N m (23 lbf ft).
► Mount the column back to the haul truck. Torque these bolts to
speechification.
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15.3.20 Critical Trough Cover Installation Check

Procedure
correctly.

continuous damage.
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15.3.21 Steering Column Wire Harness Replacement
15.3.22 Setup
Safety].
15.3.23 Procedure
1. Remove the column after removing the mounting bolts (these bolts
mount the column to the haul truck).

2. Remove the turn signal switch lever by pulling it straight out.
3. Remove the turn signal switch by removing the two screws.
LME/10880897/January 30, 2011/en

Fig. 15.3-8: Steering Column Signal Switch Removal
4. Carefully lift the snap tab (4 places) on the harness connector and
remove the wire harness from the back of the turn signal switch.
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15.3.24 Steering Column Wire Harness Replacement

► Snap in the wire harness connector to the new switch. Make sure the
connector is fully engaged and the snap tabs are fully seated.
► Place the switch back against the housing and align the screw holes.
► Install the screws and torque to 4 N m (3 lbf ft) to 5 N m (3 lbf ft).
► Reinstall the upper and lower covers.
15.3.25 Critical Steering Wheel Wire Harness Installation

Check Procedure
correctly.

continuous damage.
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15.3.26 Steering Column Knob Kit Replacement
15.3.27 Setup
Safety].
15.3.28 Procedure
1. Loosen the 5/16" nut by turning it in a clockwise direction.
2. Remove the old knob by turning it in a counterclockwise direction.
3. Thread the new knob on by turning in a clockwise direction. Thread
until snug. Retighten the 5/16" nut by turning it in a counterclockwise
direction 1/4 turn.
15.3.29 Critical Knob Kit Installation Check Procedure

correctly.
► Pull up and push down on the steering wheel to make sure the shaft
and retaining rings are seated correctly.
► Test the horn to make sure it continues to operate correctly.

continuous damage.
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Access Panels and Miscellaneous Items
15.4 Access Panels and Miscellaneous Items
Access panels are designed to give easy access for the maintenance of the
cab main components.
Access panels are:

• Cover assembly, front access
• Cover assembly steering access
• Roof cover assembly
• Dash HVAC cover assembly
• Dash access lid, assembly
• Cover upper
• Cover lower
• Cover center rear
• Cover assembly center console
• Console plate front
• Console plate center
• Cover wire
• Plate, lower door
• Plate, window switch
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16-000_000_01_Access Panels.tif
LME/10880897/January 30, 2011/en
Fig. 15.4-1: Access Panels and Miscellaneous Items (Page 1 of 2)
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16-000_000_02_Access Panels.tif
LME/10880897/January 30, 2011/en
Fig. 15.4-2: Access Panels and Miscellaneous Items (Page 2 of 2)
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Service Manual Computers and Auxiliary Systems
16 Computers and Auxiliary Systems 717

16.1 Computer and Auxiliary Systems 718
LME/10880897/January 30, 2011/en
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Computers and Auxiliary Systems Service Manual
Computer and Auxiliary Systems
16.1 Computer and Auxiliary Systems
The computers and auxiliary systems section of this service manual is under
development. For authorized procedures, and information normally found in
this section, directly contact the Maintenance and Reliability Group, LME.
LME/10880897/January 30, 2011/en
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Service Manual Class Documents
17 Class Documents 719

17.1 Class Documents 720
17.1.1 Suspension Test and Charge Procedures 720
17.1.2 Diesel Engine 20 V 4000 Operating Manual 720
17.1.3 Truck Test Procedure 720
17.1.4 Hydraulic Test Points 720
17.1.5 Dump Body Proximity Wiring Assembly 720
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Class Documents Service Manual
Class Documents
17.1 Class Documents
This section contains the supporting documentation that follows:
17.1.1 Suspension Test and Charge Procedures

• TI-2114-P (Rear Suspension Test and Charge Procedure)
• TI-2114-R (Front Suspension Test and Charge Procedure)
17.1.2 Diesel Engine 20 V 4000 Operating Manual

• MTU_Value Service Technical Documentation, Diesel Engine
20 V 4000 C22, Operating Instructions M015675/02E
17.1.3 Truck Test Procedure

• Haul Truck Test Procedure
17.1.4 Hydraulic Test Points

• Hydraulic Test Points Locations
17.1.5 Dump Body Proximity Wiring Assembly

• Dump Body Proximity Wiring Assembly
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Service Manual List of Acronyms
List of Acronyms
AC......................................................................................Alternating Current
AFP........................................................................Absolute Forward Position
ARP.....................................................................Absolute Rearward Position
CAN...........................................................................Controller Area Network
CDA............................................................................................Clean Dry Air
CF............................................................................................Compact Flash
DC..............................................................................................Direct Current
FCAW........................................................................Flux-Cored Arc Welding
IGBT............................................................Insulated Gate Bipolar Transistor
IPC.......................................................................Independent Power Control
LAN...................................................................................Local Area Network
LED..................................................................................Light Emitting Diode
LME..............................Liebherr Mining Equipment Newport News Company
OEM............................................................Original Equipment Manufacturer
PM.............................................................................Preventive Maintenance
PWM...........................................................................Pulse Width Modulation
SMAW..................................................................Shielded Metal Arc Welding
TCU.................................................................................Traction Control Unit
USB.................................................................................Universal Serial Bus
LME/10880897/January 30, 2011/en
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LME/10880897/January 30, 2011/en
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Index
10000-Hour Preventive Maintenance 5000-Hour Preventive Maintenance

Reference 173 Reference 149
LME-80-12-01 - Steering Arm Fasteners LME-80-13-01 - Steering Arm Fasteners
Replacement 176 Torque Procedure 169
1000-Hour Preventive Maintenance LME-80-14-00 - Upper Kingpin Fastener
Reference 122 Torque Procedure 171
LME-110-01-00 - Grid Motor Inspection 500-Hour Preventive Maintenance
Guidelines 128 Reference 96
LME-20-02-02 - Brake and Steering LME-10-01-01 - Exhaust Bellows and
Pressure Filter Replacement Procedure 123 Blankets Inspection 130
LME-20-03-02 - Dump System Filter LME-20-04-00 - Gear Oil Cooling
Replacement Procedure 125 System Filters Replacement Procedure 131
1500-Hour Preventive Maintenance LME-80-02-02 - Rear Brake Pad and
Reference 129 Disc Check Procedure 132
LME-10-01-01 - Exhaust Bellows and LME-80-15-01 - Front Brake Pad and
Blankets Inspection 130 Disc Check Procedure 134
LME-20-04-00 - Gear Oil Cooling LME-20-06-00 - Front Wheel Oil Drain
System Filters Replacement Procedure 131 and Fill Procedures 137
LME-80-02-02 - Rear Brake Pad and LME-80-04-02 - Wear Limit Check
Disc Check Procedure 132 Procedure 139
LME-80-15-01 - Front Brake Pad and LME-00-01-01 - Battery Maintenance 97
Disc Check Procedure 134 LME-20-01-00 - Oil Sampling Guideline 98
2500-Hour Preventive Maintenance LME-20-08-01 - Air Intake System
Reference 136 Inspection and Filter Replacement
LME-20-06-00 - Front Wheel Oil Drain Procedures 100
and Fill Procedures 137 LME-30-01-01 - Axle Box Inspection 102
LME-80-04-02 - Wear Limit Check LME-40-01-01 - Hydraulic Hoses
Procedure 139 Inspection 104
3000-Hour Preventive Maintenance LME-40-02-00 - Pump Drive Service
Reference 144 Procedure 105
LME-80-03-01 - Lower Kingpin Bushing LME-40-03-01 - Brake Accumulator Pre-
Wear Check Procedure 145 Charge Check, Drain, and Pre-Charge
5000-Hour Preventive Maintenance Procedures 106
Reference 149 LME-40-04-01 - Steering Accumulator
LME-20-07-00 - Rear Wheel Oil Drain Pre-Charge Check, Drain, and Pre-
LME/10880897/January 30, 2011/en
and Fill Procedures 150 Charge Procedures 110

LME-30-02-01 - Rear Control Arm LME-40-05-00 - Unloader Accumulator
Fasteners Torque Procedure 152 Pre-Charge Check, Drain, and Pre-
LME-80-06-02 - Steering Cylinder Charge Procedures 114
Fasteners Torque Procedure 159 LME-80-16-00 - Suspension Monitoring
LME-80-09-01 - Tie Rod Fastener and Maintenance 118
Torque Procedure 163 AC Drive Cooling System 257
LME-80-11-00 - Lower Kingpin Axle Box Cooling Duct Installation 272
Fasteners Torque Procedure 167 Axle Box Cooling Duct Removal 270
Motor Installation 263
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Index Service Manual
AC Drive Cooling System 257 Component Weights and Dimensions 68

Motor Removal 261 Rear Suspension 69
Access Panels 714 Rim 70
Auto Lube System 478 Superstructure Assembly 68
Components 480 Tire and Rim 70
Ecomat (LITES) Controller 483 Traction Motor 70
Grease Tank 481 Upper Control Arm 69
Hydraulic Pump 485 Computer and Auxiliary Systems 718
Hydraulic Pump 486 Conditional-Hour Preventive
Injectors 483 Maintenance Reference 178
Low Level Indicator 482 LME-80-05-02 - Rear Brake Assembly
Lubrication Pump 481 Fasteners Torque Procedure 155
Neutral Position Pause Function 483 LME-80-07-02 - Front Brake Assembly
Pressure Switch 482 Fasteners Torque Procedure 179
Safety Unloader Valve 481 LME-80-08-02 - Rear Wheel Assembly
SL-V Injector (Series B) 484 Fasteners Torque Procedure 181
Specifications 484 LME-80-10-00 - Replace Lower Kingpin
Stage 1 484 Fasteners 174
Stage 2 484 Control Arm 583
Stage 3 484 Upper and Lower (Front) 583
Stage 4 484 Installation 586
Vent Valve Assembly 481 Removal 584
Axle Box 679 Control Cabinet 279
Axle Box 681 AC Drive System Schematic 279
Axle Box 683 Auxiliary Inverters 286
Batteries 323 Chopper 288
24 VDC Battery Bank 323 Installation 316
Installation 326 Removal 314
Removal 324 Cooling Pump 294
Brake and Steering Manifold 425 DC Link Capacitors 289
Brake and Steering Pressure Filter 420 DC-DC Converter 285
Brake and Steering Pump Unloader Valve Field Regulator 283
Accumulator 470 Independent Power Control 300
Brake System 432 Inverter Controller 297
Brake Accumulators 434 Inverters 287
Bleed 439 Installation 312
Hand Brake Valve and Manifold 440 Removal 310
Installation 442 Main Programmable I/O Module 296
Removal 441 Main Rectifier 284
Buddy Steering and Braking Components 469 Installation 304
CAN Temperature Module 299 Removal 302
Central Service Assembly 353 Mini Programmable I/O Module 298
Class Documents 720 Pre-heaters 295
Component Weights and Dimensions 68 Traction Alternator 280
Additional Component Weights 72 Dump Body 632
Air Cleaner 72 Alignment 636
Alternator 72 Hydraulically Lift or Lower for Service
Cab with Air Conditioning 72 (Hydraulically) 641
LME/10880897/January 30, 2011/en
Chassis Assembly 68 Installation 635

Chassis Assembly with Power Module 68 Lift or Lower for Service (Manually) 642
Dump Cylinder 71 Pivot Pens and Bearing Alignment
Front Suspension 69 (Shim) 647
Front Wheel Assembly 68 Pivot Pens and Bearing Installation 646
Fuel and Hydraulic Tank Assembly 71 Pivot Pin and Bearing Removal 644
Fuel Tank Assembly 71 Pivot Pins 643
Lower Control Arm 69 Removal 633
Planetary Gear Box 70 System Description and Function 632
Planetary Gear Box Assembly 70 Welding and Repairs 632
Power Module Assembly 71 Removal 376
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724 T282C-532-Y06435 to 06436

Service Manual Index
Dump Body Control Lever 373 Hood and Grill 661

Dump Body Override Switch 374 Hood and Grill 666
Dump System 356 Hood and Grill 670
Dump Body Cylinders 375 Hydraulic Tank 342
Removal 376 Brake and Steering Section 347
Dump Pumps 358 Drain 349
Installation 362 Fill 351
Removal 360 Dump System Section 343
Dump System Pressure Filters 383 Drain 345
Dump System Pressure Filters Fill 346
Installation 386 Fuel Section 348
Pilot Control Valve and Manifold 370 Idler Arm Assembly 567
Pressure Filters Removal 384 Information Alert Device 27
Schematic 357 Kingpins 552
Troubleshooting 388 Removal 553
Drain 345 Removal 555
Fill 346 Park Brake (Carlisle) 617
Engine 193 Installation 622
Air Cleaner 220 Mechanical Release 625
Removal 221 Removal 619
Restriction Check 235 Power Module 186
Installation 223 Installation 190
Endplay Measurements 203 Removal 187
Flywheel Runout Check 201 Preventive Maintenance References 96
Installation 198 1000-Hour Preventive Maintenance
Removal 195 Reference 122
Exhaust System 205 500-Hour Preventive Maintenance
Installation 213 Reference 96
Removal 206 Radiator 238
Flow Amplifier Valve 450 Installation 247
Foot Pedal Controls 701 Removal 241
Accelerator Pedal 702 Adding Coolant 238
Dynamic Braking Pedal 702 Cleaning 239
Service Brake Pedal 701 Coolant Fill 256
Frame 631 Cores with Center Tanks 239
Welding and Repairs 631 Replacement Tubes 239
Front Brake Caliper 545 Tank Gasket 239
Front Brake Disc 551 Tubes Replacement 253
Front Brakes 541 Rear Brakes 598
Fuel System 236 Installation 603
Fuel and Hydraulic Tank Drain 236 Removal 600
Gear Oil Cooling System 491 Rear Disc Brake Hub 610
Glass 696 Safety 27
Operator Cab Glass Replacement 697 Batteries 30
Grid Box 291 Burn Prevention 29
Main Blower Assembly 293 Chemicals 30
Health and Safety Information 27 Coolant 29
Batteries 30 Fire and Explosion Hazards 28
LME/10880897/January 30, 2011/en
Burn Prevention 29 Fire Blanket 29

Chemicals 30 Fire Extinguisher 29
Coolant 29 First Aid Kit 28
Fire and Explosion Hazards 28 Oils 29
Fire Blanket 29 Protective Equipment 28
Fire Extinguisher 29 Anchor Tie-off 35
First Aid Kit 28 Brake Safety 34
Oils 29 Dump Body Safety 39
Protective Equipment 28 Hydraulics Safety 38
Hoist Cooling System 496 Jack and Lift Devices 37
Hood and Grill 661 Maintenance Parking 34
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T282C-532-Y06435 to 06436 725
Index Service Manual
Safety 27 Suspensions, Rear 516

Maintenance Preparation 33 Gas Charge 527
Tire Safety 37 Gas Discharge 525
Service and Maintenance Plan 78 Installation 520
Service Tools 54 Oil Drain 522
10025660 (Fixture Dump Cylinder Oil Fill 524
Extend Tool) 54 Pressure Check 528
10339053 (Barring Gear Tool) 55 Removal 518
Adaptor Hanging Forklift Load Touch Screen Display Panel 301
10469271 55 Towing or Recovery 50
Axle Box Stand T-099-A 56 51091-K (2 per bumper) 52
Dump Cylinder Shipping Brackets 51288AH (2 per bumper) 51
T-193-A 59 51288AM (2 per bumper) 51
Electrical System Repair Kit SVC-100 56 51288AN (includes hook and fasteners) 52
Endplay Measuring Tool 10880099 55 Horizontal Drag Link Pin Axle Box 53
Frame Stand T-367-B 59 Vertical Drag Link Pin Axle Box 52
Frame Stand T-367-G 59 Vertical Drag Link Pin Axlebox 52
Front Wheel Lifting Bracket T-107-A 57 Traction Alternator 225
Gas Tank Nipple T-107-B 57 Installation 229
Hydraulic Pressure Test Kit T-493 60 Measurements 233
Measuring Tool T-481 60 Principle of Operation 281
Nitrogen Charge Kit T-107-T 58 Removal 226
Nut T-107-A 57 System Description 280
O-ring Seal KitT-528-A 61 Traction Motor 290
Pin Puller T-075-B 56 Useful Information 62
Pin Puller T-124-C 58 Conversion of U.S. Units of Measures
Power Module Lifting Beam T-128-F 58 into Metric Equivalents 63
Power Module Shipping Stand T-500-J 60 Fraction Decimal Equivalents 64
Rear Brake Disc Hub Puller T-504-A 61 Visual Safety Alert - Safety Alert Signs and
Rear Wheel Assembly Lifting Beam Label Maintenance 33
T-128-K 59 Visual Safety Alert Devices 27
Straight Edge Parallel Tool 11002203 55 Visual Safety Alerts on the haul truck 31
Specifications 359
Spindle 552
Steering Accumulator 444
Steering Arm 574
Steering Column and Controls 703
Dimmer Switch Lever 704
Hazard Flasher 704
Horn Button 704
Left and Right Turn Signals Lever 704
Tilt and Telescopic Lever 703
Turn Signal Lever and Dimmer Switch
Removal 707
Upper and Lower Cover Removal 705
Steering Control Valve 457
Steering Cylinders 462
Steering Stop Pads 579
LME/10880897/January 30, 2011/en
Steering System 444

Superstructure 660
Suspensions, Front 502
Gas Charge 513
Gas Discharge 511
Installation 506
Oil Drain 508
Oil Fill 510
Pressure Check 514
Removal 504
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Illustration Index
24 VDC Battery Bank 323 Brake and Steering Pressure Filter

AC Drive Cooling System 257 Removal 421
AC Drive Cooling System Motor Brake and Steering Pressure Filter
Removal 261 Replacement Procedure 123
AC Drive System Motor Installation 263 Brake and Steering Pump 410
Access Panels and Miscellaneous Brake and Steering Pump At Rest (No
Items (Page 1 of 2) 714 Rotation of Prime Mover) 411
Access Panels and Miscellaneous Brake and Steering Pump Installation 418
Items (Page 2 of 2) 715 Brake and Steering Pump Removal 416
Air Cleaner Restriction Check 235 Brake and Steering Pump Start-up
Alternator Cooling Duct Installation 268 (Prime Mover Running) 412
Alternator Cooling Duct Removal 266 Brake and Steering Pump Unloader
Auto Lube Low Pressure Indicator 482 Brake Accumulator 470
Auto Lube System 478 Brake and Steering Pump Unloader
Auto Lube System Components 480 Valve Accumulator Installation 473
Auxiliary Inverters 286 Brake and Steering Pump Unloader
Axle Box 678 Valve Accumulator Removal 471
Axle Box Cooling Duct Removal 270 Brake and Steering Pump Unloading 413
Axle Box Cooling Duct Removal 272 Brake and Steering Pump Unloading 414
Axle Box Front Door Installation 683 Brake and Steering Relief Valve and
Axle Box Front Door Removal 681 Accumulator Unloading Valve in
Axle Box Rear Door Installation 680 Closed Positions 412
Axle Box Rear Door Removal 679 Brake and Steering Section of the
Battery Boxes Installation 676 Hydraulic Tank Drain 349
Battery Boxes Removal 674 Brake and Steering Section of the
Battery Disconnect Switch Box 322 Hydraulic Tank Fill 351
Battery Installation 327 Brake and Steering Unloader Valve
Battery Removal 324 Accumulator Pressure Check 475
Brake Accumulator Pre-Charge Check, Brake System 431
Drain, and Pre-Charge Procedures 108 Brake System Components 432
Brake Accumulator System Bleed 439 Buddy Steering and Braking
Brake Accumulators 434 Components 468
Brake Accumulators Installation 437 CAN Temperature Module 299
Brake Accumulators Removal 435 Central Service Assembly 353
Brake and Steering Hydraulic Tank 347 Chopper 288
LME/10880897/January 30, 2011/en
Brake and Steering Hydraulic Tank 347 Chopper 288

Brake and Steering Manifold 425 Chopper Installation 317
Brake and Steering Manifold Chopper Removal 314
Installation 429 Control Arms Installation 588
Brake and Steering Manifold Removal 427 Control Arms Removal 584
Brake and Steering Manifold Cooling Pump 294
Schematic 426 DC Link Capacitor Installation 320
Brake and Steering Pressure Filter 420 DC Link Capacitor Removal 318
Brake and Steering Pressure Filter DC Link Capacitors 289
Installation 423 DC to DC Converter Box Installation 308
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T282C-532-Y06435 to 06436 727
Illustration Index Service Manual
DC to DC Converter Box Removal 307 Example of Fasteners Marked with

DC/DC Converter 285 Torque Detection Paint 163
Dimension X Measurement (haul truck Example of Fasteners Marked with
empty with jacks installed) - driver Torque Detection Paint 159
side, front wheel assembly, aft Example of Fasteners Marked with
direction 147 Torque Detection Paint 167
Dimension X Measurement (haul truck Example of Fasteners Marked with
empty without jacks installed) - Torque Detection Paint 169
driver side, front wheel assembly, Example of Fasteners Marked with
aft direction 146 Torque Detection Paint 155
Drag Links 685 Example of Fasteners Marked with
Drag Links and Rear Control Arm Torque Detection Paint 152
Bushing Check Procedure 139 Example of Fasteners Marked with
Drag Links Installation 689 Torque Detection Paint 171
Drag Links Removal 687 Example of Fasteners Marked with
Drive Shaft Assembly 333 Torque Detection Paint 179
Drive Shaft Installation 338 Example of Fasteners Marked with
Drive Shaft Removal 336 Torque Detection Paint 182
Dump Body 632 Exhaust System Installation (Page 1 of
Dump Body Control Lever 373 6) 213
Dump Body Cylinders 375 Exhaust System Installation (Page 2 of
Dump Body Cylinders Installation 381 6) 214
Dump Body Cylinders Removal 378 Exhaust System Installation (Page 3 of
Dump Body Installation and Alignment 636 6) 215
Dump Body Lowered After Exhaust System Installation (Page 4 of
Maintenance 641 6) 216
Dump Body Manual Bypass Valve 642 Exhaust System Installation (Page 5 of
Dump Body Pads 649 6) 217
Dump Body Pads Installation 653 Exhaust System Installation (Page 6 of
Dump Body Pads Removal 650 6) 218
Dump Body Pivot Pins 643 Exhaust System Removal (Page 1 of 6) 206
Dump Body Proximity Switch 391 Exhaust System Removal (Page 2 of 6) 207
Dump Body Removal 633 Exhaust System Removal (Page 3 of 6) 208
Dump Body Removal 639 Exhaust System Removal (Page 4 of 6) 209
Dump Pumps 358 Exhaust System Removal (Page 5 of 6) 210
Dump Pumps Installation 362 Exhaust System Removal (Page 6 of 6) 211
Dump Pumps Removal 360 Field Regulator 283
Dump System Components 356 Flow Amplifier Valve 450
Dump System Filter Replacement Flow Amplifier Valve Installation (Page
Procedure 125 1 of 2) 454
Dump System Filter Replacement Flow Amplifier Valve Installation (Page
Procedure 126 2 of 2) 455
Dump System Hydraulic Tank 343 Flow Amplifier Valve Removal (Page 1
Dump System Hydraulic Tank 343 of 2) 451
Dump System Pressure Filters 383 Flow Amplifier Valve Removal (Page 2
Dump System Pressure Filters of 2) 452
Installation 386 Foot Pedal Controls 701
Dump System Pressure Filters Frame 631
LME/10880897/January 30, 2011/en
Removal 384 Front Brake Assembly Fasteners

Dump System: SchematicDump Torque Procedure 180
System Schematic 357 Front Brake Caliper 545
Engine Air Cleaner Ducts Installation 223 Front Brake Caliper Installation 550
Engine Air Cleaner Ducts Removal 221 Front Brake Caliper Removal 547
Engine Endplay Measurements 204 Front Brake Disc 551
Engine Flywheel Run-Out Check 201 Front Brakes 541
Engine Installation (Page 1 of 2) 198 Front Suspension Gas Discharge 511
Engine Installation (Page 2 of 2) 199 Front Suspension Installation 506
Engine Removal (Page 1 of 2) 195 Front Suspension Oil Drain 508
Engine Removal (Page 2 of 2) 196 Front Suspension Pressure Check 514
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Service Manual Illustration Index
Front Suspension Removal 504 Major Component Replacement

Front Suspensions 502 Guidance 86
Front Wheel (Complete) Removal 535 Mechanical Release of the Park Brake 625
Front Wheel (Complete) Removal 539 Mechanical Release of the Park Brake 626
Front Wheel Oil Drain Procedure 137 Mini Programmable I/O Module 298
Front Wheel Oil Fill 138 MTU, 20V400 Engine 193
Gear Oil Cooling 489 Oil Leakage Inspection Location 103
Gear Oil Cooling Condenser Operator Cab Front Glass Dimensions 698
Installation 275 Operator Cab Front Side Glass
Gear Oil Cooling Condenser Removal 274 Dimensions 699
Gear Oil Cooling Manifold 490 Operator Cab Glass Replacement 697
Gear Oil Cooling Oil Filters 489 Operator Cab Rear Glass Dimensions 699
Gear Oil Cooling Pump Installation 494 Park Brake (Carlisle) 617
Gear Oil Cooling Pump Removal 492 Park Brake (Carlisle) Installation (Page
Gear Oil Cooling Pump with Hydraulic 1 of 2) 622
Motor 490 Park Brake (Carlisle) Installation (Page
Gear Oil Cooling System Filters 2 of 2) 623
Replacement Procedure 131 Park Brake (Carlisle) Removal (Page 1
Grid Box 291 of 2) 619
Hand Brake Valve and Manifold 440 Park Brake (Carlisle) Removal (Page 2
Hand Brake Valve and Manifold of 2) 620
Installation 442 Pilot Control Valve Assembly 370
Hand Brake Valve and Manifold Pilot Valve Installation 372
Removal 441 Pilot Valve Removal 371
Hoist Cooling System 496 Power Module Assembly Installation 191
Hood and Grill Installation (Page 1 of 3) 670 Power Module Assembly Removal 188
Hood and Grill Installation (Page 2 of 3) 671 Pre-Heaters 295
Hood and Grill Installation (Page 3 of 3) 672 Preventive Maintenance Reference
Hood and Grill Removal (Page 1 of 3) 662 Structure 95
Hood and Grill Removal (Page 1 of 3) 666 Pump Control 410
Hood and Grill Removal (Page 2 of 3) 663 Pump Drive 331
Hood and Grill Removal (Page 2 of 3) 667 Pump Drive Gears 332
Hood and Grill Removal (Page 3 of 3) 664 Pump Drive Unit 331
Hood and Grill Removal (Page 3 of 3) 668 Pump Drive Unit Installation 340
Hydraulic A/C Pump Installation 499 Pump Drive Unit Removal 334
Hydraulic A/C Pump Removal 498 Radiator 238
Hydraulic Pump Schematic 487 Radiator Installation (Page 1 of 4) 248
Hydraulic Tank 342 Radiator Installation (Page 2 of 4) 249
Idler Arm Assembly 567 Radiator Installation (Page 3 of 4) 250
Idler Arm Assembly Installation 572 Radiator Installation (Page 4 of 4) 251
Idler Arm Assembly Removal 569 Radiator Removal (Page 1 of 4) 242
Idler Arm Bearing Check Procedure 142 Radiator Removal (Page 2 of 4) 243
Idler Arm Bearing Check Procedure 143 Radiator Removal (Page 3 of 4) 244
Independent Power Control 300 Radiator Removal (Page 4 of 4) 245
Inverter Controller 297 Rear Brake Assembly Fasteners
Inverters 287 Torque Procedure 156
Inverters Installation 312 Rear Brake Assembly Fasteners
Inverters Removal 310 Torque Procedure 157
LME/10880897/January 30, 2011/en
Jacking Points 49 Rear Brakes 598

Kingpins Installation 556 Rear Brakes Installation (Page 1 of 2) 605
Kingpins Removal 553 Rear Brakes Installation (Page 2 of 2) 606
Lower Kingpin Fasteners Torque Rear Brakes Removal 601
Procedure 168 Rear Control A-Arm (Rear Control Arm
Main Blower Assembly 293 Axle Box) 690
Main Programmable I/O Module Rear Control A-Arm Installation 694
Connection Ports 296 Rear Control A-Arm Removal 692
Main Rectifier 284 Rear Control Arm Fasteners Torque
Main Rectifier Installation 304 Procedure 153
Main Rectifier Removal 303 Rear Disc Brake Hub 610
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T282C-532-Y06435 to 06436 729
Illustration Index Service Manual
Rear Disc Brake Hub Installation (Page Steering Column Upper and Lower
1 of 2) 614 Cover Removal 711
Rear Disc Brake Hub Installation (Page Steering Control Valve 457
2 of 2) 615 Steering Control Valve Installation 460
Rear Disc Brake Hub Removal (Page 1 Steering Control Valve Removal 458
of 2) 611 Steering Cylinder and Tie Rod Bushing
Rear Disc Brake Hub Removal (Page 2 Check Procedure 141
of 2) 612 Steering Cylinder Fasteners Torque
Rear Suspension Gas Discharge 526 Procedure 160
Rear Suspension Installation 520 Steering Cylinder Fasteners Torque
Rear Suspension Oil Drain 522 Procedure 161
Rear Suspension Pressure Check 529 Steering Cylinders 462
Rear Suspensions 516 Steering Cylinders Installation 466
Rear Suspensions 516 Steering Cylinders Removal 463
Rear Suspensions Removal 518 Steering Stop Pads 579
Rear Tire and Rim Assembly 589 Steering Stop Pads Installation 581
Rear Tire and Rim Assembly Removal 591 Steering System 443
Rear Tire Studs Replacement 596 Superstructure 660
Rear Wheel Assembly Fasteners Suspension Charge Log (Sample) 119
Torque Procedure 182 Suspension Maintenance Flowchart 120
Rear Wheel Oil Drain Procedure 150 Tank Gasket 239
Rear Wheel Oil Fill Procedure 151 Tie Rod Fasteners Torque Procedure 164
Removal/Installation of the Steering Tie Rod Fasteners Torque Procedure 165
Accumulator 445 Tie Rods Installation 565
Removal/Installation of the Steering Tie Rods Removal 562
Accumulator 447 Tire and Rim Installation 594
Replace Lower Kingpin Fasteners Toe-In Adjustment 560
Procedure 175 Toe-In Check 557
Replacement of the Tubes 254 Torque Chart for Metric Threaded
Rock Knocker Installation 658 Fasteners 42
Rock Knocker Removal 656 Torque Chart for Metric Unified
Rock Knockers 655 Threaded Fasteners 41
Safety Harness Anchor Tie-Off Points 35 Touch Screen Display Panel 301
Sample Safety Harness 36 Traction Alternator 280
Schematic: AC Drive System 279 Traction Alternator Cut-Away 280
Schematic: Hoist Cooling System 497 Traction Alternator Cut-Away: Rotating
SL-V Injector (Series B) 485 Rectifier Assembly 281
Steering Accumulator Bleed 449 Traction Alternator Installation (Page 1
Steering Accumulator Pre-Charge of 2) 230
Check, Drain, and Pre-Charge Traction Alternator Installation (Page 2
Procedures 112 of 2) 231
Steering Arm 574 Traction Alternator Measurements 234
Steering Arm Fasteners Replacement 177 Traction Alternator Removal (Page 1 of
Steering Arm Fasteners Torque 2) 226
Procedure 170 Traction Alternator Removal (Page 2 of
Steering Arm Installation 577 2) 227
Steering Arm Removal 575 Traction Motor 290
Steering Column 703 Turn Signal Switch Wire Removal 705
LME/10880897/January 30, 2011/en
Steering Column and Controls Turn Unloader Accumulator Pre-Charge

Signal Lever and Dimmer Switch Check, Drain, and Pre-Charge
Removal 707 Procedures 116
Steering Column Signal Switch Upper and Lower Control Arm 583
Removal 711 Upper and Lower King Pins and
Steering Column Trough Cover Spindle 552
Removal 709 Upper Kingpin Fasteners Torque
Steering Column Upper and Lower Procedure 172
Cover Removal 705 X and Y Horizontal Measurements 145
Steering Column Upper and Lower
Cover Removal 706
copyright by
730 T282C-532-Y06435 to 06436

532 SM Collahuasi Rev000 Jan 30 2011 PDF

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en Service Manual

Order number: 10880897

Manufacturer: Liebherr Mining Equipment Newport News Co.

Address Liebherr Mining Equipment Newport News Co.

LME/10880897/January 30, 2011/en

2.2.8 Fire Extinguisher 29

2.2.15 Safety Alert Signs and Label Maintenance 33

2.4.16 Shielded Metal Arc Welding (SMAW) Welding

2.6.3 51288AM (2 per bumper) 51

3.1.4 Front Wheel Assembly 68

4.10 LME-30-01-01 - Axle Box Inspection 102

4.13.3 Brake Accumulator Pre-Charge 107

4.28.2 Steering Cylinder and Tie Rod Bushing Check 140

4.32.1 Rear Wheel Oil Drain Procedure 150

5 Power Module (Drive System) 185

5.4.4 Engine Air Cleaner Ducts Installation 223

5.7.1 Fuel and Hydraulic Tank Drain 236

6 Cooling Systems 237

7 Electrical Power and Distribution 277

7.1.6 Inverters 287

8 Hydraulic Power and Distribution 329

8.1.5 Drive Shaft Removal 336

9 Dump System 355

9.8.2 Observation: Dump Body will not Rise 388

10 Hydraulic Brake and Steering Systems 407

10.1 Brake and Steering Pump 409

10.8.4 Steering Control Valve Installation 460

10.11.4 Brake and Steering Pump Unloader Valve

11 Hydraulic Auxiliary Systems 477

11.4.1 Hydraulic A/C Pump Removal 498

12.1.4 Front Suspensions Installation 506

13 Wheel Assemblies 531

13.7.1 Tie Rods Removal 562

13.9.1 Steering Arm Removal 575

14 Frame, Dump Body and Structures 629

14.2.5 Dump Body Installation and Alignment 635

14.3.4 Dump Body Pivot Pins and Bearing Installation and

15 Operator Cab 695

15.2 Foot Pedal Controls 701

15.3.2 Left and Right Turn Signals Lever, and Dimmer

16 Computers and Auxiliary Systems 717

17 Class Documents 719

List of Acronyms 721

Illustration Index 727

LME/10880897/January 30, 2011/en

1.1.1 General Overview

If differences in interpretations between translated versions of this manual

1.2 Service Manual Organization

1.2.1 Task Analysis

1.2.2 Manual Organization

14. Operator Cab

1.2.5 Required Tools and Materials

1.2.7 Serviceable Parts

LME/10880897/January 30, 2011/en

2.2.23 Hydraulic Safety 38

2.3.2 Torque Chart for Metric Threaded Fasteners 42

2.7.3 Adaptor Hanging Forklift Load 10469271 55

2.7.10 Gas Tank Nipple T-107-A 57

This chapter contains the information that follows:

LME/10880897/January 30, 2011/en

The most important safety defence is to use common sense. Remember,

2.2.1 Visual Safety Alert Devices

Signal words used in this publication: