Manual de Manutenção (10339442 327 MM VALE Rev002 Mar 15 09)

Maintenance Manual 01 Introduction
02 Tools
Model T 282 B
03 Technical Data and Maintenance Plan
Customer:
04 Cab Controls and Instrumentation
VALE
Serial Numbers: 05 Power Module

S/N 327
06 Electrical Power and Distribution
07 Hydraulic Power and Distribution

P/N 10339442
Revision 001 08 Dump System
09 Brake and Steering System
10 Auxiliary Systems
Publication Date:
11 Suspensions
March 15, 2009
12 Wheel Assemblies
MJFCIFSS!
MINING EQUIPMENT COMPANY 13 Frame and Structures
4100 Chestnut Avenue, 14 Welding Procedures

Newport News, Virginia, 23607 USA
Telephone: (757) 245-5251
Fax: (757) 928-2211
15 Index
01 Introduction
Safety.............................................................................................................. 01-10-01
Health and Safety Information......................................................................01-12-01
Haul Truck Safety Precautions.....................................................................01-16-01
Safety Harness Anchor Tie-Off Points.........................................................01-18-01
General Maintenance Practices....................................................................01-20-01
How to Use this Publication......................................................................... 01-22-01
Useful Information......................................................................................... 01-30-01

[Page left intentionally blank]

01 Introduction
The introduction chapter gives some basic information in the areas that follow:
Safety (Ref. 01-10-000-DA)
Health and Safety Information (Ref. 01-12-000-DA)
Haul Truck Safety Precautions(Ref. 01-16-000-DA)
General Maintenance Practices(Ref. 01-20-000-DA)
How to use this Publication (Ref. 01-22-000-DA)
Useful Information(Ref. 01-30-000-DA)
General
This publication gives the service, repair, and maintenance procedures for the T 282 B
haul truck made by the Liebherr Mining Equipment Company (LME). This publication
does not have all the maintenance information about specified Original Equipment
Manufacturer (OEM) components. Refer to the specified OEM publications for more
information.
Completely read this publication before you begin any repairs, service, or maintenance
work on the haul truck. The information in this publication can change without notice.
Continue to read the information in this publication to keep your skills current.
Read and get to understand the jobsite instructions about service, repair, maintenance,
and work area safety.
T282B S/N 327 01-00-01

Introduction Maintenance Manual
01-00-02 T282B S/N 327

Maintenance Manual Introduction
Safety
01-10 Safety
This section has the safety information that follows:
Health Hazard Information

Signal Words and Safety Labels
Protective Equipment
Burns
Coolant
Oils
Batteries
Chemicals
Loctite®
Haul Truck Safety Precautions

Safety Signs and Labels on the Haul Truck
Safety Sign and Label Maintenance
Maintenance Preparation
Maintenance Parking
Brake Safety
How to Clean a Component Before Maintenance or Inspection
Anchor Tie-Off Points
Tire Safety
Jacks and Lift Devices
Hydraulics Safety
Dump Body
General Safety Precautions
Work Area Safety

The service, maintenance, and technical personnel have the responsibility to read the
safety information shown in this publications.
Remember, you are the key to your safety. Good safety procedures can protect you
and other personnel when you do repairs, service, and maintenance work. The
information shown in this publication can help personnel do safer repair, service, and
maintenance on the T 282 B haul truck. Read the information shown in this publication.
Get to know and understand the jobsite safety procedures that you must follow for your
additional safety.
T282B S/N 327 01-10-01

Safety
01-10-02 T282B S/N 327

Health and Safety Information
01-12 Health and Safety Information

Signal Words and Safety Labels in this Publication
The safety symbols in this publication alert you to an instruction or procedure that you
must follow to prevent personnel injury and damage to a component.
The safety symbols with alert messages in this publication are shown as follows:
Operation
Danger! This symbol indicates possible injury or death to persons.
Follow all instructions shown by this danger symbol.
Warning! This symbol indicates possible hazards to persons.

Follow all instructions shown by this symbol.
Caution! This symbol indicates possible damage to equipment.

Read and understand the instructions for materials, limits, and methods.
Follow all instructions to prevent injuries.
Attention! This information gives instructions to make procedures easier.

Refer to this information for additional tips.
Notice! This symbol gives additional information that is not described by danger, warning,
caution, or attention.
Read the information shown by this symbol for more information.
First Aid Kit

Prepare for emergencies. Keep a first aid kit in the area where you do the work. Make
sure the first aid kit contains the necessary material for the treatment of small injuries.
Protective Equipment
Put on approved protective equipment and the applicable clothing that can protect you
for specified procedures.
Wear a rubber apron and rubber gloves to protect your body from chemicals, and other
materials that cause the skin damage.
Parts that move can hold loose clothing, jewelry, and cause injury. Do not wear loose
clothing, or jewelry while you do the repair, service, or maintenance work.
Do not put objects into your clothing that can fall into parts or components. Keep your
clothing, pockets without small objects and items that can fall into components.
Keep your clothing, pockets without small objects, and items that can fall into
T282B S/N 327 01-12-01

components or parts that move.
Burns
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.
Coolant
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 with 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.
Make sure the filler cap is cool before you remove the filler cap.
The system 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.
For coolant leaks or spills, contain the spill with an approved material that can absorb.
Contain and remove all of the cleaning material according to local anti-freeze-disposal
laws and regulations. Do not combine used coolant with other chemicals.
Oils
Hot oil and components can cause burns and other injuries. Make sure hot oils and
components do not touch the skin.
Remove the hydraulic tank filler cap after the engine is stopped. The filler cab must be
cool enough to touch with an exposed hand. Wear approved gloves and other
protective equipment approved for the task. Follow the jobsite procedures for the safe
removal of hydraulic tank filler cap.
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 for approximately 15 minutes.
Use an alternative light to check the batteries. Do not check the batteries with the
engine in operation.
An expansion at the end of a battery indicates the battery is frozen. Carefully follow the
battery manufacturer repair, service, and maintenance instructions.
Chemicals
Follow the manufacturer instructions for the correct directions for use for specified
chemicals.
Wear the approved protective clothing and equipment for tasks that include specified
chemicals.
Know the jobsite chemical removal procedures.
01-12-02 T282B S/N 327

Loctite®
If the Loctite® gets into the eyes, or touches the skin, immediately flush the area with
clean water.
Get medical attention wile you continue to flush the area for approximately 10 minutes.
If the Loctite® gets into the mouth, drink clean water. Get medical attention while you
continue to drink clean water.
T282B S/N 327 01-12-03

01-12-04 T282B S/N 327

01-16 Haul Truck Safety Precautions

This section gives some information on the haul truck safety precautions as follows:
Safety Signs and Labels on the Haul Truck
Maintenance Parking
Brake Safety
Anchor Tie-Off Points
Tire Safety
Jacks and Lift Devices
Hydraulics Safety
Dump Body
Safety Signs and Labels

1. DO NOT OPERATE WITHOUT GUARDS
2. USE HAND RAILS
3. CONTAINS HIGH PRESSURE GAS
4. HIGH VOLTAGE
5. NOT ALL ELECTRICAL POWER ISOLATED
6. CONTAINS HIGH PRESSURE FLUID
7. KEEP CLEAR OF REAR OF TRUCK
8. KEEP CLEAR OF FRONT OF TRUCK
9. DO NOT STAND BETWEEN TIRE AND FRAME
10. HIGH VOLTAGE (sign)
11. AUTHORIZED PERSONNEL ONLY (sign)
T282B S/N 327 01-16-01

01-16-001 Safety Signs and Labels
01-16-02 T282B S/N 327

DO NOT OPERATE WITHOUT GUARDS

This caution label shows the items or areas with removable guards. The guards can
prevent injury to personnel from components that turn or move. The guards are
removable to let access for maintenance work. Do not operate the haul truck when the
guards are removed.
USE HAND RAILS
This caution label tells the personnel to use the hand rails.
CAUTION HIGH PRESSURE GAS
This label shows the components that contain high-pressure gas.
Before you do work on these systems, read the related safety information. Follow the
specified jobsite safety instructions.
HIGH VOLTAGE
This danger label shows the components or systems with high-voltage electricity.
ELECTRICAL POWER NOT ISOLATED
This caution label tells even if electrical power is disconnected, electricity can remain in
the electrical circuits. Use caution when you do work on electrical systems.
CONTAINS HIGH PRESSURE FLUID
This caution label shows the components that contain high-pressure fluids.
KEEP FROM BEHIND THE HAUL TRUCK
This label shows to keep from behind the haul truck when the engine is in operation.
Keep from behind the haul truck even if an operator is in the cab.
KEEP FROM FRONT OF THE HAUL TRUCK
This label shows to keep from the front of the haul truck when the engine is in
operation. Keep from the front of the haul truck even with an operator in the cab.
DO NOT STAND BETWEEN TIRE AND FRAME
This label shows to keep from between the tire and the frame. The tire can press and
hold you between the frame when the tire moves.
HIGH VOLTAGE (sign)
These danger signs show areas that have high-voltage electricity.
Unless you are authorized, keep from these areas.
AUTHORIZED PERSONNEL ONLY (sign)
This danger sign shows the areas for approved personnel.
T282B S/N 327 01-16-03

Unless you are approved, keep from these areas.

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.
Follow the specified 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 approved clothing and protective equipment specified for the task.
Follow the specified tag-out, and lockout procedures.
Carefully remove stored energy from all systems.
Keep personnel not approved from the work area.
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 the front wheels in the parking ditch.
Set the parking brake, and make sure the haul truck cannot move.
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 recommended brake fluids.

Remove all dirt from the component to make sure the maintenance is done safely.
Danger! The correct equipment or component clean procedures are for the safety of personnel
and equipment.
Failure to follow the instructions can cause injury to personnel, or damage to the equipment.
Always follow the correct equipment and component clean procedure.
Stop the engine and let the temperature completely decrease.

Do not clean the haul tuck with the engine in operation.
Put on the approved protective equipment, and clothing for the specified task.
01-16-04 T282B S/N 327

Do not direct, spray, or discharge steam or water on the electrical systems, or electrical
components.
Do not direct, spray, or discharge steam or water on the seals of the hydraulic components.
T282B S/N 327 01-16-05

Anchor Tie-Off
The haul truck has anchor tie-off points to which an approved safety harness is
installed. The safety harness can prevent personnel from falls when service or
maintenance work is done from above the ground.
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. park brake
The anchor tie-off points can hold a weight capacity of 2300 kg (5100 lb).
01-16-002 Safety Harness Anchor Tie-Off Points
Jack and Lift Devices

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, or damage.
Do not use any device with damaged cables.
Warning! Keep from under a haul truck held by a jack, or a lift.

The jacks and lifts are used to hold or put the haul truck into a specified position.
LME has not specified a jack or lift strong enough to hold the complete haul truck weight.
Tire Safety
Unless you are approved, do not do any maintenance, service, or repair work to the tires.
Special tools and attachments are necessary to change the haul truck tires. Get the correct
authorization before you use any specified attachment for repairs, service, or maintenance work
01-16-06 T282B S/N 327

on the tires.
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.
Warning! Keep from under a tire that is not completely on the ground.
Different conditions and material can change the haul truck and the tire weight.
Know the hazards that can occur from heavy objects.
Do not inflate the tires above the recommended pressure.

Inspect the tires and the wheels each day. Do not release a haul truck into service if the tires
have missing bolts, incorrect tire pressure, cuts, expansions, or damage.
Keep the lug nuts tighten to the correct manufacturer specification.
Hydraulics Safety
To operate correctly, hydraulic systems must store hydraulic fluid under high-pressure.
Accidents 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 systems 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.
Protect components from the hot oil.
Before you do any repairs on hydraulic systems, remove all pressure.
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, release the high-pressure oil, and hydraulic hoses.
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 use your hands, or fingers to check hydraulic hoses for leaks. Instead of your hands, or
fingers, move a piece of wood or cardboard along the hose.
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.
The pressure relief valves are installed in the hydraulic systems to prevent pressure increase
during use. Keep the relief valves clean. Do tests of the valves at intervals to make sure the
valves operate correctly.
Some procedures require the engine 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.
T282B S/N 327 01-16-07

Keep the hydraulic oil for hydraulic systems clean and replace the filters at intervals.
To prevent the corrosion of the hydraulic systems, do the lubrication of the hydraulic hoses at the
set intervals.
Keep high-pressure steam or water from the seals of the hydraulic components.
Use a solution that cannot damage the component to clean hydraulic parts.
An incorrectly serviced hydraulic system can cause the component to fail. Safe hydraulic system
performance requires general maintenance.
Dump Body Safety

Install safety cables, or bars to hold the dump body in position before the start of any procedure.
Put the dump body completely in the DOWN position before you move the haul truck.
The dump system has pressure even if the engine is not in operation. When a procedure requires
the dump body lifted, install two safety cables or bars on the anchors.
01-16-08 T282B S/N 327

Safety Harness Anchor Tie-Off Points
01-18 Safety Harness Anchor Tie-Off Points

(Ref. Fig. 01-18-001)
Operation
The haul truck has safety harness anchor tie-off points. The function of the safety
harness anchor tie-off points is to make sure personnel do not fall from the haul truck
during maintenance.
Use an approved safety harness at all times while you perform any maintenance
and/or repair work above ground on the haul truck.
Read the safety harness instructions of the manufacturer carefully. The safety harness
must be within the installation limits of the manufacturer and securely installed to the
safety harness anchor tie-off points of the haul truck.
The weight support capacity of the safety harness anchor tie-off points is 2300 kg
(5100 lb).
01-18-001 Safety Harness Anchor Tie-Off Points
Maintenance Tips
Always put on a safety harness and attach the safety harness to an anchor tie-off point
when you do work above ground.
T282B S/N 327 01-18-01

Safety Harness Anchor Tie-Off Points
01-18-02 T282B S/N 327

General Maintenance Practices
01-20 General Maintenance Practices

Only approved personnel must do the repairs, service, and maintenance on the haul
truck. If you are not approved, do not do any work on the haul truck.
Always make sure you have the correct and full instructions for the procedure.
Make sure you have the correct tools for the procedure.
Only approved personnel must do the repairs, service, and maintenance on the haul truck. If you
are not approved, do not do any work on the haul truck.
Read and understand the jobsite safety instructions before you begin work on the haul truck.
Read and understand the safety messages for each procedure before you begin the procedure.
Do not use the haul truck for a work platform.
Persons are not permitted on the platform of the haul truck while the haul truck is n motion.
Use the correct information, tools, and equipment for the procedures shown in this publication.
Before you begin a procedure, check the operation of the required tools.
Before you begin a procedure, make sure you have the recommended materials available to
complete the procedure.
Check the lubrication charts before you begin work on the haul truck. (link).
Know how to calculate units of measure to the standard used by the mine.
Check the torque values and other related information before you begin work on the haul truck.
Calculate the required time necessary to complete a procedure. Do not interrupt procedures at a
step that can cause hazards.
Do all of the steps in the procedures. Repairs, service, and maintenance work can be dangerous.
Follow all the steps, specifications, and obey the limits shown in each procedure.
Fire and Explosion Hazards

Add the fuel after the haul truck is stopped and the electrical equipment is turned off.
Use caution while the fuel is added to the haul truck.
Put the fuel nozzle against the fuel neck to prevent sparks.
Remove all trash and flammable material from the area of the haul truck before fuel is added to
the haul truck.
Diesel 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.
Know the location and the operation of the fire extinguishers. Test the fire extinguishers before
you begin to do work in the work area.
Follow the environmental and local instructions for oil, and toxic material removal.
T282B S/N 327 01-20-01

General Maintenance Practices
Fire Wall
The haul truck has special material installed that can keep flames, smoke, and fumes from
personnel 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.
Do not use the diagonal ladder to go to the ground level if an engine fire occurs. Use the ladder
on the driver-side of the haul truck to go from the platform to the ground level.
Follow the mine-specified fire safety procedures.
Fire Extinguisher
Make sure a fire extinguisher is available in the work area.
Approved personnel must test the fire extinguishers at intervals.
Approved personnel must immediately replace the instructions for use labels on the fire
extinguishers when the label is missing or cannot be read.
Prepare the Work Area

Remove oil, grease, water, and obstruction from the work surface.
Apply only approved material to absorb the oil from the ground around the work area.
Make sure you have enough space to do the repairs, service, and maintenance.
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 procedures.
01-20-02 T282B S/N 327

How to Use this Publication
01-22 How to Use this Publication

The information in this publication has chapters that describe the assemblies,
subassemblies, components, and the maintenance procedures. (Ref. Fig. )
Overview
This publication uses an alphanumeric sequence that has four parts separated by a
hyphen to show the information.
Part one of this alphanumeric sequence identifies the assembly.
Part two identifies the subsystem.
Part three identifies the procedure for the assembly or the subassembly.
Part four shows the date of the version from the manufacturer.
Procedure Format
Each procedure is identified by the type of maintenance for the assemblies,
subassemblies, and components. Each maintenance procedure is shown in the
following sequence:
The removal or installation procedures use a sequence range from 100 to 200.
The maintenance procedures use the 300 sequence.
The inspection and check procedures use the 400 sequence.
The adjustment and test procedures use the 500 sequence.
The repair procedures use the 600 sequence.
The service procedures use the 700 sequence.
The clean and paint procedures use the 800 sequence.
The standard procedures use the 900 sequence.
Each procedure has three groups.
Setup group
Procedure group
Closeout group
The setup group has the steps to prepare for each procedure.
The procedure group has the steps for each procedure.
The closeout group has the smaller procedures to complete each procedure.
Removal and Installation Procedures

The removal and installation procedures refer to the same illustration.
Removal Procedures
The removal procedures have references to other illustrations.
Installation Procedures
These procedures can include tables that show materials recommended by the OEM
for use in each procedure.
T282B S/N 327 01-22-01

How to Use this Publication
The installation procedures can include a parts table.

The parts table shows the parts that you must remove for the procedure.
Illustrations
The illustrations show the parts of an assembly, subassembly, or component. These
illustrations show how to disassemble large assemblies by numeric references. When
an illustration continues, the references are shown on the right of the page.
The reference numbers on the illustrations match the references shown in the
procedure. The same numeric reference for the part is shown after the technical label
of the part described in the procedure.
Parts Tables
The parts tables have four columns with these names:
Reference
Technical Label
Quantity
Drawing Item
Read the information from the parts tables from left to right.
Reference
The reference column shows the same numeric reference from the illustration. Each
procedure has the same numeric reference for each technical label.
Technical Label
The technical label column shows the technical label for the part.
Quantity
The quantity column shows the number of parts required for the procedure.
Drawing Item
The drawing-item has a reference in the parts catalog shown as “assembly index by
part number”. The drawing-item has another reference in the parts catalog shown as
“position number” for the assembly.
The part numbers for the replacement parts are found in the parts catalog. The parts
table in the illustration procedure from the maintenance manual shows the assembly
and drawing from the parts catalog. Use the parts catalog to find the part numbers for
all replacement parts.
01-22-02 T282B S/N 327

Useful Information
01-30 Useful Information

This section data has this information:
Temperature Conversions
Unit of Measure Conversions
Fraction Decimal Equivalents
O-ring Size Identification
Torque Specifications
Information Tables
Information Tables
Temperature Conversions
Temperature Temperature
-60 °C (-76 °F) 95 °C (203 °F)
-55 °C (-67 °F) 100 °C (212 °F)
-50 °C (-58 °F) 105 °C (221 °F)
-45 °C (-49 °F) 110 °C (230 °F)
-40 °C (-40 °F) 115 °C (239 °F)
-35 °C (-31 °F) 120 °C (248 °F)
-30 °C (-22 °F) 125 °C (255 °F)
-25 °C (-13 °F) 130 °C (265 °F)
-20 °C (-4 °F) 135 °C (275 °F)
-18 °C (0 °F) 140 °C (285 °F)
-15 °C (5 °F) 145 °C (295 °F)
-10 °C (14 °F) 150 °C (300 °F)
-5 °C (23 °F) 155 °C (310 °F)
0 °C (32 °F) 160 °C (320 °F)
5 °C (41 °F) 165 °C (330 °F)
10 °C (50 °F) 170 °C (340 °F)
15 °C (59 °F) 175 °C (345 °F)
20 °C (68 °F) 180 °C (355 °F)
25 °C (77 °F) 185 °C (365 °F)
30 °C (86 °F) 190 °C (375 °F)
35 °C (95 °F) 195 °C (385 °F)
40 °C (104 °F) 200 °C (390 °F)
45 °C (113 °F) 205 °C (400 °F)
50 °C (122 °F) 210 °C (410 °F)
55 °C (131 °F) 215 °C (420 °F)
60 °C (140 °F) 220 °C (430 °F)
65 °C (149 °F) 225 °C (435 °F)
70 °C (158 °F) 230 °C (445 °F)
75 °C (167 °F) 235 °C (455 °F)
T282B S/N 327 01-30-01

Useful Information
Temperature Temperature
80 °C (176 °F) 240 °C (465 °F)
85 °C (185 °F) 245 °C (475 °F)
90 °C (194 °F) 250 °C (480 °F)
The formula for Fahrenheit to Celsius conversion is:

((F - 32) x 5) divided by 9 = C
The formula for Celsius to Fahrenheit conversion is:
((C x 9) divided by 5) + 32 = F
The boiling point for pure water at sea level is 100 °C (212 °F)The freezing point for
pure water at sea level is 0 °C (32 °F).
Unit of Measure Conversions

Conversion of metric units of measure into U.S. equivalents:
Metric multiply 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/cm2) 14.22 pounds per square inch (psi)
gram (gr) 0.0353 ounce (oz)
kilogram (kg) 2.205 pound (lb)
tonne (metric ton)(t) 1.102 ton (short)(tn)
Conversion of U.S. units of measure into metric equivalents:
01-30-02 T282B S/N 327

Useful Information
U.S. Equivalent multiply by Metric

inch (in.) 25.4 millimeter (m)
inch (in.) 2.54 centimeter (cm)
inch (in.) 0.0254 meter (m)
foot (ft) 0.3048 meter (m)
square inch (in2) 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 tonne (metric ton (t)
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
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
15/64 .234 .234375
1/4 .250 .250000
T282B S/N 327 01-30-03

Useful Information

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
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
7/8 .875 .875000
57/64 .891 .890625
29/32 .906 .906250
59/64 .922 .921875
01-30-04 T282B S/N 327

Useful Information

15/16 .938 .937500
61/64 .953 .953125
31/32 .969 .968750
63/64 .984 .984375
O-ring Size Identification

Caution! O-rings must agree with or be higher than the specifications of the original equipment
manufacturer (OEM). O-rings must be correct for petroleum based lubricants (SAE Type 1 or
equivalent)the petroleum.
If you use the incorrect hydraulic oil this can cause an important seal failure.
See your Liebherr Service Person before you change hydraulic oil types.
The haul truck uses SAE type fittings with straight thread and divided flange. O-ring
seals are necessary for these fittings. Refer to the type of fitting to find the measure of
the o-ring you must use. Not the dimension of the tube.
(Ref. Fig. 01-30-001)
O-rings for standard SAE straight thread fittings (Ref. SAE J515a) are:
Tubing OD (inch) Dash No. Type 1 Dim. N (inch) Dia. Dim. L (inch) ID
1/8 2-1 0.064 ± 0.003 0.239 ± 0.005
3/16 3-1 0.064 ± 0.003 0.301 ± 0.005
1/4 4-1 0.072 ± 0.003 0.351 ± 0.005
5/16 5-1 0.072 ± 0.003 0.414 ± 0.005
3/8 6-1 0.078 ± 0.003 0.468 ± 0.005
1/2 8-1 0.087 ± 0.003 0.644 ± 0.005
5/8 10-1 0.097 ± 0.003 0.755 ± 0.005
3/4 12-1 0.116 ± 0.004 0.924 ± 0.006
7/8 14-1 0.116 ± 0.004 1.048 ± 0.006
1 16-1 0.116 ± 0.004 1.171 ± 0.006
1 1/4 20-1 0.118 ± 0.004 1.475 ± 0.010
1 1/2 24-1 0.118 ± 0.004 1.720 ± 0.010
2 32-1 0.118 ± 0.004 2.337 ± 0.010
O-rings for divided flange fittings (Ref. SAE J518c) are:
Nominal Flange Size O-ring Size No. Dim. N Dia. Dim. L ID Dim. M OD
(inch)
1/2 210 3.53 mm (0.139 in.) 18.64 mm (0.734 in.) 25.70 mm (1.012 in.)
3/4 214 3.53 mm (0.139 in.) 24.99 mm (0.984 in.) 32.05 mm (1.262 in.)
1 219 3.53 mm (0.139 in.) 32.92 mm (1.296 in.) 39.98 mm (1.574 in.)
1 1/4 222 3.53 mm (0.139 in.) 37.69 mm (1.484 in.) 44.75 mm (1.762 in.)
1 1/2 225 3.53 mm (0.139 in.) 47.22 mm (1.859 in.) 54.28 mm (2.137 in.)
2 228 3.53 mm (0.139 in.) 56.74 mm (2.234 in.) 63.80 mm (2.512 in.)
2 1/2 232 3.53 mm (0.139 in.) 69.44 mm (2.734 in.) 76.50 mm (3.012 in.)
T282B S/N 327 01-30-05

Useful Information
01-30-001 O-ring Dimensions
Torque Specifications
The torque necessary for a fastener is related to size, grade, and condition of the
fastener. For example, it is necessary to torque a clean fastener, without lubrication,
approximately 33 percent more to get the same clamping force as the same fastener
with lubrication. The torque necessary for plain fasteners without lubrication is
approximately 10 to 20 percent more than a dry cadmium plated fastener of the same
size and thread.
All fasteners must be in satisfactory condition to get the correct clamping force. All
fasteners must be free of nicks and burrs, and the threads should be constant and
equal. Replace all fasteners in unsatisfactory condition.
Lubricated fasteners - most fasteners (plated, and some black fateners) come with a
thin layer of oil on them. If the fastener has dirt on it or is dry, clean the fastener and
apply a thin layer of oil. Use a good grade, low sulfur oil (10W or 30W). Apply the oil as
a spray, or momentarily put the fastener in the oil.
The table that follows shows the recommended torque for lubricated fasteners. It is
possible that the table below is not applicable to fasteners by manufacturers other than
LME.
English
Fastener Dia. and Thread Grade 5 Grade 8
Size
1/4 - 20 8.5 Nm (75 lbf in.) 12.2 Nm (110 lbf in.)
1/4 - 28 9.8 Nm (85 lbf in.) 13.6 Nm (120 lbf in.)
5/16 - 18 17.5 Nm (150 lbf in.) 24.4 Nm (220 lbf in.)
5/16 - 24 19.0 Nm (170 lbf in.) 27.1 Nm (240 lbf in.)
01-30-06 T282B S/N 327

Useful Information
English
Fastener Dia. and Thread Grade 5 Grade 8
Size
3/8 - 16 31.0 Nm (23 lbf ft) 47.5 Nm (35 lbf ft)
3/8 - 24 34.0 Nm (25 lbf ft) 47.5 Nm (35 lbf ft)
7/16 - 14 47.5 Nm (35 lbf ft) 74.6 Nm (55 lbf ft)
7/16 - 20 54.0 Nm (40 lbf ft) 81.3 Nm (60 lbf ft)
1/2 - 13 74.5 Nm (55 lbf ft) 108 Nm (80 lbf ft)
1/2 - 20 88.0 Nm (65 lbf ft) 122 Nm (90 lbf ft)
9/16 - 12 108.5 Nm (80 lbf ft) 149 Nm (110 lbf ft)
9/16 - 18 122.0 Nm (90 lbf ft) 176 Nm (130 lbf ft)
5/8 - 11 149.0 Nm (110 lbf ft) 230 Nm (170 lbf ft)
5/8 - 18 176.5 Nm (130 lbf ft) 244 Nm (180 lbf ft)
3/4 - 10 271 Nm (200 lbf ft) 380 Nm (280 lbf ft)
3/4 - 16 298 Nm (220 lbf ft) 434 Nm (320 lbf ft)
7/8 - 9 434 Nm (320 lbf ft) 624 Nm (460 lbf ft)
7/8 - 14 475 Nm (350 lbf ft) 678 Nm (500 lbf ft)
1.0 - 8 650 Nm (480 lbf ft) 922 Nm (680 lbf ft)
1.0 - 14 720 Nm (530 lbf ft) 1003 Nm (740 lbf ft)
1 1/8 - 7 815 Nm (600 lbf ft) 1302 Nm (960 lbf ft)
1 1/8 - 12 895 Nm (660 lbf ft) 1464 Nm (1080 lbf ft)
1 1/4 - 7 1140 Nm (840 lbf ft) 1844 Nm (1360 lbf ft)
1 1/4 - 12 1250 Nm (920 lbf ft) 2034 Nm (1500 lbf ft)
1 3/8 - 6 1490 Nm (1100 lbf ft) 2413 Nm (1780 lbf ft)
1 3/8 - 12 1710 Nm (1260 lbf ft) 2766 Nm (2000 lbf ft)
1 1/2 - 6 1980 Nm (1460 lbf ft) 2300 Nm (1700 lbf ft)
1 1/2 - 12 2225 Nm (1640 lbf ft) 3606 Nm (2700 lbf ft)
2 1/4 - 4.5 N/A 6780 Nm (5000 lbf ft)
Metric
Fastener Dia. and Thread Size Class 10.9 Class 12.9
M3 X 0.5 1.92 Nm (17 lbf in.) 2.30 Nm (20.4 lbf in.)
M4 X 0.7 4.40 Nm (39 lbf in.) 5.25 Nm (46 lbf in.)
M5 X 0.8 8.65 Nm (75 lbf in.) 10.4 Nm (90 lbf in.)
M6 X 1 15 Nm (130 lbf in.) 18 Nm (160 lbf in.)
M7 X 1 25 Nm (220 lbf in.) 29 Nm (21 lbf ft)
M8 X 1.25 36 Nm (27 lbf ft) 43 Nm (32 lbf ft)
M8 X 1 38 Nm (28 lbf ft) 45 Nm (33 lbf ft)
T282B S/N 327 01-30-07

Useful Information
Metric
Fastener Dia. and Thread Size Class 10.9 Class 12.9
01-30-08 T282B S/N 327

02 Tools


02 Tools
Pin Puller T-075-B (Ref. Fig. 02-00-001)
Stand T-099-A (Ref. Fig. 02-00-002)
Lifting Bracket T-103-E (Ref. Fig. 02-00-003)
Nitrogen Charging and Gauging Kit T-107-T (Ref. Fig. 02-00-004)
Pin Puller T-124-C (Ref. Fig. 02-00-005)
Chain and Spreader Beam T-128-F (Ref. Fig. 02-00-006)
Rear Wheel Assembly Lifting Beam T-128-K (Ref. Fig. 02-00-007)
Suspension Removal Tool T-175-A (Ref. Fig. 02-00-008)
Shipping Brackets T-193-A (Ref. Fig. 02-00-009)
Measuring Tool T-481 (Ref. Fig. 02-00-010)
Lifting Fixture T-478 (Ref. Fig. 02-00-011)
Shipping Skid T-500-J (Ref. Fig. 02-00-012)
Disc Brake Hub Puller T-504-A (Ref. Fig. 02-00-013)
Dump Cylinder Tool 10025660 (Ref. Fig. 02-00-014)
Bearing Installation 10025794 (Ref. Fig. 02-00-015)
Electrical Repair Kit SVC-101 (Ref. Fig. 02-00-016)
T282B S/N 327 02-00-01

Tools Maintenance Manual
Overview
Pin Puller T-075-B
The function of the pin puller is to remove the pins from the control arms.
02-00-001 Control Arm Pin Puller
02-00-02 T282B S/N 327

Maintenance Manual Tools
Stand T-099-A
The function of the stand is to hold the axle box.
02-00-002 Axle Box Stand
T282B S/N 327 02-00-03

Lifting Bracket T-103-E

The function of the lifting bracket is to lift the front wheel assembly.
02-00-003 Front Wheel Lifting Bracket
02-00-04 T282B S/N 327

Nitrogen Charging and Gauging Kit T-107-T

The function of the nitrogen charging and gauging kit is to charge the accumulators
and suspensions with nitrogen.
T282B S/N 327 02-00-05

02-00-004 Nitrogen Charging and Gauging Kit
02-00-06 T282B S/N 327

Pin Puller T-124-C

The function of the pin puller is to remove the pins from the front suspension.
02-00-005 Front Suspension Pin Puller
T282B S/N 327 02-00-07

Chain and Spreader Beam T-128-F

The function of the chain and spreader beam is to lift the engine.
02-00-006 Chain and Spreader Beam
02-00-08 T282B S/N 327

Rear Wheel Assembly Lifting Beam T-128-K

The function of the rear wheel assembly lifting beam is to lift the rear wheel assembly.
02-00-007 Rear Wheel Assembly Lifting Beam
T282B S/N 327 02-00-09

Suspension Removal Tool T-175-A

The function of the suspension removal tool is to remove the pin from the rear
suspension.
02-00-008 Rear Suspension Removal Tool
02-00-10 T282B S/N 327

Shipping Brackets T-193-A

The function of the shipping brackets is to supply support to the dump cylinder during
removal and installation.
02-00-009 Dump Cylinder Shipping Brackets
T282B S/N 327 02-00-11

Measuring Tool T-481

The function of the measuring tool is to measure the depth through a hole.
02-00-010 Measuring Tool
02-00-12 T282B S/N 327

Lifting Fixture T-478

The function of the lifting fixture is to lift the wheel motor.
02-00-011 Lifting Fixture
T282B S/N 327 02-00-13

Shipping Skid T-500-J

The function of the shipping skid is to hold the power module assembly during
shipping.
02-00-012 Shipping Skid
02-00-14 T282B S/N 327

Disc Brake Hub Puller T-504-A

The function of the disc brake hub puller is to remove the hub from the rear brake.
02-00-013 Disc Brake Hub Puller
T282B S/N 327 02-00-15

Dump Cylinder Tool 10025660

The function of the dump cylinder tool is to help adjust and install the dump cylinder.
02-00-014 Dump Cylinder Tool
02-00-16 T282B S/N 327

Bearing Installation 10025794

The function of the bearing installation tool is to install the front wheel bearing.
02-00-015 Front Wheel Bearing Installation
T282B S/N 327 02-00-17

Electrical Repair Kit SVC-101

The electrical repair kit has the crimp tools necessary to maintain the wiring of the
electrical system.
02-00-016 Electrical Repair Kit
02-00-18 T282B S/N 327

03 Technical Data and Maintenance
Plan
Oil and Lubricant Specifications..................................................................03-12-01
Component Weights and Dimensions......................................................... 03-14-01
Lubrication, Fluids, and Filters.................................................................... 03-20-01
Daily Inspections and Checks............................................................. 03-20-04
Fluids, Filters, and Miscellaneous Schedules..................................... 03-20-07
Preventive Maintenance Schedule...............................................................03-30-01
100 Hours - One Time Only................................................................ 03-30-03
Weekly - Rear Wheel OEM Specification............................................03-30-04
250 Hours - Fluids, Filters, and Lubrication........................................ 03-30-07
500 Hours - Fluids, Filters, and Lubrication........................................ 03-30-08
500 Hours - Radiator...........................................................................03-30-10
500 Hours - Engine............................................................................. 03-30-11
500 Hours - Wheels, Tires, Suspensions, and Brakes........................03-30-12
500 Hours - Fuel and Hydraulics.........................................................03-30-14
500 Hours - Operator's Cab................................................................ 03-30-15
500 Hours - Dump System..................................................................03-30-16
500 Hours - Frame Assembly............................................................. 03-30-17
500 Hours - Electrical..........................................................................03-30-18
1000 Hours......................................................................................... 03-30-19
1500 Hours......................................................................................... 03-30-21
2000 Hours......................................................................................... 03-30-22
2500 Hours......................................................................................... 03-30-23
3000 Hours - Grid Box........................................................................ 03-30-24
5000 Hours - Siemens Specification................................................... 03-30-25
5000 Hours - Planetary Gear Box....................................................... 03-30-26
10000 Hours - Grid Box...................................................................... 03-30-27
Periodic Maintenance....................................................................................03-40-01
Overhaul and Replacement Schedules.............................................. 03-40-02
Bolt Torque Checks............................................................................ 03-40-03


03 Technical Data and Maintenance
Plan
The technical data and maintenance instructions chapter has the sections that follow:
Oil and Lubricant Specifications (Ref. 03-12-000-DA)
Lubrication, Fluids, and Filters (Ref. 03-14-000-DA)
Lubrication, Fluids, and Filters (Ref. 03-20-000-DA)
Preventive Maintenance Plan (Ref. 03-30-000-DA)
Overview
The technical data and maintenance instructions supply general information about the
haul truck. For more detailed data on the haul truck refer to the specified chapter for a
component or system.
The estimated overhaul or replacement for some of the components on the haul truck
is as follows:
COMPONENT HOURS
Air Compressor 6000 to 8000
Dump Cylinders 18000
Dump Pump 24000
Engine See OEM Manual
Final Drive - Gear Boxes See OEM Manual
Front Brake Calipers 6000
Front Brake Linings 6000
Front Control Arms 20000 to 25000
Front Wheel Bearings 4000 to 6000
Grid Blower Motor 12000
Rear Brake Calipers 12000
Rear Brake Linings 6000
Steering and Brake Pump 6000
Steering Cylinders 12000
Suspensions 12000 to 18000
Wheel motors See OEM Manual
T282B S/N 327 03-00-01

Technical Data and Maintenance Plan Maintenance Manual
03-00-02 T282B S/N 327

Maintenance Manual Technical Data and Maintenance Plan
Oil and Lubricant Specifications
03-12 Oil and Lubricant Specifications

For the hydraulic system to operate at its best, you must have the oil and lubricants
agree with ISO clean code 18/16.
Description
The tables that follow are the approved oil and lubricants for the haul truck.
Brake, Steering, and Dump Systems Hydraulic Oil

Liebherr Part Number Brand Name SAE Grade ISO Standard VG Note
or Manufacturer
5081-A Filter to ISO - 18/16
µm per unit volume
John Deere Bio Hy-Gard 58 Includes additives
against damage
Conoco Super Hydraulic Oil 5W-20 32 Includes additives
against the wear
Sun Oil Company Sunvis 832WR 32 Includes additives
against the wear
Mobil Delvac 1310 10W, 20 Includes additives
against the wear
Mobil Mobiltrans HD 10W 32 Includes additives
against the wear
Mobil Mobil DTE 15M 10W 46 Includes additives
against the wear
Union Oil Company 76 Unax AW ISO 32 Includes additives
against the wear
Exxon Univis N approved alternative
Shell Donat TC 30 approved alternative
Suspension Oil
or Manufacturer
5081-B
Mobil Mobilfluid 424 10W-30
Texaco Texaco TDH 1893
Chevron 1000 THF approved alternative
Shell Donzx TM approved alternative
Texaco Texaco TDH 1893 approved alternative
Front Wheel Oil

or Manufacturer
5087-B follow or above
MIL-L-2105C
Sun Oil Company Sunoco GL-5 Gear 85W-140
Oil
Conoco Conoco Universal 85W-140
Gear Lubricant
T282B S/N 327 03-12-01

or Manufacturer
Mobil Mobiltrans HD 50 220
Mobil Mobilgear SHC 680 Use 680 with
operating
temperatures usually
more than 25 °C (77
°F)
Mobil Mobilgear SHC 220 220 Use with operating
temperatures usually
less than 25 °C (77
°F)
Chevron Tegra Synthetic Gear approved alternative
Lube
Petro Canada Super Gear Fluid 680 approved alternative
Texaco Pinnacle EP approved alternative
Front Wheel Grease

or Manufacturer
5097-A
Mobil Mobilgrease CM-S NLGI 2
Rear Wheel (Planetary Drive) Oil

or Manufacturer
5087-D
Mobil Mobilgear SHC 320 320
Chevron Tegra synthetic 320 320 approved alternative
Wheelmotor Bearing Grease

or Manufacturer
Shell Aeroshell 7 120 g (4.236 oz) each
bearing, two per side
Shell Albida LC2
Auto Lube Grease

or Manufacturer
5079-A The grease must
have 2.5% or more
Molybdenum Disulfide
Mobil Mobilux EP-2 NLG1,2 Use when you
operate at
temperatures more
than -23 °C (-9 °F)
Mobil Mobilux EP-0 NLG1,1 Use when you
operate at
03-12-02 T282B S/N 327

or Manufacturer
temperatures more
than-29 °C (-20 °F)
Conoco Super-Sta M No.2 NLG1,2 Hot weather
Conoco Super-Sta M No.0 NLG1,0 Cold weather
Century Lubricants Replex NLG1,2 Hot weather
Century Lubricants Replex NLG1 Cold weather
System Blower Grease

Procedure applies only to blowers with the manufacturer first equipment installed
grease fittings installed in the blower housing.
or Manufacturer
Shell Aeroshell 7 23 g (0.812 oz) per
side
Shell Albida LC2 approved alternative
Pump Drive Gear Box Oil and Grease

or Manufacturer
5087-A
All SAE 85W-140
Lithium Grease NLG1,2 Use for the input
bearing
T282B S/N 327 03-12-03

03-12-04 T282B S/N 327

Component Weights and Dimensions
03-14 Component Weights and Dimensions

Most of the component weights listed in the tables that follow are original manufacturer
specified or calculated weights. The actual weight of a component may be different.
These weights are supplied for safety, but in all situations all goverment or company
safety rules must be followed.
Chassis Assembly with Power Module (Ref. Fig. 03-14-001)
Chassis Assembly (Ref. Fig. 03-14-002)
Superstructure Assembly (Ref. Fig. 03-14-003)
Front Wheel Assembly (Ref. Fig. 03-14-004)
Lower Control Arm (Ref. Fig. 03-14-005)
Upper Control Arm (Ref. Fig. 03-14-006)
Front Suspension (Ref. Fig. 03-14-007)
Rear Suspension (Ref. Fig. 03-14-008)
Rim (Ref. Fig. 03-14-009)
Tire and Rim (Ref. Fig. 03-14-010)
Wheel Motor (Ref. Fig. 03-14-011)
Planetary Gear Box (Ref. Fig. 03-14-012)
Planetary Gear Box Assembly (Ref. Fig. 03-14-013)
Fuel Tank Assembly (Ref. Fig. 03-14-014)
Fuel and Hydraulic Tank Assembly (Ref. Fig. 03-14-015)
Dump Cylinder (Ref. Fig. 03-14-016)
Power Module Assembly (Ref. Fig. 03-14-017)
Alternator (Ref. Fig. 03-14-018)
Air Cleaner (Ref. Fig. 03-14-019)
Cab with Air Conditioning (Ref. Fig. 03-14-020)
T282B S/N 327 03-14-01

Operation
Chassis Assembly with Power Module
length 11075 mm (436.022 in.)
height 4140 mm (162.992 in.)
width 4445 mm (174.999 in.)
weight 62038 kg (136800 lb)
03-14-001 Chassis Assembly with Power Module
03-14-02 T282B S/N 327

Chassis Assembly
length 11075 mm (436.022 in.)
height 4140 mm (162.992 in.)
width 4445 mm (174.999 in.)
weight 42800 kg (94400 lb)
03-14-002 Chassis Assembly
T282B S/N 327 03-14-03

Superstructure Assembly
length 8535 mm (336.023 in.)
height 2670 mm (105.118 in.)
width 3785 mm (149.015 in.)
weight 12700 kg (28000 lb)
03-14-003 Superstructure Assembly
03-14-04 T282B S/N 327

Front Wheel Assembly

length 1190 mm (46.85 in.)
height 1475 mm (58.071 in.)
width 1475 mm (58.071 in.)
weight (dry) 4168 kg (9200 lb)
03-14-004 Front Wheel Assembly
T282B S/N 327 03-14-05

Lower Control Arm

length 1120 mm (44.094 in.)
height 335 mm (13.189 in.)
width 1370 mm (53.937 in.)
weight 876 kg (1950 lb) x 2
03-14-005 Lower Control Arm
03-14-06 T282B S/N 327

Upper Control Arm

length 1500 mm (59.055 in.)
height 585 mm (23.031 in.)
width 1750 mm (68.897 in.)
weight 1023 kg (2300 lb) x 2
03-14-006 Upper Control Arm
T282B S/N 327 03-14-07

Front Suspension
length 1760 mm (69.291 in.)
diameter 455 mm (17.913 in.)
weight (dry) 672 kg (1500 lb) x 2
03-14-007 Front Suspension
03-14-08 T282B S/N 327

Rear Suspension
length 1270 mm (50 in.)
03-14-008 Rear Suspension
T282B S/N 327 03-14-09

Rim
height 1855 mm (73.031 in.)
width 1295 mm (50.984 in.)
weight 2865 kg (6300 lb) x 6
03-14-009 Rim
03-14-10 T282B S/N 327

Tire and Rim

height 3915 mm (154.133 in.)
width 1400 mm (55.118 in.)
weight 6674 kg (14700 lb) x 6
03-14-010 Tire and Rim
T282B S/N 327 03-14-11

Wheel Motor
length 1525 mm (60.039 in.)
height 1065 mm (41.929 in.)
width 1170 mm (46.063 in.)
weight 3900 kg (8600 lb) x 2
03-14-011 Wheel Motor
03-14-12 T282B S/N 327

Planetary Gear Box

length 2700 mm (106.299 in.)
width 1675 mm (65.945 in.)
weight 11370 kg (25100 lb) x 2
03-14-012 Planetary Gear Box
T282B S/N 327 03-14-13

Planetary Gear Box Assembly

length 3900 mm (153.543 in.)
width 1675 mm (65.945 in.)
weight 15460 kg (34100 lb) x 2
03-14-013 Planetary Gear Box Assembly
03-14-14 T282B S/N 327

Fuel Tank Assembly

length 1730 mm (68.11 in.)
height 1810 mm (71.26 in.)
width 1655 mm (65.157 in.)
03-14-014 Fuel Tank Assembly
T282B S/N 327 03-14-15

Fuel and Hydraulic Tank Assembly

length 1730 mm (68.11 in.)
height 1855 mm (73.031 in.)
width 1830 mm (72.047 in.)
03-14-015 Fuel and Hydraulic Tank Assembly
03-14-16 T282B S/N 327

Dump Cylinder
length 2720 mm (107.086 in.)
03-14-016 Dump Cylinder
T282B S/N 327 03-14-17

Power Module Assembly

length 6223 mm (244.999 in.)
height 3657.6 mm (144 in.)
width 3479.8 mm (137 in.)
03-14-017 Power Module Assembly
03-14-18 T282B S/N 327

Alternator
length 1400 mm (55.118 in.)
height 1575 mm (62.008 in.)
width 1040 mm (40.945 in.)
weight 4467 kg (9800 lb)
03-14-018 Alternator
T282B S/N 327 03-14-19

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 (440 lb) x 2
03-14-019 Air Cleaner
03-14-20 T282B S/N 327

Cab with Air Conditioning

length 2140 mm (84.252 in.)
height 1600 mm (62.992 in.)
width 1655 mm (65.157 in.)
03-14-020 Cab with Air Conditioning
T282B S/N 327 03-14-21

Additional Component Weights

T 282 B Component Weight
Axle Box 3788 kg (8400 lb)
Control Box (Siemens) 2423 kg (5300 lb)
Drag Link with Bushings (x2) 345 kg (760 lb)
Dump Body 35454 kg (78200 lb)
Dump Pump (x2) (dry) 101 kg (225 lb)
Dump Valve (dry) 146 kg (320 lb)
Front Brake Caliper 122 kg (270 lb)
Grid Box (Mosebach) 1820 kg (4000 lb)
Grid Box (Siemens) 2280 kg (5000 lb)
Idler Arm 376 kg (830 lb)
Individual Resistor Grids 46 kg (101.4 lb)
Kingpin (Upper) 238 kg (525 lb)
Kingpin (Lower) 162 kg (355 lb)
Main Blower (Siemens) 1820 kg (4000 lb)
Pump Drive Gear Box (dry) 193 kg (425 lb)
Radiator (dry) 2336 kg (5100 lb)
Radiator Cowling and Grill (dry) 730 kg (1600 lb)
Rear Brake Caliper 97 kg (214 lb)
Rear Control Arm 936 kg (2050 lb)
Steering Accumulator (dry) 1126 kg (2500 lb)
Steering Arm (x2) 201 kg (445 lb)
Steering Cylinder (x2) (dry) 196 kg (430 lb)
Steering Pump (dry) 50 kg (110 lb)
Tie Rod Assembly (x2) 297 kg (650 lb)
Danger! The dump body weights can change.

Refer to your local Liebherr Service Representative for the correct weight of your dump
body.
Use an applicable support that can hold the correct dump body weight to prevent serious
injury.
Caution! The weight of the dump body can be 35454 kg (78200 lb) or more. Dirt or unwanted
material can increase the weight of the dump body.
Know the weight of the dump body that you remove and install.
Use an applicable support that can hold the correct dump body weight to prevent serious
injury.
03-14-22 T282B S/N 327

Lubrication, Fluids, and Filters
03-20 Lubrication, Fluids, and Filters

This section supplies data needed to service and keep the performance of the haul
truck.
Lubrication, fluids and filters has the maintenance checks that follow:
Daily Inspections and Checks (Ref. 03-20-400-DA)
Fluids, Filters, and Miscellaneous Schedules (Ref. 03-20-405-DA)
Operation
The lubrication, fluids and filters section has the data necessary to service the haul
truck. The section also supplies maintenance personnel with a schedule for
maintenance. A more frequent schedule can be necessary if the haul truck operates in
bad or unsatisfactory environmental conditions.
Fluid Capacity Chart

Compartment Capacity Notes
Engine oil 390 L (103 U.S. gal) 20V4000
Radiator 420 L (111 U.S. gal) 20V4000
Front Suspension 16 L (4.2 U.S. gal)
Rear Suspension 16 L (4.2 U.S. gal)
Brake and Steering Reservoir 924 L (244 U.S. gal)
Hydraulic Reservoir 1302 L (340 U.S. gal)
Dump Cylinder 19 L (5 U.S. gal)
Pump Drive Gearbox 8.52 L (2.25 U.S. gal)
Front Wheels 60 L (16 U.S. gal)
Axle Gearbox 280 L (74 U.S. gal)
Auto Lube System 95 L (25 U.S. gal)
Diesel Fuel 3028 L (800 U.S. gal) Fuel Tank
Diesel Fuel 1514 L (400 U.S. gal) Hyd. and Fuel Tank
Central Service Assembly

The main service assembly is below the fuel and hydraulic tank.
T282B S/N 327 03-20-01

03-20-001 Central Service Assembly
Central Oil Sample Points

The main oil sample points are on the left side of the haul truck near the brake
accumulators.
03-20-02 T282B S/N 327

03-20-002 Central Oil Sample Points
Maintenance Tips
The haul truck has an automatic lubrication system that supplies lubrication to most
chassis points. The u-joint assembly and the input bearing of the gearbox of the pump
must be lubricated separately.
Caution! It is necessary to inspect the automatic lubrication system during preventive

maintenance to make sure that all components receive the correct quantity of grease.
Immediately repair or adjust the auto lube system to prevent an unwanted failure of a
component.
T282B S/N 327 03-20-03

03-20-400-DA - Daily Inspections and Checks

Setup
Obey the applicable haul truck safety precautions (Ref. 01-16-000-DA).
Procedure
Do a check of the engine oil level.

Check the fuel level.
Check the fluid level in the dump system hydraulic tank (Ref. 07-20-705-AA).
Check of the fluid level in the steering and brake hydraulic tank (Ref.
07-20-705-AA).
Inspect the steering linkage for loose or missing components.
Inspect the suspensions and the control arms for loose or missing components.
Check that the tires are inflated to a serviceable level.
Check the tire and rim assemblies for indications of incorrect torque and broken
fasteners.
Check that the rims are free of damage.
Check the visual indicator on the dump system pressure filters.
If visual indicators on the dump system pressure filters are out, do this
procedure:
Service the dump system pressure filter (Ref. 08-60-700-DA).
Check the visual indicator on the brake and steering system pressure filter.
If the visual indicators on the brake and steering pressure filter is out, do this
procedure:
Service the brake and steering system pressure filter (Ref. 09-20-700-DA).
Continue the inspections and checks with this procedure:
To inspect the axle box, do this procedure:
The access door must securely closed.
The cooling air outlets and air ducts must in serviceable condition and free of obstructions.
Check the exhaust system that follows:
All the brackets must be in place.
Check for blackened areas that indicate a leak.
Make sure the exhaust is not blocked or clogged.
Inspect all the belts on all rotating components for wear, twists or loose fit.
Inspect all the guards to make sure that they are correctly installed and not
damaged.
Inspect the radiator grill for obstructions and check the coolant level.
03-20-04 T282B S/N 327

Inspect the frame and make sure there are no missing or loose component
fasteners.
Make sure that the fire extinguishers are fully charged.
Clean out the air cleaner dust bin as necessary (Ref. 05-60-700-DA).
Make sure that the air cleaners have no damaged or loose fasteners.
Make sure that the air cleaner element housing is correctly sealed.
Check the air cleaner tubes and rubber connectors, as follows:
Make sure that there are no signs of damage or deformations to the tubes.
Make sure that there are no signs of damage to the rubber connectors (hose humps).
Make sure that the rubber connectors (hose humps) are correctly installed.
Make sure that the source connections are disconnected from the engine
pre-heater (optional).
Inspect the dump body, as follows:
Make sure that the dump body pivot pins are in place with the keepers, and correctly lubricated.
Make sure that the dump body safety cables and pins are correctly stored on the rear of the dump
body.
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 undamaged.
Inspect the dump body for deformation, or damaged parts.
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 that the ladders are free of debris.
Inspect the components in the cab as follows:
Make sure the air restriction indicators are in the serviceable areas.
Make sure all circuit breakers are closed.
Make sure the system warning lights and alarms are serviceable.
Make sure the horn is functional.
Make sure the backup alarm is operational.
Make sure all the lights are operational.
Examine the cab fresh air vent and replace the filter if necessary.
Make sure that the wipers are operational and that there is sufficient washer fluid.
T282B S/N 327 03-20-05

Examine the seat belts for wear or damage.

Make sure the cab floor is free of debris and that the windows are clean.
After the haul truck has been started, make sure that all the gauges have normal
indications.
Closeout
Remove all tools, equipment, and unwanted materials from the work area.
03-20-06 T282B S/N 327

03-20-405-DA - Fluids, Filters, and Miscellaneous Schedules

Setup
Follow the applicable haul truck safety precautions (Ref. 01-16-000-DA).
Procedure
The table that follows shows the maintenance necessary for the fluids, filters, and
miscellaneous items on the haul truck:
Item Service Hours Change Hours Requirements

Engine air cleaner every shift Open the dust bins and
remove the dirt and
unwanted material.
Air filter 500 As necessary, or annually Clean the dust bins and
tubes (Ref. 05-60-700-DA)
Air filter safety element 1500 Replace (Ref.
05-60-700-DA)
Brake and Steering every shift Level check (Ref.
Hydraulic Tank 07-20-705-AA)
Brake and Steering 250 Replace (Ref.
Hydraulic Tank - air 07-20-720-DA)
breather
Brake and Steering 500 1000 See (Ref. 09-20-700-DA)
Hydraulic System -
pressure filter element
Dump System Hydraulic every shift Level check (Ref.
Tank 07-20-705-AA)
Dump System Hydraulic 250 Replace (Ref.
Tank - air breather 07-20-715-DA)
Dump System Hydraulic 1500 35000 See (Ref. 07-20-710-DA)
Tank - strainers
Dump System - pressure 500 1000 See (Ref. 08-60-700-DA)
filter elements
Gear Oil Cooling - filters every shift 250 Visual inspection for leaks
and loose bolts. Replace
(Ref. 10-20-700-DA).
Gear Oil Cooling - air 250 Replace (Ref.
breather 10-20-705-DA)
Radiator every shift Do a coolant level check.
Batteries 200 Fill to correct level with
distilled water.
Tires 24 Make sure pressure agrees
with recommendations of
tire manufacturer.
Fuel Tank every shift Do a fuel level check.
Fuel Tank - vent breather annually
Cab Filter Element as necessary
Pump Drive U-Joint 500 Lubricate (Ref.
T282B S/N 327 03-20-07

Item Service Hours Change Hours Requirements

07-10-700-DA)
Pump Drive Gear Box 500 3000 Do a lubricant level check.
Pump Drive Gear Box 500 Lubricate input shaft
bearing (Ref.
07-10-700-DA).
Siemens Control Cabinet 2000 Clean (Ref. 05-80-800-DA)
Cab Door Latches 1000 Lubricate
Front Wheel Bearings 2500 5000 See (Ref. 12-10-400-DA)
Engine Maintenance as necessary Refer to OEM manuals.
Auto Lube System 2500 Test and lubricate (Ref.
10-10-500-DA)
Auto Lube System every refuel Fill the auto lube system.
Wheel Motors 5000 Lubricate
Main blower bearings 2000 Lubricate
Closeout
03-20-08 T282B S/N 327

Preventive Maintenance Schedule
03-30 Preventive Maintenance Schedule

The preventive maintenance schedule is as follows:
100 Hours - One Time Only (Ref. 03-30-300-DA)
Weekly - Rear Wheel OEM Specification (Ref. 03-30-305-DA)
500 Hours - Fluids, Filters, and Lubrication (Ref. 03-30-320-DA)
500 Hours - Radiator (Ref. 03-30-325-DA)
500 Hours - Engine (Ref. 03-30-330-DA)
500 Hours - Wheels, Tires, Suspensions, and Brakes (Ref. 03-30-335-DA)
500 Hours - Fuel and Hydraulics (Ref. 03-30-340-DA)
500 Hours - Operator Cab (Ref. 03-30-350-DA)
500 Hours - Dump System (Ref. 03-30-355-DA)
500 Hours - Frame Assembly (Ref. 03-30-360-DA)
500 Hours - Electrical (Ref. 03-30-365-DA)
1000 Hours (Ref. 03-30-375-DA)
1500 Hours (Ref. 03-30-380-DA)
2000 Hours (Ref. 03-30-382-DA)
2500 Hours (Ref. 03-30-390-DA)
3000 Hours (Ref. 03-30-391-DA)
5000 Hours - Siemens Specification (Ref. 03-30-392-DA)
5000 Hours - Planetary Gearbox (Ref. 03-30-394-DA)
10000 Hours (Ref. 03-30-398-DA)
Service
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. The preventive maintenance for the manufacturers of the
engine, wheel motor, and alternator will also be different. Refer to the Original
Equipment Manufacturer (OEM) manuals or with their service representative for
specific preventive maintenance information. The data, specifications and illustrations
in this maintenance schedule are based on the information that was available at the
time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time.
These changes can affect the service that is given to the product. Know the complete
T282B S/N 327 03-30-01

and most current information before you start any job. ASSURE SAFETY BEFORE
YOU BEGIN! ; contact a Liebherr Mining Equipment Co. Representative. Liebherr
dealers have the most current data available.
03-30-02 T282B S/N 327

03-30-300-DA - 100 Hours - One Time Only

Setup
Procedure
Replace the brake and steering pressure filter element (Ref. 09-20-700-DA).
Replace the dump system pressure filter elements (Ref. 08-60-700-DA).
Replace the filter elements in the gear oil cooling system (Ref. 09-20-700-DA).
Do a check of the oil level for the front wheel bearings (Ref. 12-10-410-DA).
Get a sample oil and do an oil analysis for the components or systems that follow
(ISO 4406: 16/13):
engine
dump system hydraulic tank
brake and steering hydraulic tank
pump drive gear box
left and right front wheels
main cavity of the left and right rear wheel assembly
thrust bearing cavity of the left and right rear wheel assembly
Do a visual inspection of the haul truck frame, system components, and
fasteners.
Do a check of the idler arm bearing clearance.
Closeout
T282B S/N 327 03-30-03

03-30-305-DA - Weekly - Rear Wheel OEM Specification

Setup
Procedure
Do a check of the oil in the rear wheel gears (Ref. 12-40-400-DA).

Do a visual inspection of the rear wheel assembly.
Do a check for unusual noise from the rear wheel motors and gears.
Closeout
03-30-04 T282B S/N 327


Setup
Procedure
Replace the oil in the planetary gearbox as follows:

Drain the oil from the planetary gearbox (Ref. 12-40-700-DA).
Fill the planetary gearbox with oil (Ref. 12-40-705-DA).
Closeout
T282B S/N 327 03-30-05


Setup
Procedure
Replace the oil in the front wheel assembly as follows:

Drain the oil from the front wheel (Ref. 12-10-700-DA)
Fill the front wheel with oil (Ref. 12-10-705-DA).
Tighten the capscrews of the lower kingpin (Ref. 12-12-200-DA).
Closeout
03-30-06 T282B S/N 327

03-30-317-DA - 250 Hours - Fluids, Filters, and Lubrication

Setup
Procedure
Replace the breather filter for the brake and steering hydraulic tank (Ref.
07-20-720-DA).
Replace the breather filter for the dump system hydraulic tank (Ref.
07-20-715-DA).
Replace the breather filter for the gear oil cooling system (Ref. 10-20-705-DA).
Closeout
T282B S/N 327 03-30-07

03-30-320-DA - 500 Hours - Fluids, Filters, and Lubrication

Setup

Consumable Materials:
DESIGNATION REF. PART NO.

Grease See approved lubricants (Ref.
03-12-000-DA)
Procedure
Get a sample of the engine oil and do an oil analysis.

Replace the oil in the engine.
Replace the oil filters in the engine.
Check the pressure filter elements for the dump system (Ref. 08-60-700-DA).
Check the pressure filter elements for the brake and steering system (Ref.
09-20-700-DA).
Check the engine coolant concentration, record it, and adjust the coolant
concentration as necessary.
Get a sample of the hydraulic oil in the brake and steering hydraulic tank and do
an oil analysis (ISO 4406: 18/16).
Check the hydraulic oil level in the brake and steering hydraulic tank, and add
fluid as necessary.
Get a sample of the hydraulic oil in the dump system hydraulic tank and do an oil
analysis (ISO 4406: 18/16).
Check the hydraulic oil level in the dump system hydraulic tank, and add fluid as
necessary.
Do the service procedure for of the auto lube system (Ref. 10-10-700-DA).
Inspect all inlet pipes and connections from the engine air cleaners for cracks or
damage.
Do the service operation of the air cleaners (Ref. 05-60-700-DA) as necessary.
Get a sample of the oil in the pump drive gearbox, do an oil analysis, and add
fluid as necessary.
Do the service operation of the pump drive (Ref. 07-10-700-DA).
Check the steering linkage, idler arm, tie rods, and fasteners.
Get a sample of the oil in the left and right front wheels and do an oil analysis
(ISO 4406: 25/19).
Get a sample and do an analysis of the gear lube-oil in the gearbox of the rear
wheel assembly.
Get a sample and do an analysis of the oil in the bearing housing of the rear
03-30-08 T282B S/N 327

wheel assembly.
Closeout
T282B S/N 327 03-30-09

03-30-325-DA - 500 Hours - Radiator

Setup
Procedure
Make sure that the capscrews on the top and bottom of the radiator are tight.
Make sure that the stabilizers and mounts are tight.
Inspect the filler cap for damage or wear.
Inspect the hoses for leaks, loose clamps, and wear.
Do a full inspection of the core tubes and clean the tubes, if necessary.
Inspect the fan blades and bushings for damage.
Inspect the condition of the belts and idlers, and check that they are sufficiently
tight.
Closeout
03-30-10 T282B S/N 327

03-30-330-DA - 500 Hours - Engine

Setup
Procedure
Make sure that the engine mounting bolts are tight (Ref. 05-02-200-DA).
Test the emergency shutdown system.
Record the engine oil pressures with the engine at temperature of operation for
the speeds that follow:
Low idle
High idle
Full RPM
Record the RPM that follow:
Low idle RPM
High idle RPM
Make sure that the engine to alternator installation bolts are torqued correctly
(Ref. 05-20-200-DA).
Record the air system pressure with the system fully charged.
Inspect the engine and area around the engine for fluid leaks.
Check the tachometer drive connections.
Inspect the exhaust system for leaks and loose fasteners.
If the truck has rigid covers of the expansion joints of the exhaust system,
Replace the covers and examine the expansion joints for damages.
Inspect the turbo chargers for leaks, vibration, and unusual noise.
Inspect the air intake system for damage, loose connections, and loose
fasteners.
Make sure that the air cleaner inlets and pre-cleaner fins are free from
obstructions.
Closeout
T282B S/N 327 03-30-11

03-30-335-DA - 500 Hours - Wheels, Tires, Suspensions, and

Brakes
Setup
Procedure
Inspect the front suspension bushings.

Inspect the control arm bushings.
Inspect the kingpin ball bushings (Ref. 12-12-410-DA).
Inspect the rear suspension bushings.
Inspect the height of the suspensions (Ref. 11-20-400-DA) (Ref. 11-10-400-DA)
and record the results.
Inspect the axle box, drag link, and rear control arm bushings (Ref.
13-40-400-DA).
Inspect the rear axle box and wheel motors for damage.
Inspect the steering cylinders for damage, leaks, and wear.
Check the steering cylinder and tie rod bushing movement.
Check the idler arm bearing for vertical movement, and torque the retainer bolts
(Ref. 09-46-200-DA).
Check the steering arm capscrews for the correct torque (Ref. 09-47-200-DA),
and replace all loose capscrews with new capscrews.
Inspect the steering stop pads, and torque the capscrews (Ref. 09-48-200-DA).
Test the brake and steering system pressure (Ref. 09-02-500-DA) and record the
result.
Test the pre-charge for the steering accumulator (Ref. 09-41-400-DA) and record
the result.
Inspect the steering accumulator for damage and leaks.
Check the pre-charge for the brake accumulators (Ref. 09-52-400-DA) and
record the results.
Inspect the brake accumulators for damage and leaks.
Inspect the hoses of the brake system for damage and leaks.
Do a functional test of the service brake system.
Do a functional test of the park brake system.
Do a functional test of the hand brake system.
Tighten the fasteners for the front brake caliper (Ref. 12-32-200-DA).
Tighten the fasteners for the rear brake caliper (Ref. 12-50-200-DA).
03-30-12 T282B S/N 327

Bleed the brakes, if necessary (Ref. 09-52-300-DA).

Inspect the tires for damage and wear.
Tighten the rim nuts (Ref. 12-20-200-DA) and (Ref. 12-42-205-DA).
Refer to the tire manufacturer instructions and check the tire pressure.
Tighten the fasteners for the kingpins (Ref. 12-12-200-DA).
Closeout
T282B S/N 327 03-30-13

03-30-340-DA - 500 Hours - Fuel and Hydraulics

Setup
Procedure
Get a sample of the hydraulic fluid (first time only) (ISO 4406: 16/13).
Inspect the fuel lines for leaks and wear.
Make sure that the fuel tank mounting bolts are tight.
Make sure that the fuel and hydraulic tank mounting bolts are tight (Ref.
07-20-200-DA).
Inspect the hydraulic hoses for leaks, wear, and damage.
Make sure that the 24 volt wires are secured and protected.
Closeout
03-30-14 T282B S/N 327

03-30-350-DA - 500 Hours - Operator's Cab

Setup
Procedure
Inspect the ladders and steps for loose bolts and damage.
Make sure that all doors close and lock correctly.
Inspect all window glass.
Inspect all mirrors.
Make sure that the seats are installed correctly and operate correctly.
Inspect the seat belts and make sure they are installed correctly (refer to local
site specifications).
Test the heater and check for leaks.
Test the defroster.
Inspect the windshield wipers for damage and test with washer fluid.
Test the horns.
Test all controls (drive, dump, steering, and braking).
Inspect the cab mounts and mounting bolts.
Make sure that all the handrails are in position and correctly installed.
Test the backup alarm or horn.
Make sure that the cab is clean.
Test all the lights in the cab and on the deck.
Make sure that all instruments and gauges are serviceable.
Test of the retarder pedal.
Test all the switches.
Closeout
T282B S/N 327 03-30-15

03-30-355-DA - 500 Hours - Dump System

Setup
Procedure
Inspect the dump cylinders for damage or leaks.

Inspect the upper and lower bushings and pins on the dump cylinder.
Inspect the U-joints on the pump drive shaft.
Inspect the pilot and main control valves for damage and leaks.
Test the dump system pressure (Ref. 08-02-405-DA) and record the result.
Inspect all the hoses for leaks and wear.
Refer to and follow LPSI 194 (Hydraulic Hose Maintenance).
Closeout
03-30-16 T282B S/N 327

03-30-360-DA - 500 Hours - Frame Assembly

Setup
Procedure
Inspect the dump body(Ref. 13-30-400-DA).

Inspect the frame for damage and cracks.
Inspect the axle box hoses for leaks, damage, or loose connection.
Clean the axle box.
Inspect the condition of the seal on the access door of the axle box.
Inspect axle box housing for damage and cracks.
Inspect the exhaust of the wheel motor cooling for blockage or damage.
Inspect the wheel covers for damage.
Inspect the superstructure mounts and fasteners.
Inspect the superstructure for damage and cracks.
Inspect all bicycle linkages and retainers.
Inspect the steering cylinder mounting areas.
Closeout
T282B S/N 327 03-30-17

03-30-365-DA - 500 Hours - Electrical

Setup
Notice! The inspection schedule for the traction alternator, wheel motors, and retarding grid
blower unit must agree with the schedule made for the specified haul truck.
Refer to the Siemens manual for specific inspection data.
Procedure
Make sure that the alternator is clean.

Inspect the grid blower inlet for blockages.
Make sure that all electrical connections are tight and have no corrosion.
Inspect the condition of the batteries and make sure the connections are tight
(Ref. 06-10-200-DA).
Inspect all lighting.
Closeout
03-30-18 T282B S/N 327

03-30-375-DA - 1000 Hours

Setup
Notice! The 1000 hour preventive maintenance check does not include the 500 hour preventive
maintenance checks.
Make sure that you do all of the 500 hour preventive maintenance checks.
Procedure
Check the front tire toe-in(Ref. 09-40-400-DA).

Check the steering cylinder and tie rod bushings movement.
Check the idler arm bearing for vertical movement.
Inspect the fire suppression system as follows:
Inspect all nozzles for blockages and replace all missing caps.
Look for broken or damaged discs.
Remove all container caps and look if chemical becomes hard.
Inspect the condition of all the hoses and tubing.
Inspect all detection wires and connections.
Test the system (refer to the manufacturer's manual)
Make sure that the drive coupling on the armature shaft is tight.
Replace the fuel filter elements (must pre-fill).
Drain the water and sediment from the fuel tanks.
Clean the magnetic plugs of the reservoir.
Clean the breathers of the crank case.
Get a sample and do an oil analysis of the dump system hydraulic fluid (ISO
4406: 18/16).
Get a sample and do an oil analysis of the brake and steering hydraulic fluid (ISO
4406: 18/16).
Replace the pressure filter elements for the dump system (Ref. 08-60-700-DA).
Replace the pressure filter elements for the brake and steering system (Ref.
09-20-700-DA).
Inspect all the mounting bolts for the brake calipers and inspect the piston seals
for leaks.
Inspect all the mounting bolts below the ROPS cab and torque as necessary.
Closeout
T282B S/N 327 03-30-19

03-30-20 T282B S/N 327

03-30-380-DA - 1500 Hours

Setup
maintenance checks.
Procedure
Replace the filter elements in the gear oil cooling system (Ref. 10-20-700-DA).
Inspect the front brake linings (Ref. 12-32-400-DA).
Inspect the rear brake linings (Ref. 12-50-400-DA).
Drain the dump system hydraulic tank (Ref. 07-20-700-DA) and clean the suction
strainers (Ref. 07-20-710-DA).
Replace the safety air cleaner elements (Ref. 05-60-700-DA).
Inspect and lubricate the cab door latches.
Inspect the flexible exhaust blanket for the expansion joint of the exhaust system
(Ref. 05-40-400-DA).
Closeout
T282B S/N 327 03-30-21

03-30-382-DA - 2000 Hours

Setup
Notice! The 2000 hour preventive maintenance check does not include the 500 and 1000 hour
preventive maintenance checks.
Make sure that you do all of the 500 and 1000 hour preventive maintenance checks.
Procedure
Check the lower kingpin bushing (Ref. 12-12-410-DA).

Clean the Siemens control cabinet (Ref. 05-80-800-DA).
Apply grease to the bearings of the main blower.
Closeout
03-30-22 T282B S/N 327

03-30-390-DA - 2500 Hours

Setup
maintenance checks.
Procedure
Inspect the upper kingpin (Ref. 12-12-405-DA).

Drain (Ref. 12-10-700-DA) and replace (Ref. 12-10-705-DA) the oil in the front
wheel bearing.
Do a functional test and fill the auto lube system (Ref. 10-10-500-DA).
Replace the oil in the pump drive.
Closeout
Notice! Some periodic maintenance is necessary at 2500, 5000, or 10000 hours.

Do the applicable periodic maintenance (Ref. 03-40-305-DA).
T282B S/N 327 03-30-23

03-30-391-DA - 3000 Hours - Grid Box

Setup
Procedure
Inspect the blower motor at 3000 hours or three months .
Closeout
03-30-24 T282B S/N 327

03-30-392-DA - 5000 Hours - Siemens Specification

Setup
Procedure
Refer to the Siemens manual and lubricate the bearings in the rear wheel motors.
Closeout
T282B S/N 327 03-30-25

03-30-394-DA - 5000 Hours - Planetary Gear Box

Setup
Procedure
Refer to the OEM service manual and replace the lubricant in the planetary gear
box.
Closeout
03-30-26 T282B S/N 327

03-30-398-DA - 10000 Hours - Grid Box

Setup
Procedure
Inspect the resistors at 10000 hours or 12 months .
Closeout
T282B S/N 327 03-30-27

03-30-28 T282B S/N 327

Periodic Maintenance
03-40 Periodic Maintenance

Periodic maintenance has the sections as follows:
Estimated Overhaul and/or Replacement (Ref. 03-40-300-DA)
Bolt Torque Checks (Ref. 03-40-305-DA)
Description
Estimated Overhaul and/or Replacement
The periodic maintenance schedule is recommended to maintain the safe and proper
operation of the haul truck. 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 may dictate
an increase in periodic maintenance. These changes to the schedule should agree
with the local conditions and operation for the haul truck. The periodic maintenance for
the manufacturers of the engine, wheel motor, and alternator will also be different.
Refer to the OEM (Original Equipment Manufacturer) manuals or with their service
representative for specified periodic maintenance information.
Bolt Torque Checks

The bolt torque table is a guide to help keep the correct bolt torque on critical
fasteners. When the haul truck is put in service, it is necessary that the fasteners
shown are torqued correctly. During related maintenance, as bolted joints are
"uncovered", make sure the bolts are torqued correctly, even if the bolted joint was not
touched.
All torques are for lubricated grade 8 fasteners. The drive system and engine torques
are not included in this table. Refer to the OEM (Original Equipment Manufacturer)
manuals for the necessary drive system or engine torques.
Because of the different mine conditions, there can be other fasteners not shown in
this table where periodic inspection is necessary.
T282B S/N 327 03-40-01

03-40-300-DA - Overhaul and Replacement Schedules

Setup
Not applicable.
Procedure
Refer to the table for the overhaul and replacement schedules:
Component Hours
Air compressor 6000 to 8000
Brake and steering pump 6000
Dump cylinders 18000
Dump pumps 24000
Engine See OEM Manual
Exhaust Blankets 3500
Final drive - gear boxes See OEM Manual
Front brake calipers 6000
Front brake linings 6000
Front control arms 20000 to 25000
Front wheel bearings 4000 to 6000
Grid blower motor 12000
Rear brake calipers 12000
Rear brake linings 6000
Steering cylinders 12000
Suspensions 12000 to 18000
Wheel motors See OEM Manual
Closeout
Not applicable.
03-40-02 T282B S/N 327

03-40-305-DA - Bolt Torque Checks

Setup
Not applicable.
Procedure
The table that follows shows the periodic maintenance for critical fasteners:
Component Bolt Size Torque Frequency

Front brake caliper bolts 1 inch See (Ref. 12-32-200-DA) Every 2500 hours.
Rear brake caliper bolts 7/8 inch See (Ref. 12-50-200-DA) Every 2500 hours.
Steering arm bushing 1/2 inch See (Ref. 09-47-200-DA) Once at 2500 hours, then
retainer bolts every 5000 hours after that.
Kingpin retainer bolts See (Ref. 12-12-200-DA) Every 500 hours.
Steering arm retainer bolts See (Ref. 09-47-200-DA) Every 500 hours.
Steering cylinder pin See (Ref. 09-44-200-DA) Visually inspect at 2500
retainer bolts hours, then every 5000
hours. If pin movement
shows, remove steering
cylinder and tighten the pin
retainer bolts to the
specified torque.
Rear control arm-to-frame outboard 3/4 or 1 inch, See (Ref. 13-50-200-DA) Once at 2500 hours, then
retainer bolts inboard 1 in. every 10,000 hours after
that.
Rear control arm-to-axle outer-top 3/4 inch, inner See (Ref. 13-50-200-DA) Once at 2500 hours, then
box axle box 1 in. every 5000 hours after that.
Wheel motor assembly to See (Ref. 12-40-200-DA) Every 5000 hours.
axle box bolts
Brake adapter, and disc See (Ref. 12-50-200-DA) When access to these parts
mounting bolts is available.
Closeout
Not applicable.
T282B S/N 327 03-40-03

03-40-04 T282B S/N 327

Main Dash Panel............................................................................................ 04-10-01
Controls and Indicators................................................................................ 04-12-01
Floor Mounted Center Console.................................................................... 04-20-01
How to Adjust the Dump Control Lever...............................................04-20-04
Steering Column and Controls..................................................................... 04-30-01
Foot Pedal Controls.......................................................................................04-40-01
How to Remove the Brake Pedal........................................................ 04-40-03
How to Remove the Retarding Pedal..................................................04-40-06
How to Remove the Accelerator Pedal............................................... 04-40-09
How to Install the Brake Pedal............................................................ 04-40-12
How to Install the Retarding Pedal......................................................04-40-13
How to Install the Accelerator Pedal................................................... 04-40-15
Seats............................................................................................................... 04-50-01
Glass............................................................................................................... 04-60-01
Replacement of the Glass...................................................................04-60-02
Access Panels and Miscellaneous Items.................................................... 04-70-01


(Ref. Fig. 04-00-001)(Ref. Fig. 04-00-002)
The cab has the components that follow:
Glass (Ref. 04-60-000-DA)
Filter Restriction Indicators (Ref. 05-62-000-DA)
Seats (Ref. 04-50-000-DA)
The cab controls and instrumentation has the systems that follow:
Floor Mounted Center Console (Ref. 04-20-000-DA)
Steering Column and Controls (Ref. 04-30-000-DA)
Foot Pedal Controls (Ref. 04-40-000-DA)
Main Dash Panel (Ref. 04-12-000-DA)
Fire Control System (Ref. 10-40-000-DA)
Payload Weigh System (Ref. 10-50-000-DA)
LITES Truck Control System (Ref. 10-60-000-DA)
SBS Computer (Ref. 10-80-000-DA)
Overview
The walls and floors of the cab have two layers. The cab is made with steel and has
insulation to protect against heat, cold, and sound.
The external access panels (Ref. 04-70-000-DA) and the main dash panels can be
removed to access components for maintenance.
T282B S/N 327 04-00-01

Cab Controls and Instrumentation Maintenance Manual
04-00-001 Cab Controls and Instrumentation
04-00-02 T282B S/N 327

Maintenance Manual Cab Controls and Instrumentation
04-00-002 Cab Controls and Instrumentation
T282B S/N 327 04-00-03

04-00-04 T282B S/N 327

Main Dash Panel
04-10 Main Dash Panel

(Ref. Fig. 04-10-001)
The main dash panel has the instruments and controls that follow:
Controls, indicators and display panel(Ref. 04-12-000-DA)
04-10-001 Main Dash Panel
The indicator lights come on for three seconds when the Master Ignition Switch is
turned from OFF to IGNITION.
There is a retard/grade speed label in the cab of the haul truck. It is on the left dash
panel. This label shows the maximum downgrade speeds at which the haul truck can
safely be operated on an applicable grade (Ref. Fig. 04-10-002).
T282B S/N 327 04-10-01

Main Dash Panel
04-10-002 Retard/Grade Speed Label
04-10-02 T282B S/N 327

Controls and Indicators
04-12 Controls and Indicators

The main dash panel have the controls and indicators that enable the haul truck
operations and movement. For description purposes, the main dash panel is separated
into four sections.
The left dash panel
The display panel
The right dash panel
The accessory panel
04-12-001 Controls and Indicators
T282B S/N 327 04-12-01

Left Dash Panel
04-12-002 Left Dash Panel
The controls on the left dash panel are:

1. Park Brake Switch (1)
2. Headlight Switch (2)
3. Ladder Service Light Switch (3)
4. Backup Light Switch (4)
5. Manual Lube Switch (5)
6. Data Store Switch (6)
7. Drive System Fault Reset Switch (7)
8. Windshield Wiper Switch (8)
9. Windshield Washer Switch (9)
10. Grid Dry Switch (10)
Park Brake Switch

The park brake switch (1) has two positions. If you set the park brake, a message that
reads park brake ON comes into view on the display panel. The park brake and the
propulsion inhibit indicators illuminate on the indicator panel while the park brake is set.
Press the top half of the park brake switch to set the park brake. Push the bottom half
of the switch to release the park brake.
04-12-02 T282B S/N 327

Headlight Switch
The headlight switch is a rocker switch that has three positions. The headlight switch
(2) operates the headlights, the clearance, and the main dash panel lights. Press the
bottom half of the switch one time to turn on the headlights and the clearance lights.
Press the bottom half of the switch two times to turn on the main dash panel lights.
Press the top half of the switch one time to turn off the main dash panel lights and two
times to turn off the headlights and the clearance lights.
Ladder Service Light Switch

The ladder service light switch (3) has two positions. The haul truck has a ladder
service light switch on the ground level on the left of the front bumper and one switch in
the operator cab on top of the left dash panel. The ladder service light switches
operate the ladder, the platform, and the engine service lights. There is no set ON
position or OFF position for these switches. The position of one switch calculates if the
other switch is in the ON position or the OFF position.
Backup Light Switch

The backup light switch (4) operates the white backup lights that are behind the axle
box. Press the bottom half of the switch to illuminate the backup lights. Press the top
half of the switch to extinguish the backup lights.
Manual Lube Switch

The manual lube switch (5) starts the lubrication one time during twenty-minute
intervals. During automatic lubrication, the auto lube system (Ref. 10-10-000-DA),
supplies grease from the grease tank through hoses to the injectors to different pivot
points. During an auto lube system fault condition, the related indicator that is on the
indicator panel (Ref. Fig. 04-12-005)illuminates. During an auto lube system fault
condition, you must do a manual lubrication of the pivot points and you must tell
maintenance personnel of this failure. Press the bottom half of the manual lube switch
for a short time to apply lubrication.
Data Store Switch

The data store switch (6) stores the Siemens drive system data into the TCU. If the
drive system fault indicator on the indicator panel illuminates there is a problem with
the Siemens drive system. During a Siemens system fault condition, press the bottom
half of the data store switch for a short time to store the current system data into the
TCU. The stored data can be used at another time for maintenance personnel to find
the problem.
Drive System Fault Reset Switch

The drive system fault reset switch is a rocker switch. Press the bottom half of the drive
system fault reset switch (7) to correct small system faults. The drive system fault
indicator on the indicator panel illuminates when there is a problem with the Siemens
drive system, and this indicator also illuminates when the drive system fault reset
switch is in operation. If the system faults cannot be corrected, tell maintenance
personnel about the condition.
Windshield Wiper Switch

The windshield wiper switch (8) has three positions: LOW, HIGH and PARK. Press the
bottom half of the switch one time to operate the windshield wipers at LOW. Press the
bottom half of this switch two times to operate the wipers at HIGH. Press the top half of
the switch two times to operate the wipers at PARK.
T282B S/N 327 04-12-03

Windshield Washer Switch

The windshield washer switch (9) has three positions. This switch starts the windshield
washer fluid flow and the operation of the windshield wipers at the INT, the HIGH and
the OFF cycles. Press the bottom half of the switch one time to the first position (INT)
to start the windshield wipers at INT. If this switch is put to the INT position, the
windshield wipers operate for five second intervals. The windshield washer fluid flows
at a set speed during the time the switch is in operation. Press the bottom half of the
switch two times to operate the windshield wipers at the HIGH cycle. Press the top half
one time to stop the HIGH cycle and to return to the INT position and two times to turn
off the windshield wipers and to stop the windshield washer fluid flow.
Grid Dry Switch

The grid dry switch (10) has two positions. This switch starts the grid blower. Water
can collect on the grids after the haul truck is cleaned and from the humidity. The grid
blower removes the condensation from the grids. Keep the grid blower in operation to
prevent a ground fault while you operate the haul truck in rain and snow conditions.
Press the bottom half of the switch to energize the grid blower. Press the top half of the
switch to stop the grid blower.
04-12-04 T282B S/N 327

LCD Display Panel

The liquid crystal display (LCD) panel shows the conditions of the haul truck systems
and components on the main dash panel. The display panel has indicators, gauges,
and alarms when the haul truck engine is in operation.
04-12-003 Display Panel
The display panel connects to a keypad on the right dash panel (Ref. Fig. 04-12-004).
The display panel shows the screens that follow:
Main Display Screen
Bar Gauge Screen
Fault and Alarm Window
Fault List Screen
Component Description and Operation

The display panel is always energized, as shown by the LED below the power button.
The display panel comes on when the SBS computer comes on.
Protection from the cold is necessary for the display panel because of the LCD.
Thermostats control internal heaters and the backlight. To give protection to the LCD in
very cold temperatures, the backlight must be heated before the LCD comes on. If the
ambient temperature is cold, the LCD comes on after some time. The table below
shows the temperature necessary for the heater and backlight to operate:
Ambient Temp Heater Backlight Display

Below 5 °C (41 °F) ON OFF OFF
5 to 10 °C (41 to 50 °F) ON ON ON
T282B S/N 327 04-12-05

Ambient Temp Heater Backlight Display

Above 10 °C (50 °F) OFF ON ON
Main Display Screen
04-12-004 Main Dispaly Screen
The main display screen is the primary display. The main display screen constantly
shows the speedometer, tachometer, engine temperature bar gauge, battery volt bar
gauge, cruise control set-point bar gauge, and the fuel bar gauge.
The main display screen shows the indicators, gauges and messages that follow:
Left Turn Indicator

The left and right turn signal indicator is activated by the left and right turn signal lever
that is on the left of the steering column. While this lever is in operation, the left or the
right turn indicator flashes every second on the display panel.
Right Turn Indicator

The left and right turn signal indicator is activated by the left and right turn signal lever
that is on the left of the steering column. While this lever is in operation, the left or the
right turn indicator flashes every second on the display panel.
High Beam ON Indicator

The high beam ON indicator shows on the display panel while the high beam lever that
is on the steering column is in operation.
04-12-06 T282B S/N 327

Speedometer
The speedometer gives a digital display of the haul truck ground speed in miles per
hour (mph) or kilometers per hour (km/h).
Tachometer
The tachometer shows the engine speed in revolutions per minute (rpm).
Engine Temperature Bar Gauge

The engine temperature bar gauge shows the temperature of the engine cooling
system.
Battery Volts Bar Gauge

The battery volts bar gauge shows the voltage of the battery bank when the master
switch is ON and the engine is stopped. The battery volts bar gauge shows the voltage
of the battery charger when the engine is in operation.
Cruise Control Set-Point Bar Gauge

The cruise control set-point bar gauge shows the set-point speed of the cruise control.
Fuel Bar Gauge

The fuel bar gauge shows the approximate quantity of diesel fuel in the fuel tanks.
Hand Brake ON Indicator

The hand brake ON indicator shows on the display panel when the hand brake is ON.
Park Brake ON Indicator

The park brake ON indicator shows on the display panel when the park brake is ON.
Service Brake ON Indicator

The service brake on indicator shows on the display panel while the service brake
pedal is depressed. When the service brake ON indicator comes on, it is an indication
that the brake system is serviceable. When the service brake ON light stays on after
the service brake is released, brake pressure is still applied. If possible, wait until the
indicator is OFF before you accelerate.
Cruise Control ON Indicator

The cruise control ON indicator shows on the display panel when the cruise control is
ON. The blue numbers show the set-point speed of the cruise control.
Cruise Control OFF Indicator

The cruise control OFF indicator shows on the display panel when the cruise control is
OFF.
Dump Body UP Indicator

The dump body UP indicator shows on the display panel while the dump body is not in
the DOWN position.
Bar Gauge Screen
T282B S/N 327 04-12-07

04-12-005 Bar Gauge Screen
If the ESC/SCREEN button is pushed one time, the main display screen changes to
the bar gauge screen. The bar gauge screen shows the conditions that follow:
Engine Cooling System Temperature
Alternator Armature Winding Temperature
Cruise Control Speed Set-Point
Left Wheel Motor Armature Winding Temperature
Left Wheel Motor Current Input Amps
Left Wheel Motor Speed
Right Wheel Motor Armature Winding Temperature
Right Wheel Motor Current Input Amps
Right Wheel Motor Speed
Accelerator Pedal Percentage of Travel
Retard Pedal Percentage of Travel
Steering Angle with (+) Right and (-) Left
04-12-08 T282B S/N 327

04-12-006 Fault and Alarm Window
A fault and alarm window shows on the display panel when there is a problem with one
of the systems. An alarm goes off when some of the fault and alarm windows show.
The fault and alarm window shows the alarms that follow:
Truck Overspeed
The truck overspeed alarm operates when the ground speed of the haul truck is more
than the overspeed limit set by the TCU. When the haul truck is in an overspeed
condition, the TCU automatically applies the retard brake to put the truck below the
overspeed limit.
Retard Limit Fault

The retard limit fault alarm shows when the haul truck is in an overspeed condition that
cannot be controlled by the TCU. In such an overspeed condition, the dynamic
retarding cannot operate correctly to decrease the ground speed of the haul truck. The
operator must apply the service brakes and the retard brakes to decrease the speed of
the haul truck.
Engine Overspeed
The engine overspeed alarm shows when the engine speed of the haul truck is more
than 2000 rpm.
In an engine overspeed condition, the operator must quickly and safely stop the haul
truck, apply the park and hand brakes, and stop the engine. The operator must tell
maintenance about the engine overspeed.
Engine Overtemp
The engine over temperature alarm shows when the temperature of the engine cooling
T282B S/N 327 04-12-09

system is more than 88 °C (190 °F).

In an engine over temperature condition, the operator must quickly and safely stop the
haul truck and apply the park and hand brakes. The operator should let the engine
operate at idle and monitor the engine temperature gauge. If the temperature
continues to increase, stop the engine and tell maintenance about the engine over
temperature.
Engine Oil Pressure Low

The engine oil pressure alarm shows when the engine oil pressure decreases below
the minimum pressure permitted by the engine manufacturer.
AC Drive System Overtemp and Overload

If the temperature of a component in the drive system increases to the warning level,
the TCU goes in to the Automatic Power and Reduction Procedure (APRS). If the
current in a wheel motor is more than 1250 amps, the TCU goes in to the Automatic
Power and Reduction Procedure (APRS).
In APRS mode, the TCU sends a signal that shows as an alarm on the display panel.
The TCU automatically decreases the power of the drive system to 80% until the over
temperature or overload goes below the limit that set the alarm.
If the component temperature or current continues to increase, the TCU decreases the
power of the drive system to zero. If the haul truck is in motion, the TCU uses dynamic
retarding to stop the haul truck. After the haul truck stops, the TCU decreases power of
the drive system to zero.
Alternator Overtemp
The alternator over temperature alarm shows when the temperature of the alternator
winding is more than 88 °C (190 °F).
In an alternator over temperature condition, the operator must quickly and safely stop
the haul truck and apply the park and hand brakes. The operator must put the shift
selector switch to the NEUTRAL position, let the engine operate at idle speed, and
monitor the engine temperature gauge.
The operator must push the drive system reset button. If the over temperature alarm
stays, or if the temperature continues to increase, stop the engine and tell maintenance
about the over temperature condition.
Wheel Motor Overtemp

A wheel motor over temperature alarm shows when the temperature of one of the
wheel motor windings is more than 88 °C (190 °F).
In an over temperature condition, the operator must quickly and safely stop the haul
truck and apply the park and hand brakes. The operator must put the shift selector
switch to the NEUTRAL position, let the engine operate at idle speed, and monitor the
wheel motor temperature gauge.
The operator must push the drive system reset button. If the over temperature alarm
stays, or if the temperature continues to increase, stop the engine and tell maintenance
about the over temperature condition.
04-12-10 T282B S/N 327

Wheel Motor Overload

The wheel motor overload alarm shows when the current in one of the wheel motors is
more than 1250 amps.
In an overload condition, the operator must quickly and safely stop the haul truck and
apply the park and hand brakes. The operator should put the shift selector switch to
the NEUTRAL position, let the engine operate at idle speed, and monitor the wheel
motor current gauge.
The operator must push the drive system reset button (Ref. Fig. 04-12-002). If the
overload alarm stays, or if the current continues to increase, stop the engine and tell
maintenance about the overload condition.
Wheel Motor Overspeed

The wheel motor overspeed alarms shows when the armature speed of one of the
wheel motors is more than 3600 rpm.
In an overspeed condition, the TCU automatically starts dynamic retarding to slow the
speed of the wheel motor. If necessary, the operator must apply the service brake.
SiBaS Message
The SiBaS (Siemens System) message alarm shows when there is an internal problem
in the traction control unit (TCU).
If a SiBaS alarm shows, the operator must quickly and safely stop the haul truck and
apply the park and hand brakes. The operator must put the shift selector switch to the
NEUTRAL position and let the engine operate at idle speed.
The operator must push the drive system reset button (Ref. Fig. 04-12-002) one time
only. If the alarm stays, immediately stop the engine and tell maintenance about the
alarm.
Bad Cruise Control Set-Point

The bad cruise control set-point alarm shows when a cruise control set-point is entered
and is more than the overspeed limit. The cruise control does not operate until the
set-point is less than the limit.
Accelerator Pedal out of Tolerance

The accelerator pedal out of tolerance alarm shows if the accelerator pedal is out of
calibration or defective. The operator must tell maintenance personnel about this alarm
to adjust, repair, or replace the accelerator pedal.
Retard Pedal out of Tolerance

The retard pedal out of tolerance alarm shows if the retard pedal is out of calibration or
defective. The operator must tell maintenance personnel about this alarm to adjust,
repair, or replace the retard pedal.
Steering Encoder Failure

The steering encoder failure alarm shows when there is no signal from the steering
encoder, or the steering encoder is out of range. The operator must tell maintenance
personnel about this alarm to repair or replace the steering encoder.
Low Fuel
The low fuel alarm shows when the total quantity of fuel is approximately 380 L (100.5
U.S. gal).
Battery Voltage Low
T282B S/N 327 04-12-11

The battery voltage low alarm shows when the voltage of the battery bank is less than
20 volts. The operator must tell maintenance personnel about this alarm.
Dump System Overtemp

The dump system over temperature alarm shows when the temperature of the
hydraulic oil in the dump system is more than 93 °C (199 °F).
If the dump system over temperature alarm shows, quickly and safely stop the haul
truck and apply the park and hand brakes. Put the shift selector switch to the
NEUTRAL position and stop the engine.
Brake and Steering Overtemp

The brake and steering over temperature alarm shows when the temperature of the
hydraulic oil in the dump system is more than 93 °C (199 °F).
If the brake and steering over temperature alarm shows, quickly and safely stop the
haul truck and apply the park and hand brakes. Put the shift selector switch to the
NEUTRAL position and stop the engine.
Brake Pressure Low

The brake pressure low alarm shows when the hydraulic pressure for the service brake
is less than 172 bar (2490 psi).
if the brake pressure low alarm shows, the operator must quickly and safely stop the
haul truck and apply the park and hand brakes. The operator must put the shift selector
switch to the NEUTRAL position and stop the engine.
To stop a haul truck with this alarm, apply the service brakes constantly and
continuously until the haul truck fully stops.
Steering Pressure Low

The steering pressure low alarm shows when the hydraulic pressure for the steering
system is less than 172 bar (2490 psi).
If the steering pressure low alarm shows, the operator must quickly and safely stop the
haul truck and apply the park and hand brakes. The operator must put the shift selector
switch to the NEUTRAL position and stop the engine.
Wheel Motor Air Flow Low

If the alarm message for the wheel motor air flow low shows, an alarm makes a sound.
This alarm shows when the air from the main blower is not enough to keep the
alternator and wheel motors at cool temperature.
Ground Fault
A ground fault alarm shows when there is a short circuit to ground in the AC drive
system.
Fault List Screen

The haul truck must be fully stopped to see the fault list screen. if the ESC/SCREEN
button is pushed two times, the main display screen changes to the fault list screen.
The fault list screen records all the faults that occurred during operation of the haul
truck.
Use the UP arrow button to scroll up the list. Use the DOWN arrow button to scroll
down the list.
Right Dash Panel
04-12-12 T282B S/N 327

04-12-007 Right Dash Panel
The right dash panel has the systems that follow:

The Indicator Panel
The Keypad
The Panel Switches and,
The Ignition Master Switch
T282B S/N 327 04-12-13

Indicator Panel
The indicator panel is on the right dash panel. The conditions of some haul truck
systems show on the indicator panel when the related system is in operation. If there is
a problem with the connected system, the related indicator on the indicator panel can
illuminate.
04-12-008 Indicator Panel
1. Engine Fault Indicator (1)

2. Check Engine Indicator (2)
3. Engine Maintenance Indicator (3) (not used)
4. Park Brake Indicator (4)
5. Brake Active Indicator: front and rear drag indicator (5)
6. Retard Brake Indicator (6)
7. Gear Oil Cooling Indicator (7)
8. Ladder Down Indicator (8) (not used)
9. Hydraulic Tank Valve Closed Indicator (9) (not used)
10. Drive System Fault Indicator (10)
11. Auto Lube Fault Indicator (11)
12. Propel Inhibit Indicator (12)
04-12-14 T282B S/N 327

Engine Fault Indicator

The engine fault indicator (1) comes on in red when the engine fault causes an alarm.
Stop the engine and tell maintenance about the problem.
Check Engine Indicator

The check engine indicator (2) comes on in amber when the engine rpm is less than
500 rpm, or when the engine senses a fault.
Engine Maintenance Indicator (not used)

The engine maintenance indicator (3) is not used.
Park Brake Indicator

The park brake indicator (4) comes on while the park brake is set. If the park brake is
set and you try to move the haul truck, this indicator flashes one time each second. Do
not try to move the haul truck during the time that the park brake is in operation.
Brake Active Indicator: front and rear drag indicator

This brake active indicator (5) flashes in red when there is brake drag. A front drag or
rear drag condition occurs when hydraulic pressure remains on the circuits after the
brake pedal is released. The brake active indicator flashes every second during a front
drag condition and two times every second during a rear drag condition. If this indicator
flashes, stop the haul truck and set the park brake. Let the engine of the haul truck
operate at idle speed while you tell maintenance personnel about this condition. If the
indicator extinguishes, continue operations. If the indicator does not extinguish after 5
minutes, tell maintenance personnel about this condition and follow their instructions.
Retard Brake Indicator

The retard brake indicator (6) comes on in amber when the retard brake is in operation.
Gear Oil Cooling Indicator

The gear oil cooling indicator (7) flashes when the temperature of the gear oil is higher
than 82 °C (180 °F) and the Ecomat buzzer goes off when the temperature is higher
than 90 °C (194 °F). If this indicator illuminates steadily, quickly stop the haul truck and
let the engine idle for five minutes. If the indicator remains illuminated, put the shift
selector switch to the NEUTRAL position and set the park brake. Turn the master
ignition switch to the OFF position and tell maintenance personnel about this condition.
If the indicator turns off continue with normal operations.
Ladder Down Indicator (not used)

The ladder down indicator (8) is not used.
Hydraulic Tank Valve Closed Indicator (not used)

The hydraulic tank valve closed indicator (9) is not used.
Drive System Fault Indicator

The drive system fault indicator (10) comes on in red when there is a fault in the drive
system. Push the fault reset switch (7) to try to correct the fault. If the indicator stays
on, the fault cannot be reset. Stop the engine and tell maintenance about the problem.
Auto Lube Fault Indicator

The auto lube fault indicator (11) illuminates when there is a fault with the auto lube
system. The auto lube system automatically supplies grease from the grease tank
through hoses to the injectors to different pivot points. During an auto lube system fault
T282B S/N 327 04-12-15

condition, you must manually apply the lubrication to these pivot points. You must also
tell maintenance personnel of the failure. Press the bottom half of the manual lube
switch (5) for a short time to apply lubrication. The manual lube switch starts the
lubrication one time during a twenty-minute interval.
Propel Inhibit Indicator

The propulsion inhibit indicator (12) illuminates when the propulsion lockout switch is in
operation. The park brake also sets during the time that this switch is in operation.
04-12-16 T282B S/N 327

Keypad
04-12-009 Keypad
The keypad is on the right dash panel and interfaces with the display panel. The four
buttons let you move the cursor around on the display panel. The UP and the DOWN
buttons allow the cursor to move UP and DOWN through the display panel. The
ENTER button does not operate. Finally, the ESC/SCREEN button lets you change
from screen to screen as follows:
Main Display Screen
Bar Gauge Screen
Fault List Screen
T282B S/N 327 04-12-17

Right Dash Panel Switches
04-12-010 Right Dash Panel Switches
The right dash panel has the switches that follow:

Hand Brake Switch
Cruise Control ON/OFF Switch
Cruise Control UP/DOWN Switch
Ignition Master Switch
Hand Brake Switch

The hand brake switch has two positions and the hand brake switch also has a
slide-lock that locks in the OFF position. Use your thumb to release the slide-lock and
push the symbol-side of the switch DOWN to set the hand brake. Push the top half of
the switch until the switch locks into the OFF position to release the hand brake.
"HAND BRAKE ON" shows on the display panel while the hand brake is in operation.
Cruise Control ON/OFF Switch

The cruise control on/off switch has two positions. The cruise control on/off switch
energizes (ON) or de-energizes (OFF) the cruise control system. Push the bottom half
of the switch to energize the cruise control system. Press the top half of the switch to
de-energize the cruise control system. When the cruise control speed entered is more
than the ground speed limit, the cruise control will not operate until the set-point is less
than the ground speed limit. “CRUISE CONTROL ON” shows on the display panel
while the time that the cruise control is in operation.
Cruise Control UP/DOWN Switch

The cruise control speed up/down switch has three positions. The three positions are
04-12-18 T282B S/N 327

the UP, the HOLD, and the DOWN positions. Press the top half of the switch to
increase (UP) the cruise control set speed and push the bottom half of the switch to
decrease (DOWN) the cruise control set speed. The HOLD position is the center
position. When this switch is released, it returns to the center position and the speed
set is held. The cruise control speed set shows in blue on the display panel.
Ignition Master Switch

The ignition master switch is a rotary switch that has three positions and this switch is
operated with a key. The three positions are the OFF, the IGNITION, and the START
position. Electrical power is disconnected from the engine start system when the
ignition master switch is set to the OFF position. if this switch is in the IGNITION
position, electrical power is supplied for some devices, for example, the 12VDC power
ports and the dome and reading light. If the ignition master switch is in the START
position electrical power is supplied to the engine start system. If the engine starts,
release the ignition master switch to let it move to the IGNITION position.
T282B S/N 327 04-12-19

Accessory Panel
04-12-011 Accessory Panel
The accessory panel is right of the indicator panel. The accessory panel has switches,
outlets, ports, and the automatic temperature control panel (ATCP) that controls the
automatic temperature system in the operator cab.
World Radio and Compact Disc Player

The haul truck can have an optional world radio or compact disc player. Refer to the
specified OEM instructions for the world radio or compact disc player operations.
ATCP
The automatic temperature control panel has the controls that follow:
ON/OFF
AUTO
DEF (Defrost)
FAN UP/DOWN
TEMPERATURE UP/DOWN
EXT (External Temperature)
ECON (Economy Mode)
ON/OFF
The ON and the OFF buttons energize and de-energize the heater and air conditioner
system. The numeric display illuminates when the heater and the air conditioner
system is energized. The air temperature in the operator cab shows on the display.
04-12-20 T282B S/N 327

AUTO
The AUTO button puts the heater and air condition system, and the fan speed control
into automatic mode. A panel illuminates when the AUTO mode is energized. The
system adjusts the speed of the blower fan to the lowest set speed that is necessary to
keep the set temperature in the operator cab.
DEF (Defrost)
The DEF push-button switch energizes the A/C control system that removes the
humidity from the cab. The A/C is enabled when the set-point temperature requires
heat. A panel light illuminates when the A/C control system is in DEF mode.
Fan UP/DOWN
The fan UP/DOWN push-buttons override the automatic fan speed control. The switch
lets single-digit increases and decreases of the fan speeds. The panel shows the
speed set as a percentage or HI when the speed set is at maximum and LO at the
minimum speed. The fan UP/DOWN speed continues for 5 seconds after the
push-button is pressed. The set fan speed remains until changed and until the AUTO
key is pressed.
Temperature UP/DOWN
Press the UP button to increase and the DOWN button to decrease the temperature in
the operator cab. The A/C system electronic controls the coolant valve for the cab
heater. The A/C system engages the compressor clutch to control the air temperature
in the operator cab.
EXT (External Temperature)

Push the digital display to show the outside temperature as measured by the outside
air sensor. The outside temperature shows for a period of 5 seconds. After this time,
the digital display shows the set temperature.
T282B S/N 327 04-12-21

ECON (Economy Mode)

Push the ECON button to lock out the A/C function. The control uses only clean air, fan
speed, and the coolant valve controls the set temperature. To return to the normal A/C
operation, press the ECON button. A light illuminates on the panel during the time that
the ECON button is pressed.
Accessory Panel Switch, Outlets, and Ports

The accessory panel has the ports and outlets that follow:
Engine System Data Port
AC Power Outlets
DC Power Outlet
Siemens Drive System Data Port
Payload Weigh System Data Port
Engine System Data Port

The engine system data port is a 10-pin data link. The functions of the engine system
data port when connected to a laptop computer are for calibration, fault code
download, reset fault codes, data collection and analysis, USB port usage, and
troubleshooting.
AC Power Outlets
This haul truck can have optional AC power ports supply 110 VAC.
DC Power Outlets
The DC power port supply 12 VDC.
Siemens Drive System Data Port

The Siemens drive system data port is a communication port. Performance data from
the TCU can be downloaded from this port.
Payload Weigh System Data Port

The payload weigh system data port is a Universal Serial Bus (USB) A–B data port
connector.
04-12-22 T282B S/N 327

Floor Mounted Center Console
04-20 Floor Mounted Center Console

The floor-mounted center console has the components that follow:
Shift Selector Switch
Dump Control Lever with Dump Body Override Switch
12 VDC Power Outlet
Circuit Breaker Panel
04-20-001 Floor Mounted Center Console

(Ref. Fig. 04-20-001)
Shift Selector Switch

The direction of movement for the haul truck is set by the shift selector switch. The shift
selector switch has three positions, FORWARD, NEUTRAL, and REVERSE position.
The shift selector switch sends a signal to the traction control unit (TCU) to tell the haul
truck to move in the direction selected.
The shift selector switch must be in the NEUTRAL position to start the engine. The
shift selector switch must be put in the NEUTRAL position when loading or dumping.
If the shift selector switch is in the REVERSE position, the backup lights on the rear of
the axle box and the ends of the superstructure come on. The backup horn makes a
sound when the shift selector is put in the REVERSE position.
T282B S/N 327 04-20-01

Dump Control Lever with Dump Body Override Switch

The dump control lever has the component that follows:
Dump Body Override Switch
The dump control lever is a three-position, four-function, self-centering, controller. The
dump control lever is located in the cab on the center console between the seats.
The dump control lever moves forward and back. The three positions are forward,
center, and back. If the dump control lever is pulled back (towards the rear of the cab)
the dump body lifts. if the dump control lever is pushed forward (towards the front of
the cab) the dump body lowers. If the dump control lever is released, it automatically
moves to the center, which is the "hold" position. The dump body proximity switch
activates the "float" position.
The dump body override switch is a push button switch located on the left side of the
dump control lever. The dump body override switch is momentarily operated when
pushed and held in. The function of the dump body override switch is to permit the
operator to move the haul truck forward while lowering the dump body.
Warning! The proximity switch opens when the haul truck dump body is lifted. An open
proximity switch limits the haul truck forward speed to 8 km/h (5 mph) and prevents all reverse
movement.
Serious damage to equipment or personnel can occur if you override the proximity switch.
Make sure that the proximity switch functions correctly and the dump body up indicator
shows when the dump body is lifted. Do not override the dump body proximity switch.
12 VDC Power Outlet

The floor mounted center console can have a 12 VDC power outlet.

The circuit breaker panel is in the floor mounted center console, nearest to the rear of
the cab. The circuit breaker panel has circuit breakers (CB1) to (CB28) that operate to
protect electrical circuits. There are two additional circuit breakers, CB32 and CB34, on
the ground level in the battery disconnect switch box (Ref. 06-12-000-DA).
Circuit Breaker Function

CB1 low/high beam relays, high beam switch, CB20, CB21,
flasher control, and turn signal and hazard lights
CB2 24V main power to MDEC engine
CB3 air ride seat, manual lube switch, air conditioner switch,
and door proximity switches
CB4 dump body override switch, data store switch, cruise
enable and up/down switch, fault reset switch, and
battery voltage signal to TCU
CB5 rollover switch, ignition switch, and key on signal to
Ecomat
CB6 windshield wiper and washer switch, payloaod weigh
system and outboard display, and dump body proximity
switch
CB7 MTU electronic systems
CB8 operator cab windows
04-20-02 T282B S/N 327

CB9 dump control lever, axle box temperature control switch,

auto lube pressure switch, and gear oil temperature
sensors
CB10 battery disconnect
CB11 grid dry switch, park brake switch, hand brake switch,
park and hand brake pressure switches, fuel level
sensor, dump temperature sensor, and brake and
steering temperature sensor
CB12 Ecomat power relay
CB13 blower pressure switches, steering pressure switch, front
and rear brakes pressure switches, and 24V switched
for the dispatch system power (if equipped)
CB14 propel inhibitor switch, and steering angle signal
CB15 power to the air conditioner condenser
CB16 axle box lights and switch, ladder lights and switch,
engine service lights, cab deck light, and fog lights and
switch (if equipped)
CB17 AC power outlet (24B)
CB18 start and start inhibit relays, ignition switch, MDEC start
and pre-lube relays, and engine heater control (if
equipped)
CB19 horn relay and horns, and payload weigh system
CB20 left low beam headlight, and left riser light (if equipped)
CB21 right low beam headlight, and right riser light (if
equipped)
CB22 left high beam headlight
CB23 right high beam headlight
CB24 dome light, backup switch and lights, reverse relay,
backup alarm, retard lights and relay, and brake pedal
relay and proximity switch
CB25 12V power supply, and 12V power outlet on dash
CB26 AC power outlet (24A)
CB27 accessory 12V relay, radio, and centre console 12V
power outlet
CB28 headlight switch, turn signal indicator lights, switch
LEDs, shift selector indicator, and clearance lights
indicator LEDs
T282B S/N 327 04-20-03

04-20-500-DA - How to Adjust the Dump Control Lever

Setup
Procedure
(Ref. Fig. 04-20-002)
Attach a pressure gauge to PG1 of the dump system actuator on the manifold
valve.
Move the dump control lever backward to the power UP position and HOLD.
Notice! The pressure set by the factory for PG1 and PG2 are 27 to 31 bar (390 to 450 psi), but
a pressure of 24 to 68 bar (350 to 990 psi) is satisfactory.
It is necessary to have 24 bar (350 psi) to fully shift the spool in the dump valve, and the
pilot caps are rated to 68 bar (990 psi).
If the pressure indication at PG1 is not between 27 to 31 bar (390 to 450 psi),
Stop the movement of the dump cylinder and adjust the hi-range potentiometer,
as follows:
Use a small common screw driver to adjust the hi-range potentiometer.
Turn the adjustment screw clockwise to increase the pressure, or
counterclockwise to decrease the pressure.
If the dump control lever is new, turn the adjustment screw clockwise eight full
turns, to start.
Move the dump control lever backward and note if the pressure indication at PG1
goes up or down.
Repeat the adjustment procedures until the pressure indication at PG1 is 27 to 31
bar (390 to 450 psi).
After the pressure at PG1 is correct, do this procedure:
valve.
Move the dump control lever forward to the power DOWN position and HOLD.
If the pressure indication at PG2 is 27 to 31 bar (390 to 450 psi),
The pressure is correct.
The up and down pressures are too far apart, and it is necessary to adjust the
frequency potentiometer, do this procedure:
Use a small common screw driver to adjust the frequency potentiometer until
PG2 is between 27 to 31 bar (390 to 450 psi).
04-20-04 T282B S/N 327

Notice! It is possible to have PG1 and PG2 pressures in the correct range, but have no
movement of the dump cylinder.
After the pressures are in range, but there is no dump cylinder movement, you must adjust
the frequency potentiometer.
Repeat the dump control lever adjustment procedure until PG1 and PG2 are
between 27 to 31 bar (390 to 450 psi).
Closeout
T282B S/N 327 04-20-05

04-20-002 Dump Control Lever Adjustment
04-20-06 T282B S/N 327

Steering Column and Controls
04-30 Steering Column and Controls

The steering column has the components that follow:
Tilt and Telescope Lever
Left and Right Turn Signals Lever
Dimmer Switch Lever
Hazard Flasher
Horn Button
04-30-001 Steering Column

(Ref. Fig. 04-30-001)
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 down to
unlock.
Pull or push the steering wheel as necessary and then pull the tilt and telescopic lever
to lock in position.
Dimmer Switch Lever

To make a high or low headlight selection, pull and release the dimmer switch lever.
T282B S/N 327 04-30-01

Steering Column and Controls
Left and Right Turn Signals Lever

The left and right turn signals lever switch moves up to signal a right turn, and down to
signal a left turn.
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.
Horn Button
The horn button is in the center of the steering wheel. Push the horn button to operate.
04-30-02 T282B S/N 327

Foot Pedal Controls
04-40 Foot Pedal Controls

The foot pedal controls are:
Brake Pedal
Retarding Pedal
Accelerator Pedal
04-40-001 Foot Pedal Controls

(Ref. Fig. 04-40-001)
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
amber 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.
The brake pedal interfaces with the system that follows:
Brake System (Ref. 09-50-000-DA)
Front Brakes (Ref. 12-30-000-DA)
Rear Brakes (Ref. 12-50-000-DA)
T282B S/N 327 04-40-01

Foot Pedal Controls
Retarding Pedal
The retarding pedal is the center pedal. If the operator pushes on the retarding pedal
the speed of the haul truck decreases. The retarding pedal is part of the Siemens AC
Drive System. The function of the retarding pedal is to stop the haul truck electrically.
The AC drive system can supply a high retard 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 retarding 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 retard 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 retard lights on the rear of the axle box illuminate when the retarding pedal
is pushed.
For more information on the AC drive system, refer to the Siemens manual.
The retarding pedal interfaces with the system that follows:
Siemens AC Drive System (Ref. 05-80-000-DA)
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:
04-40-02 T282B S/N 327

Foot Pedal Controls
04-40-100-DA - How to Remove the Brake Pedal

Setup
Procedure
(Ref. Fig. 04-40-002)
(Ref. Fig. 04-40-003)
Warning! Parts held under tension by spring can cause injury.

Release the tension of the spring before you do maintenance on such parts.
Remove the hex-head capscrews (2), nuts (3), and washers (4).
Remove the pedal (1) with the adjustment screws (5).
To remove the springs (10) of the brake pedal, do this procedure:
Loosen the nuts (6) to release the load of the springs (10).
Remove the four nuts (6), washers (7), and the u-bolts (8).
Remove the pin (9).
Remove the lower part of the pedal (11) and the springs (10).
Closeout
T282B S/N 327 04-40-03

Foot Pedal Controls
04-40-002 How to remove/How to install the Brake Pedal
04-40-04 T282B S/N 327

Foot Pedal Controls
04-40-003 How to remove/How to install the Brake Pedal
T282B S/N 327 04-40-05

Foot Pedal Controls
04-40-105-DA - How to Remove the Retarding Pedal

Setup
Procedure
(Ref. Fig. 04-40-004)
(Ref. Fig. 04-40-005)

Remove the capscrews (3) and the clamps (2).

Disconnect the connector (4) and remove the cable (8).
Remove the rubber protector (5).
Remove the retainer rings (6), the pin (7), and the pedal assembly (1).
To remove the plate (9), do this procedure:
Remove the capscrews (10), washers (12), and lockwashers (11).
To replace the roller (13), do this procedure:
Remove the roller shaft (14) and remove the roller (13).
To replace the springs (15), do this procedure:
Remove the capscrews (16).
Remove the sensor housing (17).
Remove the nut (18), pin (19), guide (21), washers (20), and springs (15).
Closeout
04-40-06 T282B S/N 327

Foot Pedal Controls
04-40-004 How to Remove/How to Install the Retarding Pedal
T282B S/N 327 04-40-07

Foot Pedal Controls
04-40-005 How to Remove/How to Install the Retarding Pedal
04-40-08 T282B S/N 327

Foot Pedal Controls
04-40-110-DA - How to Remove the Accelerator Pedal

Setup
Procedure
(Ref. Fig. 04-40-006)
(Ref. Fig. 04-40-007)

Remove the capscrews (3) and the clamps (2).

Disconnect the connector (4) and remove the cable (8).
Remove the rubber protector (5).
Remove the retainer rings (6), the pin (7), and the pedal assembly (1).
To remove the plate (9), do this procedure:
To replace the roller (13), do this procedure:
Remove the roller shaft (14) and remove the roller (13).
To replace the springs (15), do this procedure:
Remove the sensor housing (17).
Remove the nut (18), pin (19), guide (21), washers (20), and springs (15).
Closeout
T282B S/N 327 04-40-09

Foot Pedal Controls
04-40-006 How to Remove/How to Install the Accelerator Pedal
04-40-10 T282B S/N 327

Foot Pedal Controls
04-40-007 How to Remove/How to Install the Accelerator Pedal
T282B S/N 327 04-40-11

Foot Pedal Controls
04-40-200-DA - How to Install the Brake Pedal

Setup

Make sure that the haul truck is in the same condition as the removal (Ref.
04-40-100-DA).
Parts Table:
REFERENCE TECHNICAL LABEL QUANTITY DRAWING-ITEM

1 Brake pedal 1
2 Hex-head capscrews 2
3 Nut 2
4 Washer 2
5 Screws 2
6 Nut 4
7 Washers 4
8 U-bolt 2
9 Pin 1
10 Spring 2
11 Brake pedal 1
Procedure
(Ref. Fig. 04-40-002)
(Ref. Fig. 04-40-003)

Install the u-bolts (8), washers (7), and nuts (6).

Install the springs (10) and the pin (9) on the lower part of the pedal (11).
Tighten the nuts (6).
Install the pedal (1) with the hex-head capscrews (2), washers (4), and nuts (3).
Tighten the capscrews (2).
Adjust the height of the pedal with the adjustment screws (5).
Closeout
Make sure that the pedal has the correct adjustment.

04-40-12 T282B S/N 327

Foot Pedal Controls
04-40-205-DA - How to Install the Retarding Pedal

Setup

04-40-105-DA).
Parts Table:

1 Pedal assembly 1
2 Clamp 2
3 Capscrew 2
4 Connector 1
5 Cover 1
6 Retainer ring 2
7 Pin 1
8 Cable 4
9 Plate 1
10 Capscrew 2
11 Lockwasher 2
12 Washer 2
13 Roller 1
14 Roller shaft 1
15 Spring 2
16 Capscrew 2
17 Sensor housing 1
18 Nut 1
19 Pin 1
20 Washer 2
21 Guide 1
Procedure
(Ref. Fig. 04-40-004)
(Ref. Fig. 04-40-005)

To assemble the springs (15), do this procedure:

Install the washers (20), springs (15), guide (21), pin (19), and nut (18) on the
pedal assembly (1).
Install the sensor housing (17) with the capscrews (16).
T282B S/N 327 04-40-13

Foot Pedal Controls
Install the roller (13) and the roller shaft (14).

Install the plate (9) with the capscrews (10), lockwashers (11), and washers (12).
Install the pedal assembly (1) on the plate (9) with the pin (7) and the retainer
rings (6).
Connect the connector (4) and attach the cable (8) with the capscrews (3) and
clamps (2).
Install the rubber cover (5).
Closeout
04-40-14 T282B S/N 327

Foot Pedal Controls
04-40-210-DA - How to Install the Accelerator Pedal

Setup

04-40-110-DA).
Parts Table:

1 Pedal assembly 1
2 Clamp 2
3 Capscrew 2
4 Connector 1
5 Cover 1
6 Retainer ring 2
7 Pin 1
8 Cable 4
9 Plate 1
10 Capscrew 2
11 Lockwasher 2
12 Washer 2
13 Roller 1
14 Roller shaft 1
15 Spring 2
16 Capscrew 2
17 Sensor housing 1
18 Nut 1
19 Pin 1
20 Washer 2
21 Guide 1
Procedure
(Ref. Fig. 04-40-006)
(Ref. Fig. 04-40-007)

To assemble the springs (15), do as follows:

Install the washers (20), springs (15), guide (21), pin (19), and nut (18) on the
pedal assembly (1).
Install the sensor housing (17) with the capscrews (16).
T282B S/N 327 04-40-15

Foot Pedal Controls
Install the roller (13) and the roller shaft (14).

Install the plate (9) with the capscrews (10), lockwashers (11), and washers (12).
Install the pedal assembly (1) on the plate (9) with the pin (7) and the retainer
rings (6).
Connect the connector (4) and attach the cable (8) with the capscrews (3) and
clamps (2).
Install the rubber cover (5).
Closeout
04-40-16 T282B S/N 327

Seats
04-50 Seats
The cab of the haul truck has two seats. One seat is for the operator, the other seat is
for a passenger.
04-50-001 Seats
Operation
(Ref. Fig. 04-50-001)
The seats are adjustable with the switches that follow:
Rear height
Front height
Weight and ride suspension
Upper and lower lumbar support
Seat back angle
The seats can adjust forward and backward with the metal bar below the seat.
The armrests on the seats can move up to permit easy access to the seat. The incline
of the armrests can be adjusted with the nut installed at the end of the armrests.
The headrests can adjust up and down.
T282B S/N 327 04-50-01

Seats
04-50-02 T282B S/N 327

Glass
04-60 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.
Detailed Description
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.
T282B S/N 327 04-60-01

Glass
04-60-300-DA - Replacement of the Glass

Setup
Procedure
(Ref. Fig. 04-60-001)
(Ref. Fig. 04-60-002)
(Ref. Fig. 04-60-003)
(Ref. Fig. 04-60-004)
(Ref. Fig. 04-60-005)
Find the end of the locking seal.

Use the applicable tool to pull some of the locking seal out of the rubber
moulding.
Manually, pull the remaining locking seal out of the rubber moulding.
Carefully push out on the glass and remove.
Examine the rubber moulding and replace if necessary.
If the rubber moulding was removed, do as follows:
Install the rubber moulding in the window frame and make sure that the two ends
of the moulding touch at the bottom.
Put the bottom edge of the glass in position in the rubber moulding.
Gradually push the glass into the rubber moulding around the frame.
Use a locking seal insert tool to install the locking seal.
Put one end of the locking seal into the rubber moulding at the bottom center of
the frame.
Carefully install the locking seal into the rubber moulding around the frame, and
do not stretch the seal.
Make sure the locking seal is fully installed into the rubber moulding.
Closeout
04-60-02 T282B S/N 327

Glass
04-60-001 Replacement of the Glass
T282B S/N 327 04-60-03

Glass
04-60-002 Dimensions of the Glass, front
04-60-04 T282B S/N 327

Glass
04-60-003 Dimensions of the Glass, front side
T282B S/N 327 04-60-05

Glass
04-60-004 Dimensions of the Glass, rear side
04-60-06 T282B S/N 327

Glass
04-60-005 Dimensions of the Glass, rear
T282B S/N 327 04-60-07

Glass
04-60-08 T282B S/N 327

Access Panels and Miscellaneous Items
04-70 Access Panels and Miscellaneous Items

Access panels are designed to give easy access for the maintenance of the cab main
components.
Access panels (Ref. Fig. 04-70-001)(Ref. Fig. 04-70-002)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
T282B S/N 327 04-70-01

04-70-001 Access Panels
04-70-02 T282B S/N 327

04-70-002 Access Panels
T282B S/N 327 04-70-03

04-70-04 T282B S/N 327

05 Power Module
Power Module Assembly.............................................................................. 05-02-01
How to Remove the Power Module Assembly.................................... 05-02-03
How to Install the Power Module Assembly........................................ 05-02-07
Engine.............................................................................................................05-10-01
How to Remove the Engine................................................................ 05-10-03
How to Install the Engine.................................................................... 05-10-06
Engine Start........................................................................................ 05-10-08
Engine Shutdown................................................................................ 05-10-09
Engine Specification Tables and Maintenance Tables....................... 05-10-10
Traction Alternator........................................................................................ 05-20-01
How to Remove the Traction Alternator.............................................. 05-20-02
How to Install the Traction Alternator.................................................. 05-20-05
Traction Alternator Measurements......................................................05-20-07
Engine Flywheel Runout Check.......................................................... 05-20-09
Engine Endplay Measurements.......................................................... 05-20-11
Traction Alternator Specification Tables and Maintenance Tables..... 05-20-14
Radiator.......................................................................................................... 05-30-01
How to Remove the Radiator.............................................................. 05-30-03
How to Install the Radiator.................................................................. 05-30-09
How to Replace the Tubes of the Radiator......................................... 05-30-12
How to Fill the Radiator with Coolant.................................................. 05-30-15
Radiator Specification Tables and Maintenance Tables..................... 05-30-16
Exhaust System............................................................................................. 05-40-01
How to Remove the Exhaust System..................................................05-40-02
How to Install the Exhaust System..................................................... 05-40-10
How to Replace the Exhaust Blankets................................................ 05-40-13
How to Inspect the Expansion Joints and the Exhaust Blanket.......... 05-40-15
Exhaust System Specification Tables and Maintenance Tables.........05-40-16
Fuel System....................................................................................................05-50-01
How to Remove the Fuel Tank........................................................... 05-50-02
How to Install the Fuel Tank............................................................... 05-50-03
How to Fill the Fuel Tank.................................................................... 05-50-04
How to Drain the Fuel and Hydraulic Tank......................................... 05-50-05
Fuel Tank Specification Tables and Maintenance Tables...................05-50-06
Engine Air Cleaner.........................................................................................05-60-01
How to Remove the Engine Air Cleaner Ducts................................... 05-60-02
How to Install the Engine Air Cleaner Ducts....................................... 05-60-04
Air Cleaner Restriction Check............................................................. 05-60-06
How to Do the Air Cleaner Servicing...................................................05-60-08
Air Cleaner Specification Tables and Maintenance Tables.................05-60-11
Filter Restriction Indicators.......................................................................... 05-62-01
Engine Heater.................................................................................................05-70-01
How to Remove the Engine Heater.................................................... 05-70-02
How to Install the Engine Heater........................................................ 05-70-05
Engine Heater Specification Tables and Maintenance Tables............05-70-06

Siemens AC Drive System................................................................................................. 05-80-01
How to Clean the Control Cabinet............................................................................05-80-02
Traction Control Unit.......................................................................................................... 05-82-01
Inverters and Traction Motors........................................................................................... 05-84-01
Choppers and Retard Grid................................................................................................. 05-86-01
AC Drive Cooling System...................................................................................................05-88-01
How to Remove the AC Cooling System Motor....................................................... 05-88-03
How to Remove the Alternator Cooling Duct............................................................05-88-05
How to Remove the Axle Box Cooling Duct............................................................. 05-88-07
How to Install the AC Cooling System Motor........................................................... 05-88-09
How to Install the Alternator Cooling Duct................................................................05-88-10
How to Install the Axle Box Cooling Duct................................................................. 05-88-11
How to Inspect the AC Drive Cooling System.......................................................... 05-88-13

05 Power Module
Overview
The power module chapter has these sections:
Power Module Assembly (Ref. 05-02-000-DA)
Engine (Ref. 05-10-000-DA)
Traction Alternator (Ref. 05-20-000-DA)
Radiator (Ref. 05-30-000-DA)
Exhaust System (Ref. 05-40-000-DA)
Fuel System (Ref. 05-50-000-DA)
Engine Air Cleaner (Ref. 05-60-000-DA)
Engine Heater (Ref. 05-70-000-DA)
T282B S/N 327 05-00-01

Power Module Maintenance Manual
05-00-02 T282B S/N 327

Maintenance Manual Power Module
05-02 Power Module Assembly

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.
05-02-001 Power Module Assembly
Overview
(Ref. Fig. 05-02-001)
The power module assembly has the components that follow:
The power module assembly connects to the systems that follow:
T282B S/N 327 05-02-01

Engine Air Cleaner (Ref. 05-60-000-DA)

Electrical System (Ref. 06-00-000-DA)
05-02-02 T282B S/N 327

05-02-100-DA - How to Remove the Power Module Assembly

Setup
Follow the safety guidelines the haul truck safety precautions section.(Ref.
01-16-000-DA).
Install a safety harness when you do work from above the ground. (Ref.
01-20-000-DA).
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.(Ref. 13-30-900-DA).
Remove the hood and the grill. (Ref. 13-20-100-DA).
Remove the superstructure crossmember (Ref. 13-20-105-DA).
Remove the alternator cooling duct from the top of the traction alternator. (Ref.
05-88-105-DA).
Disconnect the gearbox drive flange on the pump drive from the traction
alternator. (Ref. 07-10-100-DA).
Disconnect the exhaust pipe flanges. (Ref. 05-40-100-DA).
Remove the engine heater from the lower crossmember. (Ref. 05-70-100-DA).
Drain the radiator. (Ref. 05-30-300-DA).
Warning! Fluids under pressure can cause injury.

Remove the brake, steering systems , of all pressure.(Ref. 09-52-300-DA).
Close the fuel and hydraulic valves. (Ref. 07-20-100-DA).

Disconnect the inlet ducts from the air cleaner to the engine. (Ref.
05-60-100-DA).
Procedure
(Ref. Fig. 05-02-002)
Notice! The empty weight of the power module is more than 20000 kg (44100 lb).
Install a lift that can hold the empty power module assembly weight.
Make sure all of the supply line shutoff valves are in the OFF position.
Tag and disconnect the air, oil, and the fuel lines in the area of the power module
assembly.
Install protective covers on all of the disconnected lines.
Open the engine ports.
Tag, and disconnect the electrical cables in the area of the power module
T282B S/N 327 05-02-03

assembly.
Disconnect the ground straps installed between the power module assembly and
the frame.
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.
Install the chain and the spreader to the engine skid rear.(Liebherr part number
T-128-F Ref. 02-00-000-DA)
Install the left and the right rollout rails and the front rail support.
Remove the tension from the chains.
Remove the locknuts (5), cinch washers (4), fibromounts (3), washers (2), and
capscrews (1).
Lift the engine skid from the rear approximately 50 to 75 mm (1.968 to 2.953 in.).
Install the left and the right rollout assemblies.
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..
Install the chain and the spreader beam (Liebherr part number T-128-F Ref.
02-00-000-DA) to the front of the engine skid.
The chain and the spreader beam must be attached to all four lift points on the
engine skid.
Lift the engine skid enough to remove the weight from the front shock mounts.
Carefully and slowly, move the front skid mounts from the front bumper.
Install wooden supports between the skid mounts and the bumper to make the
power module assembly level..
Make the power module assembly lev, and put the front skid mounts against the
wooden supports on the front bumper.
Lift the power module assembly enough to clear the front bumper.
Carefully move the power module assembly forward away from the haul truck.
Install the front and the rear engine stands to the power module assembly.
Put the power module assembly on the Liebherr part number T-500–J. (Liebherr
part number T-500-J Ref. 02-00-000-DA)
05-02-04 T282B S/N 327

Closeout
Remove the tools and the materials that are not necessary from the work area.
T282B S/N 327 05-02-05

05-02-002 Removal/Installation of the Power Module Assembly
05-02-06 T282B S/N 327

05-02-200-DA - How to Install the Power Module Assembly

Setup

Use a safety harness when you do maintenance above ground (Ref.
01-20-000-DA).
Make sure that the haul truck is in the same condition as the removal procedure
(Ref. 05-02-100-DA).
Parts Table:

1 Capscrew 8 10467957-3
2 Washer 8 10467957-4
3 Fibromount 8 10467957-1
4 Washer, cinch 8 10467957-2
5 Locknut 8 10467957-5
6 Capscrew 3 53365AB-102
7 Lockwasher 3 53365AB-14
8 Washer 3 53365AB-6
Procedure
(Ref. Fig. 05-02-002)
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.
Install the chain and spreader beam (Liebherr P/N T-128-F Ref. 02-00-000-DA) to
the four lift points of the engine skid.
Install the left and right rollout roller assemblies.
Notice! The weight of the power module assembly without fluids is more than 20000 kg (44100
lb).
Use an applicable lift device that can hold this weight.
Adjust the chain and spreader beam to keep the power module assembly level.
Lift the power module assembly enough to remove the front and rear engine
stands.
Remove the front and rear engine stands from the power module assembly.
Lift the power module assembly enough from the front bumper until you can
move the power module.
-or-
T282B S/N 327 05-02-07

Remove the power module assembly from the shipping skid (Liebherr P/N T-500-J Ref.
02-00-000-DA).
Carefully and slowly, move the power module assembly in position on the rollout
rails.
Carefully and slowly, move the power module assembly back into position on the
shock mounts.
Lower the power module assembly against the rubber shock mounts.
Remove the chain and spreader beam (Liebherr P/N T-128-F Ref. 02-00-000-DA)
from the front of the engine skid.
Lift the aft of the engine skid 50 to 75 mm (1.968 to 2.953 in.).
Remove the left and right rollout rails and the front rail support.
Remove the left and right rollout roller assemblies.
Lower the power module assembly until it is against the rubber shock mounts.
Install the capscrews (1), washers (2), cinch washers (4), fiBXomounts (3), and
locknuts (5).
Install the fasteners and washers from the rubber shock mounts that hold the
power module assembly to the main frame.
Connect the ground straps between the power module assembly and the main
frame.
Remove the tags and connect all the necessary electrical cables in the area of
the power module assembly.
Remove the protective covers on all the disconnected and open lines.
Remove the tags and connect all the necessary air, oil, and fuel lines.
Install the capscrews (6) and lockwashers (7), and washers (8) to connect the
hose support bracket to the traction alternator.
Closeout
Make sure that all supply line shutoff valves are in the ON position.
Connect the inlet ducts from the air cleaner to the engine (Ref. 05-60-200-DA).
Open the fuel and hydraulic valves (Ref. 07-20-200-DA).
Fill the coolant in the radiator (Ref. 05-30-700-DA).
Connect the exhaust pipe flanges (Ref. 05-40-200-DA).
Connect the gearbox drive flange on the pump drive from the traction alternator
(Ref. 07-10-200-DA).
Install the alternator cooling duct to the top of the traction alternator (Ref.
05-88-205-DA).
Install the superstructure crossmember (Ref. 13-20-205-DA).
Install the hood and grill (Ref. 13-20-200-DA).
05-02-08 T282B S/N 327

Lower the dump body (Ref. 13-30-905-DA).

T282B S/N 327 05-02-09

05-02-10 T282B S/N 327

Engine
05-10 Engine
The engine on the haul truck is an MTU/DDEC, 20V4000, Diesel engine with 2720 kW
(3650 HP)..The engine uses the air cleaners to prevent the materials and particles that
are not necessary from the engine. The engine coolant is kept warm by the engine
heaters.
The engine connects the systems that follow:

Engine Air Cleaners (Ref. 05-60-000-DA)
These components are attached to the engine:
Starters
Battery Charging Alternator
Operation
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 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/DDEC engine manual for more data.
Engine Air Cleaners

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, a 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 shows the
airflow of the engine. A manometer or an air service gauge calibrated in water is used
for the check of the airflow pressure returned to the engine.
A secondary safety filter keeps the material and particles that are not necessary from
the engine if the service of the primary filter is necessary.
Engine Heater
The engine heater is installed on the lower crossmember of the frame of the haul truck.
The engine heater operates on the diesel fuel from the fuel tanks on the haul truck.
T282B S/N 327 05-10-01

Engine
In low temperatures, the engine does not create the necessary heat for normal
operations without an engine heater. An engine heater is installed to let the engine
keep the temperatures for normal operation.
The engine heater has two modes of operation. The primary mode of operation occurs
when the haul truck engine operates at idle speed. The secondary mode of operation
occurs when the haul truck is parked and the engine is not in operation. The mode of
operation is set by manual movement of the valves on the engine heater.
Primary Mode
When the haul truck is let to idle speed without an engine heater installed, the cylinder
walls cool and the fuel to the cylinders does not burn completely. Some of the
unburned fuel goes into the exhaust system. The temperature of the exhaust system
increases, and can cause the ignition of the unburned fuel in the exhaust system when
the haul truck returns to normal operation.
With an engine heater installed, the coolant from the after cooler circuit of the engine
goes through the heater. The warm coolant is then returned to the after cooler circuit.
This keeps the intake air to the cylinders at a hot temperature so that the fuel in the
cylinders completely burns.
Secondary Mode
If the haul truck is parked for some time in cold conditions, the oil viscosity or the
cylinders do not have sufficient heat for the ignition of the fuel to cause the engine to
start.
In the secondary mode, the heater keeps the engine warm. The coolant is removed
from the engine block, sent to the heater, and returned to the block. This warm coolant
keeps the engine block, and engine oil warm, so that the engine can start.
Replace the safety element at approximately 1500–hour intervals.
05-10-02 T282B S/N 327

Engine
05-10-100-DA - How to Remove the Engine

Setup

Remove the power module assembly (Ref. 05-02-100-DA).
Procedure
(Ref. Fig. 05-10-001)
(Ref. Fig. 05-10-002)
Remove the radiator from the engine skid (Ref. 05-30-100-DA).
Notice! The weight of the radiator fan is 151 kg (335 lb).

Attach an applicable lift device or support to the radiator fan (1).

Remove the capscrews (6), washers (5), and radiator fan (1).
Attach the rigging for the engine (2) and the engine rollout assembly (7) as shown
in the recommended procedure of the manufacturer.
Remove the traction alternator from the engine (Ref. 05-20-100-DA).
-or-
Remove the capscrews (3) and washers (4).
Remove the engine (2) from the engine skid.
Closeout
T282B S/N 327 05-10-03

Engine
05-10-001 Removal/Installation of the Engine
05-10-04 T282B S/N 327

Engine
05-10-002 Removal/Installation of the Engine
T282B S/N 327 05-10-05

Engine
05-10-200-DA - How to Install the Engine

Setup

DESIGNATION REFERENCE PART NO.

Permatex® anti-seize See (Ref. 03-12-000-DA)
recommended lubricants
Parts Table:

1 Fan, radiator 1 51020BX-39
2 Engine 1 51020BX-36
3 Capscrew 6 51020BX-14
4 Washer 6 51020BX-28
5 Washer 8 51020BX-27
7 Rollout, engine 1 51608-R
Procedure
(Ref. Fig. 05-10-001)
(Ref. Fig. 05-10-002)
Attach the recommended rigging for the engine (2) and the engine rollout
assembly (7) as shown in the manufacturer's recommended procedure.
Put the engine (2) in position on the engine skid.
Lubricate the capscrews (3) with Permatex anti-seize.
Install the capscrews (3) and washers (4).
Tighten the capscrews (3) to 381 Nm (280 lbf ft).
Notice! The weight of the radiator fan is 151 kg (335 lb).

Attach an applicable lift device or support to the radiator fan (1).

Lubricate the capscrews (6) with Permatex anti-seize.
Install the radiator fan (1), capscrews (6), and washers (5).
Install the traction alternator to the engine (Ref. 05-20-200-DA).
Install the radiator to the engine skid (Ref. 05-30-200-DA).
05-10-06 T282B S/N 327

Engine
Closeout
Install the power module assembly (Ref. 05-02-200-DA).

Inspect for the correct installation of the power module assembly.
T282B S/N 327 05-10-07

Engine
05-10-900-DA - Engine Start

Setup

Do the daily inspections and checks (Ref. 03-20-400-DA).
Follow the instructions of the engine manufacturer and the instructions of the
mine.
Make sure there are no personnel below the haul truck.
Refer to the operation manual of the engine manufacturer for instructions on how
to start the engine in cold weather.
Procedure
Make sure the park brake is in the ON position.

Push the horn to make a sound as a warning to personnel that the haul truck will
start.
Put the shift selector switch in the NEUTRAL position.
Caution! The engine must operate with the correct level of engine oil.
If the oil is below the low mark on the dipstick, damage to the engine can occur.
Make sure that there is an indication of oil pressure after the engine starts.
Turn the master switch to the START position and hold in the START” position
until the engine is at idle speed.
If the engine does not start,
Put the master switch to the OFF position before you try again.
If the engine starts,
Check the engine oil pressure.
If the oil pressure gauge shows no oil pressure,
Stop the engine immediately.
Caution! The engine must be warm before operation of the haul truck.
Operate the engine at idle speed for five minutes before the haul truck moves.
Make sure that all the systems are serviceable and the indications on the gauges
are correct.
Closeout
Not applicable.
05-10-08 T282B S/N 327

Engine
05-10-905-DA - Engine Shutdown

Setup
Not applicable.
Procedure
Caution! The temperature of the turbochargers must decrease before the engine shutdown.
This is necessary to prevent damage to the turbochargers.
Operate the engine at idle speed for five minutes before the shutdown.
Put the shift selector switch in the NEUTRAL position.

Apply the park brake.
If the park brake is defective,
Put the haul truck on a level surface.
Apply the hand brake.
Put chocks on the wheels.
Push the engine stop switch at the bumper.
Turn the master switch in the OFF position.
If the park brake operates correctly,
Turn the master switch in the OFF position.
Closeout
Not applicable.
T282B S/N 327 05-10-09

Engine
05-10-990-DA - Engine Specification Tables and Maintenance

Tables
Setup
Notice! There a different types of engines on the different trucks.

Know the correct part number of your engine.
Refer to the specification tables in this procedure.
Procedure
Table A is for the oil capacity of the engine.
Part Number Liters Oil Specification Notes

10468018 390 L (103 U.S. gal) See OEM Manual 20V4000
Table B is for the overhaul and replacement schedules.
Component Part Number Hours

Engine 10468018 See OEM Manual
Table C is for the checks and inspections of the engine.
Part Number Inspection Overhaul

10468018 See (Ref. 03-00-000-DA) See (Ref. 03-00-000-DA)
Closeout
Not applicable
05-10-10 T282B S/N 327

Traction Alternator
05-20 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:
Pump Drive (Ref. 07-10-000-DA)
Operation
The traction alternator is the electrical power supply for the haul truck. The output of
the traction alternator is a 3-phase AC power. The output voltage of the traction
alternator is a function of the engine rpm and field current.
The traction alternator is attached to the pump drive.
The traction alternator does not supply the control power for the haul truck. The 24 volt
battery (Ref. 06-10-000-DA) supplies the control power.
Refer to the Siemens manual for more data on the traction alternator.
T282B S/N 327 05-20-01

Traction Alternator
05-20-100-DA - How to Remove the Traction Alternator

Setup
Procedure
(Ref. Fig. 05-20-001)
(Ref. Fig. 05-20-002)
Notice! The weight of the traction alternator is 4467 kg (9800 lb).

Attach an applicable lift device to the lift points on the traction alternator (3).
Loosen and move the traction alternator screen guards to the aft of the alternator.
Remove the bolts (4).
Use a barring tool on the engine to rotate the engine crankshaft when you
remove the bolts (4).
Remove the screws (2) and washers (1).
Remove the traction alternator (3) and put protective covers on all open ports.
Closeout
05-20-02 T282B S/N 327

Traction Alternator
05-20-001 Removal/Installation of the Traction Alternator
T282B S/N 327 05-20-03

Traction Alternator
05-20-002 Removal/Installation of the Traction Alternator
05-20-04 T282B S/N 327

Traction Alternator
05-20-200-DA - How to Install the Traction Alternator

Setup

Do the engine flywheel check (Ref. 05-20-400-DA).
Do the alternator measurements (Ref. 05-20-405-DA).
Do the engine endplay measurements (Ref. 05-20-410-DA).

Adhesive Loctite 242 5084-F
Parts Table:
REFERENCE. TECHNICAL LABEL QUANTITY DRAWING-ITEM

1 Washer 16 51020BX-30
2 Screw 16 51020BX-121
3 Alternator 1 51020BX-42
4 Screw 21 51020BX-26
5 Washer 8 51020BX-29
Procedure
(Ref. Fig. 05-20-001)
(Ref. Fig. 05-20-002)
Loosen and move the alternator screen guards to the aft of the alternator.
Remove the bolts (9) and flex plate from the rotor.
If the quantity of the Shims Necessary (Ref. 05-20-410-DA) is a positive number,
Install the necessary shims, plus or minus 0.13 mm (0.005 in.) to the alternator
rotor.
If the quantity of Shims Necessary (Ref. 05-20-410-DA) is a negative number,
Remove the necessary shims, plus or minus 0.13 mm (0.005 in.) from the
alternator rotor.
Install the bolts (9) to the rotor.
Tighten the dry bolts (9) to 380 Nm (280 lbf ft).
Notice! The weight of the traction alternator is 4467 kg (9800 lb).

Attach an applicable lift device to the lift points on the traction alternator (3).
T282B S/N 327 05-20-05

Traction Alternator
Lift the traction alternator (3) and keep the traction alternator level.
Install guide studs in the screw holes of the flywheel housing.
Slowly align the alternator (3) with the engine and the guide studs.
Align the holes in the flexible coupling with their opposite holes in the flywheel.
Continue to move the alternator (3) to the engine until both are fully together.
Apply a thin layer of permatex anti-seize lubricant to the screws (2) and
capscrews (6).
Install the screws (2), washers (1), and remove the guide studs.
Tighten the screws (2) to 125 Nm (90 lbf ft).
Move the alternator screen covers in position.
Apply a thin layer of Loctite 242 to the bolts (4).
Install the bolts (4) and use a barring tool on the engine to rotate the engine
crankshaft during the installation.
Tighten the bolts (4) to 305 Nm (225 lbf ft).
Closeout
Check the engine endplay measurements (Ref. 05-20-410-DA).

The engine endplay measurements must be the same as they are in the setup.
If the engine endplay measurements are not the same, you must stop the
installation and do this procedure:
Remove the alternator (Ref. 05-20-100-DA) and do the alternator shim
measurements (Ref. 05-20-405-DA).
If the engine endplay measurements are the same as in the setup, do this
procedure:
Install the alternator screen guards.
Install the side cover to the engine.
05-20-06 T282B S/N 327

Traction Alternator
05-20-400-DA - Traction Alternator Measurements

Setup
Procedure
(Ref. Fig. 05-20-003)
Put the alternator in a horizontal position.

Remove the protective screens from the engine end of the traction alternator.
Hold the engine end of the rotor with an applicable support and fully align the
rotor to the center of the windings.
Attach a dial indicator with a magnetic base to the frame face of the traction
alternator.
Set the pointer of the dial indicator on the pump drive mount flange.
Set the dial indicator to zero.
Carefully pull the rotor of the engine end forward until it fully stops.
Use the dial indicator to measure the distance the rotor moves from the initial
position to the forward position.
Release the rotor.
The rotor moves back a small distance in the frame.
If the measurement is more than 0.25 mm (0.01 in.),
See the OEM of the alternator, or your Liebherr service representative.
If the measurement is less than 0.25 mm (0.01 in.),
Get and record five more measurements.
If all the measurements are not equal to the first measurement or less than 0.13
mm (0.005 in.) of the first measurement,
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
(0.005 in.) of the first measurement, do this procedure:
Use a depth micrometer, and a straight edge and gauge blocks to get the next
measurement.
-or-
Use a depth micrometer and the measuring tool (Liebherr P/N T-481Ref. 02-00-000-DA) to
get the next measurement.
Measure the distance from the frame mount surface to the flex plate at the areas
between the flex plate mount bolts.
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 (0.005 in.) (Ref.
05-20-200-DA).
T282B S/N 327 05-20-07

Traction Alternator
Closeout
05-20-003 Alternator Measurements
05-20-08 T282B S/N 327

Traction Alternator
05-20-405-DA - Engine Flywheel Runout Check

Setup
Procedure
(Ref. Fig. 05-20-004)
Use a dial indicator to check the flywheel radial runout.

Turn the flywheel 360 degrees to measure the radial runout.
If the measurement is more than 0.152 to 0.178 mm (0.006 to 0.007 in.),
See the engine manufacturer for data.
If the measurement is in these limits 0.152 to 0.178 mm (0.006 to 0.007 in.), do
this procedure:
Use a dial indicator to do a check of the flywheel face runout.
Turn the flywheel 360 degrees to measure the radial runout.
If the measurement is more than 0.152 to 0.178 mm (0.006 to 0.007 in.),
See the engine manufacturer for data.
If the measurement is in these limits 0.152 to 0.178 mm (0.006 to 0.007 in.),
The engine flywheel runout is satisfactory.
Closeout
T282B S/N 327 05-20-09

Traction Alternator
05-20-004 Engine Flywheel Run-Out Check
05-20-10 T282B S/N 327

Traction Alternator
05-20-410-DA - Engine Endplay Measurements

Setup
Procedure
(Ref. Fig. 05-20-005)
Use a straight edge, gauge blocks, depth micrometer, and pry bar to get the next
measurement.
-or-
Use the measurement tool (Liebherr P/N T-481Ref. 02-00-000-DA), a depth micrometer,
and a pry bar to get the next measurement.
Carefully remove one of the side covers from the engine and prevent damage to
the gasket.
Attach the straight edge and gauge blocks to the rear face of the flywheel
housing with clamps.
-or-
Attach the measurement tool (Liebherr P/N T-481Ref. 02-00-000-DA) to the rear face of the
flywheel housing.
Measure the width of the straight edge or measurement tool and record it as "X".
Carefully use the pry bar to prevent damage to the internal components and
move the crankshaft forward until it stops.
Use the depth micrometer to measure four times the distance between the
measurement tool and the flywheel housing, at every 90 degrees.
Calculate the average of the four measurements, subtract X, and record as AFP
(Absolute Forward Position).
If this measurement is a negative number, make sure that there is a negative sign
in front of the number.
Carefully use the pry bar to prevent damage to the internal components and
move the crankshaft rearward until it stops.
Use the depth micrometer to measure four times the distance between the
measurement tool and the flywheel housing, at every 90 degrees.
Calculate the average of the four measurements, subtract X, and record as ARP
(Absolute Rearward Position).
If this measurement is a negative number, put a negative sign in front of the
number.
Use this formula to calculate and record the Total Engine Endplay:
Total Engine Endplay equals AFP minus ARP.
Use this formula to calculate and record Half of Endplay:
Half of Endplay equals the Total Engine Endplay divided by two.
T282B S/N 327 05-20-11

Traction Alternator
Use this formula to calculate the quantity of shims you must add or remove to the
alternator (Ref. 05-20-200-DA):
Shims Necessary equals AFP minus Half of Endplay.
If the Shims Necessary is a negative number, record the number with a negative
sign in front of the number.
Closeout
05-20-12 T282B S/N 327

Traction Alternator
05-20-005 Engine Endplay Measurements
T282B S/N 327 05-20-13

Traction Alternator
05-20-900-DA - Traction Alternator Specification Tables and

Maintenance Tables
Setup
Notice! There a different types of traction alternators on the different trucks.

Know the correct part number of your traction alternator.
Procedure
Table A is for the specifications of the traction alternator.
Part Number Weight Height Width

15566-K 4467 kg (9800 lb)

Traction Alternator 15566-K See OEM Manual
Table C is for the checks and inspections of the traction alternator.
Part Number Checks Inspections

15566-K See OEM See OEM
Closeout
Not applicable
05-20-14 T282B S/N 327

Radiator
05-30 Radiator
(Ref. Fig. 05-30-001)(Ref. Fig. 05-30-002)
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:
05-30-001 Radiator
Operation
The engine sends hot coolant to the radiator. The radiator decreases the temperature
of the coolant and sends cool coolant back to the engine.
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.
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.
Cleaning
To clean the radiator use a high pressure, hot water cleaner at a maximum of 83 bar
(1200 psi). You must clean carefully the cores with a layer of epoxy to not cause
damage to the epoxy coating. Do a test on a small section of one tube before you start
to clean the radiator.
T282B S/N 327 05-30-01

Radiator
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).
Cores with Center Tanks

To repair cores with center tanks, you must remove fully 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.
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 to prevent damage to the tank gasket during the installation.
05-30-002 Tank Gasket
05-30-02 T282B S/N 327

Radiator
05-30-100-DA - How to Remove the Radiator

Setup

Remove the batteries, battery cover, and battery box (Ref. 06-10-100-DA).
Remove the hood and grill (Ref. 13-20-100-DA).
Remove the superstructure crossmember (Ref. 13-20-105-DA).
Drain the radiator (Ref. 05-30-300-DA).
Procedure
(Ref. Fig. 05-30-003)
(Ref. Fig. 05-30-004)
(Ref. Fig. 05-30-005)
(Ref. Fig. 05-30-006)
Notice! The weight of the radiator without fluids is 2336 kg (5100 lb).
Use an applicable lift device that can hold that weight.
Attach applicable lift eyes in the holes on the top of the radiator (35).
Disconnect the hoses (45) and put protective covers on the hoses and open
ports.
Remove the u-bolts (5), locknuts (1), and washers (2).
Remove the capscrews (10), and washers (11).
Remove the clamps (7), hoses (8), pipes (9) and (13), and gaskets (12).
Remove the clamps (3), hoses (4), and pipes (6), and (14).
Remove the capscrews (16), lockwashers (17), gasket (18), and pipe (15).
Remove the locknuts (27), washers (26), and u-bolts (19).
Remove the capscrews (30), and washers (31).
Remove the clamps (20), hoses (21), pipes (33), (34), (28) and (29), and gaskets
(32).
Remove the capscrews (23), lockwashers (24), pipes (22), and gaskets (25).
Remove the capscrews (39), lockwashers (38), and move the brace away from
the radiator.
Notice! The weight of the fan guard is 35 kg (77.2 lb).

Remove the locknuts (36), capscrews (40), washers (37), and fan guards (44).
Remove the locknuts (52), capscrews (47), washers (46).
T282B S/N 327 05-30-03

Radiator
Remove the fan ring (51) from the radiator (35).

Remove the locknuts (50), capscrews (48), washers (49).
Remove the locknuts (41), capscrews (43), and washers (42).
Carefully pull the radiator (35) from the the fan and away from the engine.
Put the radiator (35) on wooden blocks or applicable supports.
Slowly put the radiator (35) on the front radiator frame face on wooden blocks or
applicable supports.
Closeout
Remove all the tools, equipment, and unwanted materials from the work area.
05-30-04 T282B S/N 327

Radiator
05-30-003 Removal/Installation of the Radiator
T282B S/N 327 05-30-05

Radiator
05-30-06 T282B S/N 327

Radiator
T282B S/N 327 05-30-07

Radiator
05-30-08 T282B S/N 327

Radiator
05-30-200-DA - How to Install the Radiator

Setup


Parts Table:

1 Locknut 4 51020BX-2
2 Washer 4 51020BX-113
3 Clamp, t-bolt 8 51020BX-99
4 Hose, silicon 2 51020BX-98
5 U-bolt 2 51020BX-53
6 Pipe 1 51020BX-57
9 Pipe 1 51020BX-60
11 Washer 6 51020BX-20
12 Gasket 2 51020BX-55
13 Pipe 1 51020BX-59
14 Pipe 1 51020BX-58
15 Pipe (supplied with radiator) 1 51020BX
17 Washer 4 51020BX-25
18 Gasket 1 51020BX-71
19 U-bolt 2 51020BX-52
22 Pipe 2 51020BX-77
24 Washer 8 51020BX-25
25 Gasket 2 51020BX-54
26 Washer 4 51020BX-25
28 Pipe 1 51020BX-75
29 Pipe 1 51020BX-76
31 Washer 8 51020BX-20
32 Gasket 2 51020BX-56
T282B S/N 327 05-30-09

Radiator

33 Pipe 1 51020BX-78
34 Pipe 1 51020BX-79
35 Radiator 1 51020BX-38
36 Locknut 12 51020BX-3
37 Washer 24 51020BX-25
38 Washer 4 51020BX-29
42 Washer 6 51020BX-28
44 Guard, fan 4 51020BX-63, 64, 65, 66
46 Washer 16 51020BX-30
49 Washer 6 51020BX-25
50 Locknut 14 51020BX-4
51 Ring, fan 1 51020BX-45
52 Locknut 14 51020BX-4
Procedure
(Ref. Fig. 05-30-003)
(Ref. Fig. 05-30-004)
(Ref. Fig. 05-30-005)
(Ref. Fig. 05-30-006)
Notice! The weight of the radiator without fluids is 2336 kg (5100 lb).
Carefully put the radiator (35) in position on the engine skid.

Install the locknuts (41), capscrews (43), and washers (42).
Assemble the fan ring (51) with the locknuts (50), capscrews (48), and washers
(49).
Install the ring (51) to the radiator (35) with the locknuts (52), capscrews (47), and
washers (46).
Notice! The weight of the fan guard is 35 kg (77.2 lb).

Install the fan guards (44), locknuts (36), capscrews (40), and washers (37).
Install the capscrews (39) and washers (38) to attach the brace to the radiator.
05-30-10 T282B S/N 327

Radiator
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.
Install the t-bolt clamps (20), hoses (21), pipes (33), (34), (28) and (29), and
gaskets (32).
Install the capscrews (30), and washers (31).
Install the locknuts (27), washers (26), and u-bolts (19).
Install the capscrews (16), lockwashers (17), gasket (18), and pipe (15).
Install the T-bolt clamps (3), hoses (4), and pipes (6), and (14).
Install the T-bolt clamps (7), hoses (8), pipes (9) and (13), and gaskets (12).
Install the capscrews (10), and washers (11).
Install the u-bolts (5), locknuts (1), and washers (2).
Remove the protective covers and connect the hoses (45).
Closeout
Install the superstructure crossmember (Ref. 13-20-205-DA).

Install the hood and grill (Ref. 13-20-200-DA).
Install the batteries, battery cover, and battery box (Ref. 06-10-200-DA).
Fill the coolant in the radiator (Ref. 05-30-700-DA).
T282B S/N 327 05-30-11

Radiator
05-30-300-DA - How to Replace the Tubes of the Radiator

Setup
Procedure
(Ref. Fig. 05-30-007)
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 (1200 psi).
To remove the tubes, increase the temperature of the tubes and grommets with
hot water.
Use a breaker tool at the top and bottom, but not at the middle of tube, to loosen
the tube from the grommet.
Put the upper jaw of the installation tool around the circular part of the bottom of
the tube below the flat part.
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.
Close the handles of the installation tool together.
Lift the tube only until the bottom of the tube is away from the grommet.
Remove the installation tool.
Pull the tube out only a small distance to allow you to pull the tube down and out
of the top grommet.
Remove the tube.
Discard the used rubber grommets.
Clean the tube holes and remove the unwanted material.
Make sure that the tube holes are dry and install new rubber grommets.
Lightly hit the grommet with a rubber hammer until the shoulder of the grommet is
against the metal ferrule on the header plate.
If you install the used tube, carefully do this procedure:
Use a fine grit emery cloth or polish wheel to clean and the ends of the tube and
remove the unwanted material.
Apply a layer of petroleum jelly to the inner holes of the grommets and the outer
ends of the tubes.
Push the top end of the tube into the grommet of the top header plate.
Adjust the bottom of the tube to the center of the grommet in the bottom header
plate.
05-30-12 T282B S/N 327

Radiator
Use your hand or the installation tool to push the tube down and into the
grommet.
Push the tube down until the formed bead is in the locking groove of the bottom
grommet.
Make sure that the formed bead is correctly installed in the bottom grommet.
Make sure that the tubes are straight and correctly aligned.
Make sure that the top and bottom baffles are correctly installed.
The top baffle is larger than the bottom baffle.
Closeout
T282B S/N 327 05-30-13

Radiator
05-30-007 Replacement of the Tubes
05-30-14 T282B S/N 327

Radiator
05-30-700-DA - How to Fill the Radiator with Coolant

Setup


Anti-freeze BASF G05 or equivalent
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.
Make sure that the system is cool.

Open the fill access cover for the radiator.
Fill the system with an approved coolant until it reaches the bottom of the fill
neck.
Start the haul truck (Ref. 05-10-900-DA).
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.
Do a visual check of the radiator sight gauge.
Stop the engine (Ref. 05-10-905-DA).
Do a visual check of the radiator sight gauge and add recommended coolant as
necessary.
Close the fill access cover for the radiator.
Closeout
T282B S/N 327 05-30-15

Radiator
05-30-900-DA - Radiator Specification Tables and Maintenance

Tables
Setup
Notice! There a different types of radiators on the different trucks.

Know the correct part number of your radiator.
Procedure
Table A is for the capacity of the radiator.
Part Number Liters Coolant Notes

13073-Z 0 L (0 U.S. gal) See OEM Manual Engine 20V4000

Radiator 13073-Z See OEM Manual
Part Number Checks Inspection

13073-Z See OEM See OEM
Closeout
Not applicable
05-30-16 T282B S/N 327

Exhaust System
05-40 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:
Superstructure (Ref. 13-20-000-DA)
Operation
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.
Maintenance Tips
A pressure gauge can be connected to the port with a thread on the mufflers to check
the back pressure of the exhaust system.
T282B S/N 327 05-40-01

Exhaust System
05-40-100-DA - How to Remove the Exhaust System

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-40-001)
(Ref. Fig. 05-40-002)
(Ref. Fig. 05-40-003)
(Ref. Fig. 05-40-004)
(Ref. Fig. 05-40-005)
(Ref. Fig. 05-40-006)
Loosen the clamps (2).

Remove the exhaust pipes (1).
Notice! The weight of the mufflers is 24 kg (52.91 lb).

Remove the lower halves of the brackets (4) and mufflers (3).
Remove the clamp blankets (11).
Remove the exhaust pipes (8) and (9).
Remove the locknuts (18), capscrews (16), and washers (17).
Remove the brackets (15) from the bracket (14).
Remove the locknuts (22) and washers (23).
Remove the clamp blankets (21).
Remove the clamps (42).
Remove the exhaust blankets (39) (Ref. 05-40-300-DA).
Remove the locknuts (26), washers (25), capscrews (24), and rod (28).
Remove the locknuts (26), washers (25), capscrews (24), rods (27), and (27A).
Remove the locknuts (33), washers (32), capscrews (31), brackets (34), and (38).
05-40-02 T282B S/N 327

Exhaust System
Remove the locknuts (35), washers (36), and capscrews (37).

Remove the exhaust pipes (40) and gaskets (41).
Closeout
T282B S/N 327 05-40-03

Exhaust System
05-40-001 Removal/Installation of the Exhaust System
05-40-04 T282B S/N 327

Exhaust System
T282B S/N 327 05-40-05

Exhaust System
05-40-06 T282B S/N 327

Exhaust System
T282B S/N 327 05-40-07

Exhaust System
05-40-08 T282B S/N 327

Exhaust System
T282B S/N 327 05-40-09

Exhaust System
05-40-200-DA - How to Install the Exhaust System

Setup

01-20-000-DA).
05-40-100-DA).
Parts Table:
REFERENCE TECHNICAL NAME QUANTITY DRAWING-ITEM

1 Pipe, tail 2 51027AX-33
2 Clamp, v-band 2 51027AX-21
3 Muffler 2 51027AX-22
4 Bracket 2 51027AX-41
5 Washer 12 51027AX-17
6 Capscrew 12 51027AX-9
8 Pipe 1 51027AX-29
9 Pipe 1 51027AX-32
11 Blanket, clamp 2 51027AX-42
12 Pipe 1 51027AX-31
13 Pipe 1 51027AX-28
14 Bracket 1 51027AX-40
15 Bracket 2 51027AX-39
17 Washer 12 51027AX-16
18 Locknut 12 51027AX-2
19 Clamp 2 51027AX-23
21 Blanket 2 51027AX-47
22 Locknuts 4 51027AX-1
23 Washer 4 51027AX-15
25 Washer 16 51027AX-16
26 Locknut 12 51027AX-2
27 Rod 1 51027AX-48
27A Rod 51027AX-45
28 Rod 1 51027AX-46
32 Washer 48 51027AX-14
33 Locknut 24 51027AX-4
34 Brackets 2 51027AX-36
05-40-10 T282B S/N 327

Exhaust System

35 Locknut 24 51027AX-4
36 Washer 48 51027AX-14
37 Capscrew 16 510217AX-12
38 Bracket 1 51027AX-37
39 Blanket, exhaust 2 51027AX-43
40 Pipe 2 51027A-26
41 Gasket 2 51027AX-25
43 Pipe 1 51027AX-27
44 Pipe 1 51027AX-30
Procedure
(Ref. Fig. 05-40-001)
(Ref. Fig. 05-40-002)
(Ref. Fig. 05-40-003)
(Ref. Fig. 05-40-004)
(Ref. Fig. 05-40-005)
(Ref. Fig. 05-40-006)
Install the exhaust pipes (40) and gaskets (41).

Install the capscrews (37), washers (36), and locknuts (35).
Install the locknuts (33), washers (32), capscrews (31), brackets (34), and (38).
Install the locknuts (26), capscrews (24), washers (25), rods (27), and (27A).
Install the rod (28) on the bracket (38) with the locknuts (26), capscrews (24), and
washers (25).
Put the slots of the exhaust blankets (39) in position around the bracket (38) (Ref.
05-40-300-DA).
Install the exhaust pipes (43) and (44), and clamps (42).
Install the clamps (19) and clamp blankets (21) on the exhaust pipes (43) and
(44).
Install the brackets (15) on the bracket (14) with the capscrews (16), washers
(17), and locknuts (18).
Install the clamp blankets (21), clamps (19) on the exhaust pipes (43) and (44).
Install the clamp blankets (21) and clamps (19) on the brackets (15), with the
washers (23) and locknuts (22).
Tighten the clamps (42).
Notice! The weight of the mufflers is 24 kg (52.91 lb).

Use an applicable support that can hold this weight.
Install the lower halves of the brackets (4) and mufflers (3) to the superstructure
with the capscrews (6) and washers (5).
T282B S/N 327 05-40-11

Exhaust System
Install the exhaust pipes (8), (9), and clamps (7).

Install the exhaust pipes (12) and (13).
Install the clamps (10).
Install the clamp blankets (11).
Install the exhaust pipes (1).
Check and tighten all clamps.
Closeout
05-40-12 T282B S/N 327

Exhaust System
05-40-300-DA - How to Replace the Exhaust Blankets

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-40-007)
To replace the exhaust blankets, do this procedure:

Remove the spring retainer (1) from the exhaust blanket (2).
Remove the exhaust blanket (2) from the expansion joint (3).
Inspect the exhaust blankets and the expansion joints (Ref. 05-40-400-DA).
If the exhaust blankets are damaged, or used for 3500 hours:
Discard the exhaust blankets (2).
To install the exhaust blankets, do this procedure:
Install the exhaust blanket (2) on the expansion joint (3).
Install the spring retainer (1) on the exhaust blankets (2).
Closeout
Danger! Leakage from the exhaust system can cause fire.

Make sure that the insulation of the exhaust system is in the correct position and all parts
are in the correct position.
T282B S/N 327 05-40-13

Exhaust System
05-40-007 Replacement of the Exhaust Blankets
05-40-14 T282B S/N 327

Exhaust System
05-40-400-DA - How to Inspect the Expansion Joints and the

Exhaust Blanket
Setup

01-20-000-DA).
Remove the exhaust blankets (Ref. 05-40-300-DA).
Procedure
To inspect visually the expansion joints, do this procedure:

Inspect for black areas that show leakage of exhaust gases.
Inspect for shiny areas that show damage to the expansion joints.
Inspect for holes and cracks in the expansion joints.
If the expansion joint is damaged,
Replace the expansion joint.
To inspect visually the exhaust blankets, do this procedure:
Inspect the internal mesh of the blankets for damage, unwanted material, or
contamination.
Inspect for compression of the insulation material.
If the exhaust blanket is damaged,
Replace the exhaust blanket.
Closeout
Danger! Leakage from the exhaust system can cause fire.

Make sure that the insulation of the exhaust system is in the correct position and all parts
are in the correct position.
T282B S/N 327 05-40-15

Exhaust System
05-40-900-DA - Exhaust System Specification Tables and

Maintenance Tables
Setup
Notice! There are different types of exhaust systems on the different trucks.
Know the correct part number of your exhaust system.
Procedure
Table A is for the specifications of the exhaust system.
Part Number Weight Length Notes

51027AX 164 kg (360 lb) See OEM Manual 20V4000

Exhaust System 51027AX See OEM Manual

51027AX
Closeout
Not applicable
05-40-16 T282B S/N 327

Fuel System
05-50 Fuel System

The engine on the haul truck is an MTU/DDEC, 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:
Hydraulic Power and Distribution (Ref. 07-00-000-DA)
Operation
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.
There are covers on the fuel tank for a better servicing.
T282B S/N 327 05-50-01

Fuel System
05-50-100-DA - How to Remove the Fuel Tank

Setup

01-20-000-DA).
Procedure
Step
Closeout
05-50-02 T282B S/N 327

Fuel System
05-50-200-DA - How to Install the Fuel Tank

Setup

01-20-000-DA).
Procedure
Step
Closeout
T282B S/N 327 05-50-03

Fuel System
05-50-700-DA - How to Fill the Fuel Tank

Setup

01-20-000-DA).
Procedure
Procedure pending
Closeout
05-50-04 T282B S/N 327

Fuel System
05-50-705-DA - How to Drain the Fuel and Hydraulic Tank

Setup

If it is not necessary to drain the fuel from the fuel tank on the right side of the
haul truck, do this procedure:
Close the fuel shutoff valve on the fuel tank.
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 U.S. gal).
Make sure that the capacity of the container is enough.
Put an applicable container below the central service assembly.

Drain the fuel from the fuel tank through the central service assembly.
Closeout
T282B S/N 327 05-50-05

Fuel System
05-50-900-DA - Fuel Tank Specification Tables and Maintenance

Tables
Setup
Notice! There a different types of fuel tanks on the different trucks.

Know the correct part number of your fuel tank.
Procedure
Table A is for the fuel capacity of the fuel tank.
Part Number Liters Fuel Notes

51191AG 3029 L (800 U.S. gal) diesel 20V4000

Fuel tank 51191AG See OEM Manual
Part Number Checks inspections

51191AG
Closeout
Not applicable
05-50-06 T282B S/N 327

Engine Air Cleaner
05-60 Engine Air Cleaner

The engine uses air cleaners to prevent unwanted particles and materialsto 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:
Operation
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.
If the primary filter element becomes unserviceable, there is a safety element to
prevent the flow of unwanted material to the engine.
T282B S/N 327 05-60-01

Engine Air Cleaner
05-60-100-DA - How to Remove the Engine Air Cleaner Ducts

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-60-001)
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.
Disconnect the air restrictor lines (8) and put protective covers on the lines.
Remove the T-bolt clamps (10) and the elbows (9).
Remove the locknuts (4) capscrews (5), washers (6), and clamps (3).
Remove the T-bolt clamps (7).
Remove the hose hump (12) and the tube (11).
Remove the locknuts (18) capscrews (19), washers (20), and clamps (17).
Remove the tube (13) and the hose hump (14).
Remove the hose hump (2) and the tube (16).
Put protective covers on the tubes and open ports.
Closeout
05-60-02 T282B S/N 327

Engine Air Cleaner
05-60-001 Removal/Installation of the Engine Air Cleaner Ducts
T282B S/N 327 05-60-03

Engine Air Cleaner
05-60-200-DA - How to Install the Engine Air Cleaner Ducts

Setup

01-20-000-DA).
Make sure that all the inlet tubes are clean, free of unwanted material and
contamination, and there are no indications of damage.
Parts Table:

1 Clamp, T-bolt 8 51026AU-17
2 Hose hump 2 51026AU-19
3 Clamp 1 51026AU-22
4 Locknut 2 51026AU-6
5 Capscrew 2 51026AU-7
6 Washer 4 51026AU-8
9 Elbow 1 51026AU-18
11 Tube 1 51026AU-28
13 Tube 1 51026AU-27
16 Tube 1 51026AU-26
17 Clamp 1 51026AU-22
16 Tube 1 51026AU-26
17 Clamp 1 51026AU-22
18 Locknut 2 51026AU-6
19 Capscrew 2 51026AU-7
20 Washer 4 51026AU-8
Procedure
(Ref. Fig. 05-60-001)
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.
Notice! Damaged hose humps can cause the air cleaners to not work correctly.
Make sure that there are no indications of damage to the rubber hose humps.
05-60-04 T282B S/N 327

Engine Air Cleaner
Install the hose hump (2) and the tube (16).

Install two T-bolt clamps (1) turned 180 degrees from each other.
Install the tube (13) and the hose hump (14).
Install the locknuts (4) capscrews (5), washers (6), and clamps (3).
Install the hose hump (12) and the tube (11).
Install the locknuts (18) capscrews (19), washers (20), and clamps (17).
Install the elbows (9) and T-bolt clamps (10).
Remove the protective covers and connect the air restrictor lines (8).
Closeout
T282B S/N 327 05-60-05

Engine Air Cleaner
05-60-400-DA - Air Cleaner Restriction Check

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-60-002)
Disconnect the air restriction line from the air cleaner duct.
Attach a water manometer or an air service gauge, calibrated in inches of water,
to the air intake duct.
Start the engine (Ref. 05-10-900-DA).
Operate the engine at maximum power.
Record the indication of airflow restriction shown on the manometer or the air
service gauge.
Disconnect the water manometer or air service gauge.
Connect the air restriction line to the air cleaner duct.
If the airflow restriction is more than 20 mbar (20 inches of water), do this
procedure:
Do the air cleaner servicing procedure (Ref. 05-60-700-DA).
Closeout
05-60-06 T282B S/N 327

Engine Air Cleaner
05-60-002 Air Cleaner Restriction Check
T282B S/N 327 05-60-07

Engine Air Cleaner
05-60-700-DA - How to Do the Air Cleaner Servicing

Setup

Inspect all inlet pipes and connections from the engine air cleaners for cracks or
damage.
Procedure
(Ref. Fig. 05-60-003)
Caution! The air cleaner prevents unwanted material to the engine.

When you do servicing operations on the air filters do not to let dirt or unwanted material
into the air ducts.
Open the dust bins (1) and remove the dirt and unwanted material.
Use a rigid fiber brush to remove dirt and unwanted material from the tubes.
Release the latches and open the cover (10).
Remove the cotter pin (9), wing nut (8), filter sealing washer (7), and primary filter
element (3).
If the filter restriction indicator was red you must replace the primary filter
element:
Discard the used primary filter element (3) and get a new filter element.
If you must replace the safety filter, do this procedure:
Remove the cotter pin (6), wing nut (5), filter sealing washer (4), and safety filter
element (2).
Discard the used safety filter element (2).
Install the new safety filter element (2), filter sealing washer (4), wing nut (5), and
cotter pin (6).
To inspect the primary filter element (3) for damage, do this procedure:
Inspect for holes and abrasions.
Inspect for dents in liners or end caps.
Inspect the gaskets for wear or damage.
Inspect for corrosion on the metal parts.
Inspect for tears or punctures on radial seal end caps.
Discard the damaged primary filter element and replace with a serviceable filter
element.
To install the primary filter element, do this procedure:
Install the primary filter element (3), filter sealing washer (7), wing nut (8), and
cotter pin (9).
05-60-08 T282B S/N 327

Engine Air Cleaner
Close and attach the cover (10).

Close the dust bin (1).
Make sure that the dust bin (1) is correctly installed and seals fully to the air
cleaner body.
Inspect all the connections and make sure that they are tight.
Closeout
T282B S/N 327 05-60-09

Engine Air Cleaner
05-60-003 Air Cleaner Servicing Procedure
05-60-10 T282B S/N 327

Engine Air Cleaner
05-60-900-DA - Air Cleaner Specification Tables and

Maintenance Tables
Setup
Notice! There a different types of engine air cleaners on the different trucks.
Know the correct part number of your engine air cleaner.
Procedure
Table A is for the specifications of the air cleaners.
Part Number Weight Notes

13011-L 200 kg (440 lb) See OEM Manual 20V4000

air cleaner 13011-L See OEM Manual

13011-L
Closeout
Not applicable
T282B S/N 327 05-60-11

Engine Air Cleaner
05-60-12 T282B S/N 327

Filter Restriction Indicators
05-62 Filter Restriction Indicators

The filter restriction indicators are installed on the ceiling of the cab above the main
dash panel.
05-62-001 Filter Restriction Indicators
Operation
The filter restriction indicators monitor the air to the engine from the air cleaners.
The indicator shows green when the filter element in the air cleaners is serviceable. A
red indication shows that replacement of the air filter is necessary.
T282B S/N 327 05-62-01

Filter Restriction Indicators
05-62-02 T282B S/N 327

Engine Heater
05-70 Engine Heater

The engine heater is installed on the lower crossmember of the frame of the haul truck.
The engine heater operates on diesel fuel from the fuel tanks on the haul truck.
The engine heater connects to these systems and components:
Hydraulic Power and Distribution (Ref. 07-00-000-DA)
Operation
The engine heater has two modes of operation. The primary mode of operation is
when the haul truck engine operates at idle speed. The secondary mode of operation
is when the haul truck is parked and the engine is not in operation. The mode of
operation is set by manual movement of the valves on the engine heater.
Primary Mode
When the engine operates at idle speed for some time without an engine heater, the
engine cannot make enough heat to stay warm. The cylinder walls become cool and
prevent the complete combustion of the fuel in the cylinders. Some of the unburned
fuel goes into the exhaust system. When the haul truck returns to usual operation, the
temperature of the engine and the exhaust gases increases. This can cause the
ignition of the unburned fuel in the exhaust system.
On the trucks that have an engine heater coolant from the circuit after the cooler of the
engine goes through the heater. The warm coolant then returns to the circuit after the
cooler. This keeps the intake air to the cylinders at a hot temperature and helps for the
complete combustion of the fuel in the cylinders.
Secondary Mode
If the haul truck is parked for some time in cold conditions, it is difficult to start the
engine. The engine can not start because of the oil viscosity, or the cylinders do not
have enough heat for the ignition of the fuel.
In the secondary mode, the engine heater keeps the engine warm. The coolant goes
from the engine block to the heater, and returns to the block. This warm coolant keeps
the engine block and engine oil warm so that the engine can start.
Refer to the OEM fro more data on the engine heater.
T282B S/N 327 05-70-01

Engine Heater
05-70-100-DA - How to Remove the Engine Heater

Setup
Procedure
(Ref. Fig. 05-70-001)
(Ref. Fig. 05-70-002)
Put the fuel and coolant shutoff valves in the CLOSED position.
Disconnect the electrical cable (1) from the engine heater (5).
Disconnect the fuel lines (6) and (7).
Remove the clamps (2) and disconnect the coolant hoses.
Notice! The weight of the engine heater is 47 kg (103.6 lb).

Remove the capscrews (3) and lockwashers (4).

Remove the engine heater (5) and bracket mounts (8).
Closeout
05-70-02 T282B S/N 327

Engine Heater
05-70-001 Removal/Installation of the Engine Heater
T282B S/N 327 05-70-03

Engine Heater
05-70-002 Removal/Installation of the Engine Heater
05-70-04 T282B S/N 327

Engine Heater
05-70-200-DA - How to Install the Engine Heater

Setup

Parts Table:

2 Clamp 2 51695-V-30
3 Capscrew 4 51695-V-45
4 Lockwasher 4 51695-V-46
5 Engine heater 1 51695-V-1
7 Hose 1 51695-V-40
Procedure
(Ref. Fig. 05-70-001)
(Ref. Fig. 05-70-002)
Notice! The weight of the engine heater is 47 kg (103.6 lb).

Install the bracket mounts (8), engine heater (5), lockwashers (4), and capscrews
(3).
Connect the coolant hoses to the engine heater (5), and install the clamps (2).
Connect the fuel lines (6) and (7).
Connect the electrical cable (1) to the engine heater (5).
Put the fuel and coolant shutoff valves in the OPEN position.
Closeout
T282B S/N 327 05-70-05

Engine Heater
05-70-900-DA - Engine Heater Specification Tables and

Maintenance Tables
Setup
Notice! There a different types of engine heaters on the different trucks.

Know the correct part number of your engine heater.
Procedure
Table A is for the specifications of the engine heater.
Part Number Weight Heat Capacity Notes

13551-H 47 kg (103.6 lb) See OEM Manual 20V4000

Heater 13551-H See OEM Manual
Table C is for the checks and inspections of the engine heater.

13551-H
Closeout
Not applicable
05-70-06 T282B S/N 327

Siemens AC Drive System
05-80 Siemens AC Drive System

The Siemens AC drive system supplies traction control, engine control, and safety
interlock functions.
The Siemens AC drive system connects to these systems:
Cab Controls and Instrumentation (Ref. 04-00-000-DA)
Electrical System (Ref. 06-00-000-DA)
The Siemens AC drive system has these systems:
Inverters and Traction Motors (Ref. 05-84-000-DA)
Choppers and Retard Grid (Ref. 05-86-000-DA)
AC Drive Cooling System (Ref. 05-88-000-DA)
Traction Control Unit (Ref. 05-82-000-DA)
Operation
The Siemens AC drive system starts when the master switch is in the ON position. The
traction alternator supplies the traction power for the haul truck. The 24 VDC battery
supplies the control power for the haul truck. The Siemens AC drive system does many
functions. The functions are:
control the output voltage of the traction alternator
control the speed of the engine
control the traction and retard for the wheel motors
supply electrical power to move the haul truck
supply air to cool the wheel motors, traction alternator, and the components in the control cabinet
supply heat to the inverters and choppers in cold weather
supply protection for over-voltages, over-currents, and over-temperatures
Refer to the Siemens manual for more information on the Siemens AC drive system.
T282B S/N 327 05-80-01

Siemens AC Drive System
05-80-800-DA - How to Clean the Control Cabinet

Setup

Clean the external area around the control cabinet before you open the control
cabinet.
Open the control cabinet.
Procedure
Caution! The control cabinet is sealed to keep out the water.

Never use water to internally clean the control cabinet.
Attention! Compressed air can cause damage to components and loosen the wires.
Use a vacuum with a soft brush attachment to clean in the control cabinet.
Use a vacuum with a soft brush attachment to remove unwanted material from
the inside of the control cabinet.
Make sure that all wires and components are connected and the connectors are
fastened correctly.
Make sure there are no loose bolts or washers in the inverter cabinets.
Make sure that all plugs and EPROMs are correctly connected.
Refer to the Siemens maintenance manual for more information.
Closeout
05-80-02 T282B S/N 327

Traction Control Unit
05-82 Traction Control Unit

The traction control unit (TCU) monitors and controls the Siemens AC drive system.
The TCU is in the control cabinet.
Operation
The TCU has an internal computer and power supply. The TCU uses the commands
from the operator, and data and feedback from the haul truck to control the drive
system. The TCU uses temperature sensors to monitor the temperature of important
components.
If the TCU is defective, it can operate at a decreased level of operation. If the TCU
cannot operate correctly at a decreased level of operation, the TCU does a controlled
shutdown procedure.
The TCU is sealed, but is installed beside an air intake. The TCU stays cool from the
large quantity of air that goes through the air intake.
The TCU sends temperature information to the controls and indicators and the display
panel (Ref. 04-10-000-DA) in the cab. The TCU uses an automatic power reduction
and shutdown (APRS) procedure if one of the important components becomes too hot.
APRS decreases component operation and stops operation if necessary to prevent
damage to components.
The computer in the TCU monitors the performance of the haul truck and stores this
information. The service and maintenance personnel can access to this information is
through the drive system data port on the main dash (Ref. 04-12-000-DA). Refer to the
system fault code section of the Siemens manual.
Refer to the Siemens manual for more information on the traction control unit.
T282B S/N 327 05-82-01

Traction Control Unit
05-82-02 T282B S/N 327

Inverters and Traction Motors
05-84 Inverters and Traction Motors

The traction motors are the wheel motors in the rear wheel assembly. The inverters are
installed in the control cabinet.
Operation
The inverters supply the power from the traction alternator to the traction motors. The
traction motors supply the power to turn the rear wheels of the haul truck. The wheels
and weight of the haul truck give resistance (a load) to the traction motor.
There are two isolated inverters. One inverter for each traction motor supplies
independent control for each wheel motor. Independent control is necessary because
of the large difference in wheel speeds during low speed movement.
When the retard pedal is applied, the inverters immediately remove the power to the
traction motors. Haul truck movement continues to turn the wheels, and the wheels
turn the shafts of the traction motors. The traction motors now generate electrical
power. This electrical power is sent to the retard grid and becomes a load to the rear
wheels. An increase in the electrical power to the retard grid will increase the load on
the rear wheels. This load slows and stops the haul truck.
Refer to the Siemens manual for more information on the inverters and traction motors.
T282B S/N 327 05-84-01

Inverters and Traction Motors
05-84-02 T282B S/N 327

Choppers and Retard Grid
05-86 Choppers and Retard Grid

The choppers and retard grid operate during dynamic retard of the haul truck. The two
choppers are in the control cabinet. The two retard grids are installed on the right side
of the superstructure.
Operation
During dynamic retard, electrical energy from the traction motors passes through the
resistors on the retard grid. The resistors turn the electrical energy into heat. The heat
is removed by the grid blowers. The traction control unit (TCU) uses the choppers to
control the electrical energy that passes through the retard grids.
A retard limit fault alarm shows on the display panel when the retard system is in full
operation, but is not able to decrease the speed of the haul truck. The operator must
apply the service brakes and the retard pedal to decrease the speed of the haul truck.
The retard limit fault alarm is removed when the speed of the haul truck decreases
enough.
Refer to the Siemens manual for more information on the choppers and retard grid.
T282B S/N 327 05-86-01

Choppers and Retard Grid
05-86-02 T282B S/N 327

AC Drive Cooling System
05-88 AC Drive Cooling System

The function of the AC drive cooling system is to keep cool the control cabinet, traction
alternator, and wheel motors.
05-88-001 AC Drive Cooling System
Operation
(Ref. Fig. 05-88-001)
The AC drive cooling system has a main blower, cooling ducts, and pressure switches.
The main blower has an AC motor that operates the two fans. The fans for the main
blower are installed on the bottom of the control cabinet and above the traction
alternator.
Air enters through the cooling air inlet grills in the drive system control cabinet. The
fans move unfiltered air through an air-to-air heat exchanger in the control cabinet. The
main blower supplies air through the alternator cooling duct to the traction alternator. At
the same time, the main blower supplies pressurized air through the axle box cooling
ducts to the axle box. The air in the axle box goes through both wheel motors,
planetary gear boxes, disc brakes, and then out.
The main blower pressurizes the axle box to approximately 150 mm (5.905 in.) of
water. Two pressure switches in the axle box monitor this pressure. If the pressure in
the axle box goes lower than 25 mm (0.984 in.) of water, a 24 volt contact opens.
When the contact opens, it sends a signal to the traction control unit (TCU) that the
pressure is lower than the minimum permitted pressure.
If the temperature of the windings in the wheel motors or the traction alternator go
more than 88 °C (190 °F) an alarm operates on the display panel (Ref. 04-12-000-DA).
When this alarm operates, the operator must stop the haul truck and monitor the
temperature gauge. If the fault stays, the operator must shutdown the engine.
T282B S/N 327 05-88-01

See AC Drive System Overtemp and Overload section (Ref. 04-12-000-DA) for more
information.
05-88-02 T282B S/N 327

05-88-100-DA - How to Remove the AC Cooling System Motor

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-88-002)
Notice! The weight of the main blower is 2200 kg (4900 lb).

Use the applicable lift device that can hold this weight.
To disconnect the alternator and axle box ducts, do this procedure:

Remove the nuts (7), capscrews (8), lockwashers (9), and washers (10).
To remove the blower motor, do this procedure:
Remove the locknuts (1), capscrews (2), washers (3) and (4), fibromounts (6),
and brace (5).
Remove the screws (11), lockwashers (12), washers (13), and blower motor (14).
Closeout
T282B S/N 327 05-88-03

05-88-002 Removal/Installation of the AC Cooling System Motor
05-88-04 T282B S/N 327

05-88-105-DA - How to Remove the Alternator Cooling Duct

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-88-003)
Remove the clamps (1) and flex duct (2).

Remove the nuts (3), capscrews (4), lockwashers (5), washers (6), and transition
duct (7).
Closeout
T282B S/N 327 05-88-05

05-88-003 Removal/Installation of the Alternator Cooling Duct
05-88-06 T282B S/N 327

05-88-110-DA - How to Remove the Axle Box Cooling Duct

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 05-88-004)
Notice! The weight of the axle box transition duct is more than 12 kg (26.46 lb).
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 (66.1 lb).
Remove the nuts (21), lockwashers (20), washers (19), capscrews (17), clamps
(18), and duct (16).
Remove the clamps (1) and flex ducts (2).
Notice! The weight of the axle box Y duct is more than 119 kg (260 lb).
Remove the locknuts (4), washers (5), capscrews (6), and Y duct (3).
Closeout
T282B S/N 327 05-88-07

05-88-004 Removal/Installation of the Axle Box Cooling Duct
05-88-08 T282B S/N 327

05-88-200-DA - How to Install the AC Cooling System Motor

Setup

01-20-000-DA).
Parts Table:

1 Locknut 2 51030AA-32
2 Capscrew 2 51030AA-29
3 Washer 4 51030AA-30
4 Washer, cinch 2 51030AA-31
5 Brace 1 51030AA-27
6 Fibromount 2 51030AA-28
7 Nut 10 51030AA-2
9 Lockwasher 10 51030AA-7
10 Washer 20 51030AA-5
11 Screw 21 51030AA-34
13 Washer 21 51030AA-8
14 Blower motor 1 51030AA-21
Procedure
(Ref. Fig. 05-88-002)
Notice! The weight of the main blower is 2200 kg (4900 lb).

To install the blower motor, do this procedure:

Install the blower motor (14), washers (13), lockwashers (12), and screws (11).
Install the fibromounts (6), brace (5), washers (4) and (3), capscrews (2) and
locknuts (1).
To connect the alternator and axle box ducts, do this procedure:
Install the washers (10), lockwashers (9), capscrews (8) and nuts (7).
Closeout
T282B S/N 327 05-88-09

05-88-205-DA - How to Install the Alternator Cooling Duct

Setup

01-20-000-DA).
Parts Table:

1 Clamp 4 51030AA-13
2 Flex duct 1 51030AA-18
3 Nut 10 51030AA-2
6 Washer 20 51030AA-5
7 Transition duct 1 51030AA-23
Procedure
(Ref. Fig. 05-88-003)
Install the transition duct (7), washers (6), lockwashers (5), capscrews (4), and
nuts (3).
Install the flex duct (2) and clamps (1).
Closeout
05-88-10 T282B S/N 327

05-88-210-DA - How to Install the Axle Box Cooling Duct

Setup

01-20-000-DA).
Parts Table:

1 Clamp 8 51030AA-12
3 Y duct 1 51030AA-22
5 Washer 2 51030AA-8
7 Clamp 4 51030AA-11
10 Washer 24 51030AA-5
11 Transition duct 1 51030AA-24
13 Nut 12 51030AA-2
14 Clamp 4 51030AA-11
16 Duct 1 51030AA-16
18 Clamp 2 51030AA-26
19 Washer 4 51030AA-14
21 Nut 4 51030AA-10
Procedure
(Ref. Fig. 05-88-004)
Install the flex ducts (2) and clamps (1).
Notice! The weight of the axle box transition duct is more than 12 kg (26.46 lb).
Install the Y duct (3), washers (5), capscrews (6), and locknuts (4).
T282B S/N 327 05-88-11

Notice! The weight of the axle box cooling duct is more than 30 kg (66.1 lb).
Install the duct (16) and clamps (18).

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 (260 lb).
Install the transition duct (11), washers (10), capscrews (9), lockwashers (12),
and nuts (13).
Closeout
05-88-12 T282B S/N 327

05-88-400-DA - How to Inspect the AC Drive Cooling System

Setup
Procedure
Inspect the inlet grills for unwanted material or contamination.

Make sure that the ducts are in a serviceable condition and have no holes or
damage.
Make sure that the clamps and brackets are tight and in position.
Closeout
T282B S/N 327 05-88-13

05-88-14 T282B S/N 327

Schematics.....................................................................................................06-01-01
Electrical Schematics.......................................................................... 06-01-03
24 VDC Battery Bank..................................................................................... 06-10-01
How to Remove the 24 VDC Battery Bank......................................... 06-10-02
Installation of the 24 VDC Battery Bank..............................................06-10-04
Battery Disconnect Switch Box....................................................................06-12-01
Circuit Breaker Panel.................................................................................... 06-20-01
Grid Box..........................................................................................................06-30-01
Grid Box Maintenance Guidelines...................................................... 06-30-02


The electrical system on the haul truck supplies 12 VDC, 24 VDC, and 110 VAC.
The electrical system connects to these systems:
Cab Controls and Instrumentation (Ref. 05-00-000-DA)
The electrical system has these components and systems:
24 VDC Battery Bank (Ref. 08-02-000-DA)
Overview
The 24 V-12 V converter supplies 12 VDC accessory power to the DC power ports and
the radio.
The 24 V-110 V converter supplies 110 VAC to the AC power ports.
The six 12 VDC batteries are connected in series-pairs (24 VDC). 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.
T282B S/N 327 06-00-01

Electrical Power and Distribution Maintenance Manual
06-00-02 T282B S/N 327

Maintenance Manual Electrical Power and Distribution
Schematics
06-01 Schematics
Schematics
The schematics section has the system schematics that follow:
Electrical Schematics (Ref. 06-01-990-DA)
T282B S/N 327 06-01-01

Schematics
06-01-02 T282B S/N 327

Electrical Schematics
06-01-001 Electrical Schematics
T282B S/N 327 06-01-03

06-01-04 T282B S/N 327

T282B S/N 327 06-01-05

06-01-06 T282B S/N 327

T282B S/N 327 06-01-07

06-01-08 T282B S/N 327

T282B S/N 327 06-01-09

06-01-10 T282B S/N 327

T282B S/N 327 06-01-11

06-01-12 T282B S/N 327

T282B S/N 327 06-01-13

06-01-14 T282B S/N 327

T282B S/N 327 06-01-15

06-01-16 T282B S/N 327

T282B S/N 327 06-01-17

06-01-18 T282B S/N 327

T282B S/N 327 06-01-19

06-01-20 T282B S/N 327

T282B S/N 327 06-01-21

06-01-22 T282B S/N 327

T282B S/N 327 06-01-23

06-01-24 T282B S/N 327

T282B S/N 327 06-01-25

06-01-26 T282B S/N 327

24 VDC Battery Bank
06-10 24 VDC Battery Bank

The 24 VDC battery bank supplies control power for the haul truck.
Operation
The haul truck uses six batteries to supply 24 VDC.
The battery bank supplies the power to start the haul truck. The battery charge
alternator charges the battery during operation of the haul truck. If the battery voltage
decreases to an unserviceable level, an alarm shows on the display panel.
T282B S/N 327 06-10-01

24 VDC Battery Bank
06-10-100-DA - How to Remove the 24 VDC Battery Bank

Setup

Put the battery disconnect switch in the OFF position and lock it in this position.
Open the access panels above the battery boxes.
Procedure
(Ref. Fig. 06-10-001)
Disconnect the negative battery cable (8) from the negative terminal on the
battery.
Disconnect the positive battery cable (9) from the positive terminal on the battery.
Disconnect the interconnect cable (7) between each of the three series pairs.
Remove the battery retainer (2) and the rubber sponge (1).
Notice! The weight of the battery is 60 kg (132 lb).

Attach an applicable lift device to the batteries (6).

Remove the batteries (6).
Closeout
06-10-02 T282B S/N 327

24 VDC Battery Bank
06-10-001 Removal/Installation of the 24 VDC Battery Bank
T282B S/N 327 06-10-03

24 VDC Battery Bank
06-10-200-DA - Installation of the 24 VDC Battery Bank

Setup

Make sure that the haul truck is in the same position as the removal procedure
(Ref. 06-10-100-DA).

Sponge, rubber 5055-N
Parts Table:

2 Retainer 3 53236-X-11
3 Capscrew 12 53236-X-4
4 Lockwasher 12 53236-X-6
5 Washer 12 53236-X-5
6 Battery 6 53236-X-10
7 Interconnect 3 51058-C-3
8 Cable, negative 1 51058-C-2
9 Cable, positive 1 51058-C-1
Procedure
(Ref. Fig. 06-10-001)
Notice! The weight of the battery is 60 kg (132 lb).

Attach an applicable lift device or support to the batteries (6).

Put the batteries (6) in position.
Install the battery retainers (2).
Install the rubber sponge (1).
Install the capscrews (3), washers (5), and lockwashers (4).
Connect the interconnect cable (7) between each of the three series pairs.
Connect the positive battery cable (9) to the positive terminal on the battery.
Connect the negative battery cable (8) to the negative terminal on the battery.
Closeout
Close the access panels above the battery box.

Put the battery disconnect switch in the ON position.
06-10-04 T282B S/N 327

24 VDC Battery Bank
T282B S/N 327 06-10-05

24 VDC Battery Bank
06-10-06 T282B S/N 327

Battery Disconnect Switch Box
06-12 Battery Disconnect Switch Box
06-12-001 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 :
battery disconnect switch
starter isolator switch
propulsion lockout switch
The battery disconnect switch is a rotary switch. The battery disconnect switch has two
positions. The battery disconnect switch is installed at the driver side of the front
bumper.
There are two circuit breakers in the battery disconnect switch box.
CB32 - this circuit breaker controls the devices that operate with 12V current.
CB34 - power distribution for air start (if equipped).
Operation
When the battery disconnect switch is in the OFF position, the 24 VDC is removed
from the 24 VDC circuits. The battery disconnect switch must be in the OFF position
when the haul truck is parked for long periods. This prevents a load on the battery
bank that is not necessary.
T282B S/N 327 06-12-01

Battery Disconnect Switch Box
06-12-02 T282B S/N 327

06-20 Circuit Breaker Panel

The circuit breaker panel has circuit breakers (CB1) to (CB28) that operate to protect
the electrical circuits. There are two additional circuit breakers, CB32 and CB34, on the
ground level in the battery disconnect switch box.
The circuit breaker panel is in the floor mounted center console. The circuit breaker
panel section has the system schematics that follow:
Electrical Schematics (Ref. 06-01-990-DA)
Schematics
The function of the circuit breakers is:

CB1 low/high beam relays, high beam switch, CB20, CB21,
flasher control, and turn signal and hazard lights
CB2 24V main power to MDEC engine
CB3 air ride seat, manual lube switch, air conditioner switch,
and door proximity switches
CB4 dump body override switch, data store switch, cruise
enable and up/down switch, fault reset switch, and
battery voltage signal to TCU
CB5 rollover switch, ignition switch, and key on signal to
Ecomat
CB6 windshield wiper and washer switch, payload weigh
system and outboard display, and dump body proximity
switch
CB7 MTU electronic systems
CB8 operator cab windows
CB9 dump control lever, axle box temperature control switch,
auto lube pressure switch, and gear oil temperature
sensors
CB10 battery disconnect
CB11 grid dry switch, park brake switch, hand brake switch,
park and hand brake pressure switches, fuel level
sensor, dump temperature sensor, and brake and
steering temperature sensor
CB12 Ecomat power relay
CB13 blower pressure switches, steering pressure switch, front
and rear brakes pressure switches, and 24V switched
for the dispatch system power (if equipped)
CB14 propel inhibitor switch, and steering angle signal
CB15 power to the air conditioner condenser
CB16 axle box lights and switch, ladder lights and switch,
engine service lights, cab deck light, and fog lights and
switch (if equipped)
CB17 AC power outlet (24B)
CB18 start and start inhibit relays, ignition switch, MDEC start
and pre-lube relays, and engine heater control (if
equipped)
CB19 horn relay and horns, and payload weigh system
T282B S/N 327 06-20-01


CB20 left low beam headlight, and left riser light (if equipped)
CB21 right low beam headlight, and right riser light (if
equipped)
CB22 left high beam headlight
CB23 right high beam headlight
CB24 dome light, back-up switch and lights, reverse relay,
back-up alarm, retard lights and relay, and brake pedal
relay and proximity switch
CB25 12V power supply, and 12V power outlet on dash
CB26 AC power outlet (24A)
CB27 accessory 12V relay, radio, and centre console 12V
power outlet
CB28 headlight switch, turn signal indicator lights, switch
LEDs, shift selector indicator, and clearance lights
indicator LEDs,
06-20-02 T282B S/N 327

Grid Box
06-30 Grid Box

The grid box is installed on the right side of the superstructure.
Operation
06-30-001 Grid Box
The grid box has two groups of resistors. Each group has eight resistors connected in
series. The resistors become cool by a centrifugal blower system with two wheels. The
blower motor is a series-wound DC motor. The blower motor gets power directly from
the resistor grids. The speed of the blower motor changes with the load applied to the
grid box.
Grid Box Assembly

4.0 MW total power
two banks of resistors connected in series
56 kW (75 HP) motor power, 325 VDC
dual centrifugal wheels with dual air inlet
12000 cfm airflow per wheel
A36 steel, welded construction
paint one coat inorganic zinc rich primer, topcoat two-part epoxy
T282B S/N 327 06-30-01

Grid Box
06-30-300-DA - Grid Box Maintenance Guidelines

Setup
Danger! Electrical current is present in the grid box.

Failure to follow the instructions can cause injury or damage to equipment.
Make sure that the power to the motor and the resistors is disconnected and locked in
disconnected position.
Make sure that the grid box is free of unwanted material, oil, and dirt.
Procedure
(Ref. Fig. 06-30-002)
To do maintenance on the blower motor, do this procedure:

Remove the cover (1).
Remove the inspection plates (7).
Follow the instructions of the manufacturer and inspect the commutator and the
brushes.
Report unusual wear to your Liebherr representative.
To do maintenance on the resistors, do this procedure:
Use a flashlight to do a visual inspection of the resistors (5).
Make sure that you do an inspection of the end of the resistor stack for signs of
permanent deflection of the ribbon elements (6).
Inspect for melted elements. Replace all worn or damaged components.
Notice! The last two grids of the resistor stack have the highest temperature in service.
Damage can occur frequently in the last two grids.
Examine the last two grids carefully.
Examine the resistor stacks for unwanted material or contamination.

Remove the unwanted material from the resistors.
Notice! The weight of each resistor is 29.5 kg (65 lb).

If you have to perform a more detailed inspection (at 10000 hours), do this
procedure:
Remove the bars (2), (3), and (4).
06-30-02 T282B S/N 327

Grid Box
Remove each second grid.

Examine the resistors (5) carefully for any signs of deflection, melted parts, or
other damages.
Replace all worn or damaged components.
Report unusual wear to your Liebherr representative.
Closeout
T282B S/N 327 06-30-03

Grid Box
06-30-002 Inspection of the Grid Box
06-30-04 T282B S/N 327

Pump Drive.....................................................................................................07-10-01
How to Remove the Pump Drive.........................................................07-10-03
How to Remove the U-Joint Assembly................................................07-10-05
How to Install the Pump Drive.............................................................07-10-07
How to Install the U-Joint Assembly....................................................07-10-09
U-Joint Assembly Periodic Check....................................................... 07-10-10
Servicing Procedure for the Pump Drive.............................................07-10-11
U-joint Specification and MaintenanceTables..................................... 07-10-13
Hydraulic Tank............................................................................................... 07-20-01
How to Remove the Fuel and Hydraulic Tank.....................................07-20-06
How to Install the Fuel and Hydraulic Tank.........................................07-20-10
How to Drain the Dump Section of the Hydraulic Tank.......................07-20-12
How to Drain the Brake and Steering Section of the Hydraulic Tank..07-20-13
How to Fill the Brake and Steering Section of the Hydraulic Tank......07-20-15
How to Fill the Dump Section of the Hydraulic Tank...........................07-20-18
Service Procedure for the Dump System Strainers............................ 07-20-19
How to Replace the Breather of the Dump Section of the Hydraulic Tank...
07-20-22
How to Replace the Breather of the Brake and Steering Section of the
Hydraulic Tank.................................................................................................07-20-24
Fuel and Hydraulic Tank Specification and MaintenanceTables........ 07-20-26
Central Service Assembly.............................................................................07-30-01


The hydraulic power and distribution chapter includes the elements of the hydraulic
system that are common for the dump and brake and steering systems.
The hydraulic filters are in this chapter because they are installed on the hydraulic
tank.
Overview
The hydraulic power and distribution chapter has these sections:
Pump Drive (Ref. 07-10-000-DA)
Hydraulic Tank (Ref. 07-20-000-DA)
Central Service Assembly (Ref. 07-30-000-DA)
T282B S/N 327 07-00-01

Hydraulic Power and Distribution Maintenance Manual
07-00-02 T282B S/N 327

Maintenance Manual Hydraulic Power and Distribution
Pump Drive
07-10 Pump Drive

(Ref. Fig. 07-10-001)
The pump drive is installed forward of the dump pumps. The pump drive supplies the
force to operate the pumps in the hydraulic system.
The pump drive has these components:
U-Joint
07-10-001 Pump Drive
Component Description
The pump drive supplies power, from the traction alternator, to the dump pumps, the
brake and steering pump, and the gear oil cooling pump. The traction alternator turns
at the same speed as the engine when the haul truck is in operation. The U-joint
assembly transmits the force from the traction alternator to the pump drive. The gears
in the pump drive are mechanically connected to the dump pumps. The pump drive
supplies the mechanical energy to operate the dump pumps. There is a lubrication
point on the pump drive for the input bearing.
There is a 7/8:1 speed increase on the pump drive. The speed of the pump drive is 800
rpm when the engine is at idle speed (700 rpm). The speed of the pump drive is 2171
rpm when the engine is at full throttle (1900 rpm).
U-Joint
The U-joint is a mechanical connection that attaches the pump drive to the aft of the
traction alternator. The U-joint has three grease fittings for servicing with a grease gun.
T282B S/N 327 07-10-01

Pump Drive
07-10-002 Pump Drive
07-10-02 T282B S/N 327

Pump Drive
07-10-100-DA - How to Remove the Pump Drive

Setup

01-20-000-DA).
If necessary to remove the dump pumps, do this procedure:
Remove the dump pumps (Ref. 08-10-100-DA).
Procedure
(Ref. Fig. 07-10-003)
Notice! The weight of the pump drive without fluids is 193 kg (425 lb).
Attach an applicable lift device to the pump drive (5).
Notice! The oil capacity for the pump drive is 8.52 L (2.25 U.S. gal).
Use an applicable container to collect the fluid and to prevent leakage and contamination.
Drain the pump drive (5) through the connection (14).

Remove the hose assemblies (12) and (13) and install plastic caps on all open
ports.
Remove the locknuts (9).
Remove the capscrews (7) and locknuts (6).
Remove the pump drive (5), adapters (4), and o-rings (3).
Closeout
T282B S/N 327 07-10-03

Pump Drive
07-10-003 Removal/Installation of the Pump Drive
07-10-04 T282B S/N 327

Pump Drive
07-10-105-DA - How to Remove the U-Joint Assembly

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 07-10-004)
Remove the capscrews (11), washers (12), and upper guard (6).
Remove the capscrews (8), washers (9), lockwashers (10), and lower guard (7).
Notice! The weight of the U-joint assembly is 37 kg (81.6 lb).

Attach an applicable lift device to the U-joint assembly (5).

Remove the capscrews (3), lockwashers (4), and U-joint (5).
Closeout
T282B S/N 327 07-10-05

Pump Drive
07-10-004 Removal/Installation of the U-Joint Assembly
07-10-06 T282B S/N 327

Pump Drive
07-10-200-DA - How to Install the Pump Drive

Setup

01-20-000-DA).
(Ref. 07-10-100-DA).
Parts Table:

1 Capscrew 4 51542AJ-8
2 Lockwasher 12 51542AJ-18
3 O-ring 2 51542AJ-22
4 Adapter 2 51542AJ-36
5 Pump drive 1 51542AJ-33
6 Locknut 12 10467957-28
7 Capscrew 12 10467957-10
8 Stud 4 51542AJ-23
9 Locknut 4 51542AJ-1
Procedure
(Ref. Fig. 07-10-003)
Notice! The weight of the pump drive without fluids is 160 kg (355 lb).
Attach an applicable lift device to the pump drive (5).

If the studs (8) are not installed, do this procedure:
Apply a layer of medium grade Loctite to the ends with short threads of the studs
(8) and install in the pump drive (5).
Continue with this procedure:
Install the o-rings (3), adapters (4), and pump drive (5).
Install the locknuts (9).
Install the capscrews (11) and lockwashers (10).
Install the the capscrews (7) and locknuts (6).
Remove the plastic caps from the ports and install the hose assemblies (12) and
(13).
T282B S/N 327 07-10-07

Pump Drive
Use the oil fill connection (16) to fill the pump drive (5).
Open the shutoff valve (15).

Fill the pump drive (5) until the oil starts to flow from the shutoff valve (15).
Closeout
If the dump pumps are removed,

Install the dump pumps (Ref. 08-10-200-DA).
Do the pump drive servicing procedure (Ref. 07-10-700-DA).
07-10-08 T282B S/N 327

Pump Drive
07-10-205-DA - How to Install the U-Joint Assembly

Setup

01-20-000-DA).
(Ref. 07-10-105-DA).
Parts Table:

1 Locknut 12 10467957-28
2 Capscrew 12 10467957-10
3 Capscrew 12 10467957-9
4 Lockwasher 12 10467957-13
5 U-joint 1 10467957-21
6 Guard, upper 1 10467957-23
7 Guard, lower 1 10467957-22
8 Capscrew 4 10467957-7
9 Lockwasher 4 10467957-12
10 Washer 4 10467957-11
11 Capscrew 2 10467957-8
12 Washer 2 10467957-11
Procedure
(Ref. Fig. 07-10-004)
Notice! The weight of the U-joint assembly is 37 kg (81.6 lb).

Attach an applicable lift device to the U-joint assembly (5).

Install the U-joint (5), capscrews (3), and lockwashers (4).
Install the capscrews (2) and locknuts (1).
Tighten the capscrews (2) and (3).
Install the lower guard (7), capscrews (8), lockwashers (9), and washers (10).
Install the upper guard (6), capscrews (11), and washers (12).
Closeout
Do the pump drive servicing procedure (Ref. 07-10-700-DA).

T282B S/N 327 07-10-09

Pump Drive
07-10-500-DA - U-Joint Assembly Periodic Check

Setup

01-20-000-DA).
Procedure
To do a check of the play between the traction alternator and the U-joint, do this
procedure:
Put a pipe wrench on the flange of the drive shaft between the traction alternator
and the U-joint
Move the drive shaft forward and back with the pipe wrench.
There must be no play between the traction alternator and the U-joint.
If there is play between the traction alternator and the U-joint,
Replace the U-joint assembly.
To do a check of the play between the pump drive and the U-joint, do this
procedure:
Put a pipe wrench on the flange of the drive shaft between the pump drive and
the U-joint
Move the drive shaft forward and back with the pipe wrench.
There must be no play between the pump drive and the U-joint.
If there is play between the traction alternator and the U-joint,
Replace the U-joint assembly.
Closeout
07-10-10 T282B S/N 327

Pump Drive
07-10-700-DA - Servicing Procedure for the Pump Drive

Setup

01-20-000-DA).

Oil SAE 85W-140 5087-A
Grease, input bearing Lithium NLGI 2 See recommended lubricants (Ref.
03-12-000-DA)
Grease, u-joint (climate dependent) Lithium NLGI 1 See recommended lubricants (Ref.
03-12-000-DA)
Procedure
Do a check of the oil level in the pump drive gear box.
Use an applicable container to catch the fluid and to prevent leakage and contamination.
If the haul truck is at the first 500 hour preventive maintenance,

Change the oil in the pump drive gear box.
Use the special adapter, if applicable to your truck, to drain the oil from the pump
drive.
If the pump drive gear box has 1000 hours of operation since the last preventive
maintenance done,
Replace the breather.
If the pump drive gear box has 3000 hours of operation since the last preventive
maintenance done,
Change the oil in the pump drive gear box.
Use the special adapter, if applicable to your truck, to drain the oil from the pump
drive.
Apply lithium NLGI 1 grease to the U-joint and slip shaft.
Apply lithium NLGI 2 grease to the input bearing.
T282B S/N 327 07-10-11

Pump Drive
Closeout
07-10-12 T282B S/N 327

Pump Drive
07-10-900-DA - U-joint Specification and MaintenanceTables

Setup
Notice! There a different types of U-joints on the different trucks.

Make sure that you know the correct part number of your U-joint.
Procedure
Table A is for the specifications of the U-joint.
Part Number Weight Material Notes
Closeout
T282B S/N 327 07-10-13

Pump Drive
07-10-14 T282B S/N 327

Hydraulic Tank
07-20 Hydraulic Tank

The hydraulic tank is on the outer side of the left frame rail. It is a fuel and hydraulic
tank.
07-20-001 Hydraulic Tank
(Ref. Fig. 07-20-001)
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.
Dump System Hydraulic Tank
T282B S/N 327 07-20-01

Hydraulic Tank
07-20-002 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
07-20-02 T282B S/N 327

Hydraulic 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 (340 U.S. gal).
There are two hydraulic return lines on the bottom of the dump system 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.
07-20-003 Dump System Hydraulic Tank
There is an access panel attached to the fuel and hydraulic tank with capscrews 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.
T282B S/N 327 07-20-03

Hydraulic Tank
Brake and Steering Hydraulic Tank
07-20-004 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
07-20-04 T282B S/N 327

Hydraulic Tank
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 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 (245.5 U.S. gal).
07-20-005 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.
Refer to the procedures in this section to know how to do the servicing of the dump
and brake steering section of the hydraulic tank.
T282B S/N 327 07-20-05

Hydraulic Tank
07-20-100-DA - How to Remove the Fuel and Hydraulic Tank

Setup

Drain the dump system hydraulic tank (Ref. 07-20-700-DA).
Drain the brake and steering hydraulic tank (Ref. 07-20-700-DA).
Drain the fuel from the fuel and hydraulic tank(Ref. 05-50-705-DA).
Close the fuel and hydraulic shutoff valves (Ref. 07-20-000-DA).
Procedure
(Ref. Fig. 07-20-006)
(Ref. Fig. 07-20-007)
Notice! The weight of an empty fuel and hydraulic tank is 1900 kg (4200 lb).
Put an applicable container below the tank (15) to collect the fluid.
Put tags and identify the hoses (1), tube assemblies (24), and electrical
connectors (4) as applicable.
Remove all hoses and electrical connectors that are attached to the tank (15).
Remove the capscrews (35), washers (34), clamp halves (33), and o-ring (2).
Remove the capscrews (3), flange (32), and o-ring (5).
Remove the capscrews (31), adapter (30), and o-ring (29).
Remove the capscrews (14), washers (22), clamp halves (23), and o-rings (13).
Install protective covers on the hoses (1) and all open ports.
Discard the o-rings (2), (5), (29), (13), and (28).
Remove the capscrews (9), washers (10), and locknuts (11).
Remove the capscrews (6), lockwashers (7), washers (8), and expansion joint
(12).
Remove the capscrews (37) and clamps (36).
Disconnect the tube assemblies (24) and put protective covers on the hoses and
open ports.
Disconnect the electrical connectors (4).
Connect one chain and two come-along chains to the lift points on the top of the
tank (15).
Attach an applicable lift device to the chains, and make sure the chains are over
the center of the tank (15).
07-20-06 T282B S/N 327

Hydraulic Tank
Use the lift device to adjust the tension of the chains to hold the weight of the
tank (15).
Remove the capscrews (16), locknuts (20), cinch washers (21), and fibromounts
(17).
Slowly lift the tank (15) from the mounts and remove the fuel and hydraulic tank
(15).
Closeout
T282B S/N 327 07-20-07

Hydraulic Tank
07-20-006 Removal/Installation of the Fuel and Hydraulic Tank
07-20-08 T282B S/N 327

Hydraulic Tank
07-20-007 Removal/Installation of the Fuel and Hydraulic Tank
T282B S/N 327 07-20-09

Hydraulic Tank
07-20-200-DA - How to Install the Fuel and Hydraulic Tank

Setup

Make sure that the fuel and hydraulic tank is fully clean and in serviceable
condition.
(Ref. 07-20-100-DA).
Parts Table:

2 O-ring 1 53275AN-54
3 Capscrew 4 53275AN-217
5 O-ring 1 53275AN-218
6 Capscrew 4 51035AW-19
7 Washer 4 51035AW-9
8 Lockwasher 4 51035AW-11
10 Washer 8 51035AW-9
11 Locknut 4 51035AW-1
12 Expansion joint 1 51035AW-151
15 Tank, fuel and hydraulic 1 51038AA-48
17 Fibromount 2 51038AA-26
18 Washer 2 51038AA-18
21 Washer, cinch 2 51038AA-47
25 Clamp half 2 53993-N-23
26 Washer 4 53993-N-23
27 Capscrew 4 53993-N-23
28 O-ring 1 53993-N-23
29 O-ring 1 53275AN-152
30 Adapter 1 53275AN-153
32 Flange 1 53275AN-216
33 Clamp half 2 53275AN-54
34 Washer 4 53275AN-54
38 Washer 2 51038AA-18
39 Locknut 2 51038AA-17
Procedure
07-20-10 T282B S/N 327

Hydraulic Tank
(Ref. Fig. 07-20-006)

(Ref. Fig. 07-20-007)
Notice! The weight of an empty fuel and hydraulic tank is 1900 kg (4200 lb).
Connect one chain and two come-along chains to the lift points on the top of the
tank (15).
Attach an applicable lift device to the chains, and make sure the chains are over
the center of the tank (15).
Make sure that you keep the tank (15) level.
Put the fuel and hydraulic tank (15) in position on the tank mounts on the frame.
Install the capscrews (19), lockwashers (18), washers (38), and locknuts (39). .
Install the capscrews (16), locknuts (20), cinch washers (21), and fibromounts
(17).
Connect the electrical connectors (4) and remove the identification tags.
Install the expansion joint (12), capscrews (6), washers (7), and lockwashers (7).
Remove the protective covers from the hoses (1) and ports.
Install the capscrews (27), washers (26), clamp halves (25), and o-rings (28).
Install the capscrews (31), adapter (30), and o-ring (29).
Install the capscrews (3), flange (32), and o-ring (5).
Install the capscrews (35), washers (34), clamp halves (33), and o-ring (2).
Remove the identification tags from the hoses (1).
Remove the protective covers from the tube assemblies (24) and ports.
Connect the tube assemblies (24) and remove the identification tags.
Install the clamps (36) and capscrews (37).
Connect the electrical connectors (4).
Closeout
Open the fuel and hydraulic shutoff valves (Ref. 07-20-000-DA).

Fill the brake and steering hydraulic tank (Ref. 07-20-705-AA).
Fill the dump system hydraulic tank (Ref. 07-20-705-AA).
Fill the fuel in the fuel and hydraulic tank.
T282B S/N 327 07-20-11

Hydraulic Tank
07-20-700-DA - How to Drain the Dump Section of the Hydraulic

Tank
Setup
Procedure
Warning! Hydraulic fluid can cause skin irritation.

Always put on protective clothing and eye protection when you work with hydraulic fluid.
Notice! The capacity of the dump system hydraulic tank is 1515 L (400 U.S. gal).
To drain the dump section of the hydraulic tank manually, do this procedure:
Put an applicable container below the dump section of the hydraulic tank.
Remove the plug in the bottom of the dump section of the hydraulic tank.
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:
Install a scavenge pump to the HYDRAULIC FILL HOIST quick connection on the
central service box.
Use an applicable container to drain the hydraulic fluid.
After the hydraulic tank is empty, disconnect the scavenge pump.
Closeout
Know and follow all environmental regulations on how to safely discard the
hydraulic fluid.
Correctly discard all the hydraulic fluid from the container.
07-20-12 T282B S/N 327

Hydraulic Tank
07-20-705-AA - How to Drain the Brake and Steering Section of

the Hydraulic Tank
Setup
Procedure
(Ref. Fig. 07-20-008)

Notice! The capacity of the brake and steering hydraulic tank is 1515 L (400 U.S. gal).
To drain the brake and steering hydraulic tank manually, do this procedure:
Put an applicable container below the brake and steering hydraulic tank.
Remove the plug in the bottom of the brake and steering hydraulic tank.
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, do this procedure:
Install a scavenge pump to the BRAKE AND STEERING FILL quick connection
on the central service box.
Use an applicable container to drain the hydraulic fluid into.
After the hydraulic tank is empty, disconnect the scavenge pump.
Closeout
Know and follow the environmental regulation on how to safely discard the
hydraulic fluid from the container.
T282B S/N 327 07-20-13

Hydraulic Tank
07-20-008 Brake and Steering Hydraulic Drain
07-20-14 T282B S/N 327

Hydraulic Tank
07-20-710-DA - How to Fill the Brake and Steering Section of the

Hydraulic Tank
Setup
Procedure
(Ref. Fig. 07-20-009)
(Ref. Fig. 07-20-010)
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.

Connect the hydraulic service cart to the BRAKE AND STEERING FILL quick
connection on the central service box.
Add hydraulic fluid to the brake and steering hydraulic tank.
Make sure that the hydraulic fluid is at the FULL level on the sight gauge of the
brake and steering hydraulic tank.
Loosen the suction line at the brake and steering pump.
Tighten the suction line when hydraulic fluid shows.
Add hydraulic fluid to fully fill the brake and steering hydraulic tank.
Loosen the bleeder screw on the brake and steering pressure filter.
Tighten the bleeder screw when hydraulic fluid shows.
Add hydraulic fluid to fully fill the brake and steering hydraulic tank.
Disconnect the hydraulic service cart from the BRAKE AND STEERING FILL
quick connection on the central service box.
Closeout
Remove all tools, equipment, and unwanted material from the work area.
T282B S/N 327 07-20-15

Hydraulic Tank
07-20-009 Brake and Steering Hydraulic Replenishment
07-20-16 T282B S/N 327

Hydraulic Tank
07-20-010 Brake and Steering Hydraulic Replenishment
T282B S/N 327 07-20-17

Hydraulic Tank
07-20-715-DA - How to Fill the Dump Section of the Hydraulic

Tank
Setup


Oil, hydraulic See recommended lubricants (Ref.
03-12-000-DA)
Procedure

Connect the hydraulic service cart to the HYDRAULIC FILL HOIST quick
Add hydraulic fluid to the dump system hydraulic tank.
Make sure that the hydraulic fluid is at the FULL level on the sight gauge of the
dump system hydraulic tank.
Loosen all four suction lines at the dump pumps.
Tighten each of the suction lines when the hydraulic fluid shows.
Add hydraulic fluid to fully fill the dump system hydraulic tank.
Loosen the bleeder screws on the two dump system pressure filters.
Tighten each of the bleeder screws when the hydraulic fluid shows.
Add hydraulic fluid to fully fill the dump system hydraulic tank.
Disconnect the hydraulic service cart from the HYDRAULIC FILL HOIST quick
Closeout
07-20-18 T282B S/N 327

Hydraulic Tank
07-20-720-DA - Service Procedure for the Dump System

Strainers
Setup

Parts Table:

1 Capscrew 44 51417-Z-1
2 Lockwasher 44 51417-Z-2
3 Cover, clean-out 2 51417-Z-22
4 O-ring 2 51417-Z-7
5 O-ring 1 51417-Z-8
6 Cover, clean-out 1 51417-Z-23
7 Strainer 2 51038AA-25
10 Washer 4 51038AA-61
11 Pipe 2 51038AA-46
Procedure
(Ref. Fig. 07-20-011)
Check the vacuum pressure on the strainer at 300 hours.

If the pressure is more than 125 mm (4.921 in.) of water column,
Clean or replace the strainers.

To get access to the strainers, do this procedure:

Close the dump system hydraulic shutoff valve (Ref. 07-20-000-DA).
Remove the capscrews (1), lockwashers (2), access covers (3) and (6), and
remove and discard the o-rings (4) and (5).
Remove the capscrews (8), lockwashers (9), and washers (10).
Remove the strainers (7) and pipes (11).
Clean the strainers (7) and pipes (11).
-or-
Discard the used strainers (7) and replace with new strainers.
T282B S/N 327 07-20-19

Hydraulic Tank
Install the clean or new strainers (7) and pipes (11).

Install the washers (10), lockwashers (9), and capscrews (8).
Install new orings (4) and (5).
Install the access covers (3) and (6), lockwashers (2), and capscrews (1).
Open the dump system shutoff valve (Ref. 07-20-000-DA).
Closeout
Fill the hydraulic fluid in the dump system hydraulic tank (Ref. 07-20-715-DA).
07-20-20 T282B S/N 327

Hydraulic Tank
07-20-011 Dump System Strainers Servicing
T282B S/N 327 07-20-21

Hydraulic Tank
07-20-725-DA - How to Replace the Breather of the Dump

Section of the Hydraulic Tank
Setup

Parts Table:

1 Breather 1 51038AA-85
Procedure
(Ref. Fig. 07-20-012)
Remove and discard the breather (1).

Know and follow the environmental regulations how to discard the breather (1).
Install a new breather (1).
Closeout
07-20-22 T282B S/N 327

Hydraulic Tank
07-20-012 Dump System Tank Breather Replacement
T282B S/N 327 07-20-23

Hydraulic Tank
07-20-730-DA - How to Replace the Breather of the Brake and

Steering Section of the Hydraulic Tank
Setup

Parts Table:

1 Breather 1 51038AA-85
Procedure
(Ref. Fig. 07-20-013)

Know and follow the environmental regulation how to discard the breather (1).
Install a new breather (1).
Closeout
07-20-24 T282B S/N 327

Hydraulic Tank
07-20-013 Brake and Steering Breather Replacement
T282B S/N 327 07-20-25

Hydraulic Tank
07-20-900-DA - Fuel and Hydraulic Tank Specification and

MaintenanceTables
Setup
Notice! There a different types of fuel and hydraulic tanks on the different trucks.
Make sure that you know the correct part number of your fuel and hydraulic tank.
Procedure
Table A is for the specifications of the fuel and hydraulic tank.
Closeout
07-20-26 T282B S/N 327

07-30 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.
Refer to the Parts Catalog for details about the central service assembly.
T282B S/N 327 07-30-01

07-30-001 Central Service Assembly
07-30-02 T282B S/N 327

08 Dump System
Dump System Components..........................................................................08-02-01
How to Flush the Dump System..........................................................08-02-03
How to Inspect the Dump System.......................................................08-02-04
Dump System Pressure Check........................................................... 08-02-07
Dump System Schematic....................................................................08-02-11
Dump Pumps..................................................................................................08-10-01
How to Remove the Dump Pumps......................................................08-10-03
How To Install The Dump Pumps....................................................... 08-10-05
Fault Isolation - Noisy Pump............................................................... 08-10-07
Fault Isolation - Unresponsive Pump.................................................. 08-10-08
Fault Isolation - Oil Overheating......................................................... 08-10-09
Fault Isolation- Oil Foaming................................................................ 08-10-10
Dump Valve.................................................................................................... 08-20-01
Removal of the Dump Valve............................................................... 08-20-03
Installation of the Dump Valve............................................................ 08-20-05
Fault Isolation - High Pressure in "HOLD".......................................... 08-20-07
Fault Isolation - High Operating Pressure........................................... 08-20-08
Fault Isolation - High Operating Temperature.....................................08-20-09
Fault Isolation- Loss of Power or Slow Reaction.................................08-20-10
Fault Isolation - Dump Body Movement Voids.................................... 08-20-11
Fault Isolation - Dump Body Lifts Slowly (or does not lift)...................08-20-12
Fault Isolation - Decrease of Speed in "FLOAT".................................08-20-13
Fault Isolation- Void or Vibration when Dump Body Lowered.............08-20-14
Fault Isolation - Dump Body Lowers Slowly (engine not in operation)08-20-15
Pilot Control Valve and Manifold Assembly................................................08-30-01
How to remove the Pilot Control Valve............................................... 08-30-03
How to remove of the Manifold Valve................................................. 08-30-05
How to install the Pilot Control Valve.................................................. 08-30-07
How to install the Manifold Valve........................................................ 08-30-08
Fault Isolation Procedure - High Oil Temperature...............................08-30-09
Fault Isolation Procedure - Loss of Power.......................................... 08-30-10
Fault Isolation Procedure - Dump Body Moves Slowly....................... 08-30-11
Fault Isolation Procedure - Dump Body Movement in "HOLD"........... 08-30-12
Dump Body Control Lever............................................................................ 08-40-01
Dump Body Control Lever Adjustment................................................08-40-03
Dump Body Cylinders................................................................................... 08-50-01
How to Remove the Dump Body Cylinders.........................................08-50-02
How to install the Dump Body Cylinders............................................. 08-50-06
Dump System Pressure Filters.....................................................................08-60-01
How to Remove the Pressure Filters.................................................. 08-60-03
How to install the Pressure Filters.......................................................08-60-05
Service Procedure for the Dump System Pressure Filter....................... 08-60-


08 Dump System
The dump system has the components that follow:
Dump Pumps (Ref. 08-10-000-DA)

Dump Valve (Ref. 08-20-000-DA)
Pilot Control Valve and Manifold Assembly (Ref. 08-30-000-DA)
Dump Control Lever (Ref. 08-40-000-DA)
Dump Cylinders (Ref. 08-50-000-DA)
Dump System Pressure Filters (Ref. 08-60-000-DA)
The dump system connects to the components that follow:
Dump Control Lever and Override Switch (Ref. 04-20-000-DA)
Dump Body Cylinders (Ref. 08-50-000-DA)
Warning! The haul truck can only move forward at a set speed between 0 to 54.7 km/h (0 to 34
mph) when the dump body is the UP position. This speed is set by the manufacturer and agreed
on by the mine. An open proximity switch prevents reverse movement when the dump body is
the UP position.
Serious damage to equipment or personnel can occur if you ignore the proximity switch.
Make sure that the proximity switch operates correctly and the dump body up indicator
shows when the dump body is the UP position. Do not ignore the dump body proximity
switch.
System Operation
(Ref. Fig. 08-02-004)
The dump pumps send hydraulic fluid from the dump system hydraulic tank through
the pressure filters. From the pressure filters, clean hydraulic fluid flows to the dump
valve. The dump valve sends hydraulic fluid to the pilot control valve and the dump
cylinders.
If the dump control lever moves, 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 temperature of the hydraulic oil is monitored continuously during the operation of
the haul truck. If the hydraulic oil temperature is more than 93 °C (199 °F), a warning
shows on the computer display in the cab.
There are three test locations on the dump valve to test the pressure in the dump
system.
Dump body operations are:
Lift the Dump Body
Lower the Dump Body
Lower the Dump Body while Moving the Haul Truck
T282B S/N 327 08-00-01

Dump System Maintenance Manual
Lift the Dump Body

Pull the dump control lever back and the dump body lifts. If you release the dump
control lever before the dump body is fully the UP position, the dump body stays in that
position. Pull and hold the dump control lever back to fully lift the dump body.
Lower the Dump Body

Push the dump control lever forward and the dump body lowers. If the you release
dump control lever before the proximity switch is engaged, the dump body stops and
holds in that position. To fully lower the dump body, you must hold the dump control
lever forward. The dump body gets near to the frame and goes lower than the
proximity switch, it automatically goes into the "float" position against the dump body
pads on the frame.
Lower the Dump Body while Moving the Haul Truck (Hill Start)
To do a "hill start", push and hold the override switch and push on the accelerator
pedal. As soon as the traction motors apply forward torque on the haul truck, release
the service brake.
Maintenance Tips
It is important that the dump system is clean and flushed when the hydraulic fluid has
contamination. Contamination can be caused by rust, water, dirt, or by a worn or
unserviceable component. Preventative maintenance that includes fluid analysis keeps
the dump system clean. A clean dump system can extend the life of the components.
08-00-02 T282B S/N 327

Maintenance Manual Dump System
Dump System Components
08-02 Dump System Components

(Ref. Fig. 08-02-001)
The dump system has the components that follow:
Dump Pumps (Ref. 08-10-000-DA)

Dump Valve (Ref. 08-20-000-DA)
Pilot Control Valve and Manifold Assembly (Ref. 08-30-000-DA)
Dump Control Lever (Ref. 08-40-000-DA)
Dump Cylinders (Ref. 08-50-000-DA)
Dump System Pressure Filters (Ref. 08-60-000-DA)
T282B S/N 327 08-02-01

08-02-001 Dump System Components
08-02-02 T282B S/N 327

08-02-300-DA - How to Flush the Dump System

Setup

Procedure
Warning! The hydraulic fluid can cause skin irritation.

Always put on protective clothing and eye protection when you use the hydraulic fluid.
Put a large container below the dump system hydraulic tank. The capacity of the
dump system hydraulic tank is 1302 L (340 U.S. gal).
Disconnect all the hydraulic hoses and put the ends in the container.
Disconnect and empty the hoses from the pressure filters. Replace the elements
(Ref. 08-60-000-DA).
Clean and inspect the dump system tank (Ref. 08-02-400-DA).
Reconnect all the hydraulic hoses to the pressure filters and the dump system
tank.
Closeout
Fill the dump system hydraulic tank with new, clean hydraulic fluid (Ref.
07-20-705-AA). The capacity of the dump system hydraulic tank is 1302 L (340
U.S. gal).
T282B S/N 327 08-02-03

08-02-400-DA - How to Inspect the Dump System

Setup

Parts Table:
REFERENCE TECHNICAL PART QUANTITY DRAWING-ITEM

1 Capscrew 44 51417-Z-1
2 Washer 44 51417-Z-2
3 Cover, clean out 1 51417-Z-23
4 O-ring 1 51417-Z-8
5 Capscrew 4 51038AB-8
6 Lockwasher 4 51038AB-16
7 Washer 4 51038AB-61
8 Cover, clean out 2 51417-Z-22
9 O-ring 2 51417-Z-7
10 Strainer pipe 2 51038AB-46
11 Strainers 2 51038AB-25
Procedure
(Ref. Fig. 08-02-002)
Remove the capscrews (1), washers (2), clean out cover (3), and o-ring (4).
Remove the capscrews (1), washers (2), clean out covers (8), and o-rings (9).
Remove the strainers (11).
Remove the capscrews (5) and lockwashers (6), washers (7), and hydraulic
strainer pipes (10).
Prepare a solution of 50 percent diesel fuel and 50 percent hydraulic fluid.
Apply the diesel fuel or hydraulic fluid solution to a cellulose sponge.
Clean the inside of the tank and the strainers (11) with the cellulose sponge and
solution.
Inspect the strainers (11) and strainer pipes (10) for contamination, replace if
necessary.
Disconnect the supply hoses from the dump pump and the drain hoses.
Clean the inlet holes of the dump pump.
Inspect the dump pump and replace if necessary.
Remove the filter elements (Ref. 08-60-100-DA).
Inspect the filter elements for contamination, replace if necessary.
Make sure that the dump valve, the pilot valve, and the dump body cylinders are
serviceable.
08-02-04 T282B S/N 327

Install the filter elements (Ref. 08-60-200-DA).

Install the hydraulic strainer pipes (10), washers (7), lockwashers (6), and
capscrews (5).
Install the strainers (11).
Install the clean out cover (3), capscrews (1), washers (2), and o-ring (4).
Install the clean out covers (8), the capscrews (1), washers (2), and o-rings (9).
Connect the supply hoses to the dump pump.
Fill the dump system hydraulic tank (Ref. 07-20-705-AA).
Loosen the supply hoses a small quantity to let the air out, then tighten.
Closeout
T282B S/N 327 08-02-05

08-02-002 Dump System Inspection
08-02-06 T282B S/N 327

08-02-405-DA - Dump System Pressure Check

Setup
Procedure
(Ref. Fig. 08-02-003)
Attach pressure gauges, 415 bar (6020 psi) minimum, to the left and right inlet
section pressure gauges on the dump valve.
Set the park brake.
Put the haul truck in NEUTRAL and start the engine.
Let the engine run at idle speed for three to five minutes.
The dump system hydraulic oil temperature must be50 to 60 °C (122 to 140 °F).
Disconnect the electrical wire from the float valve cartridge (SV) of the manifold
valve.
Push the dump control lever forward to the DOWN position and HOLD.
Make sure that the left and right inlet section pressure gauges show 203 to 210
bar (2940 to 3050 psi).
Connect the electrical the float valve cartridge (SV) of the manifold valve.
valve.
Pull the dump control lever rearward to the UP position and HOLD.
Pull the dump control lever to the rear to lift the dump body in the HOLD position.
the pressure is correct.
valve.
Pull the dump control lever forward to the DOWN position and HOLD.
If the pressure indications at PG1 and PG2 are not 27 to 31 bar (390 to 450 psi),
You must adjust the high range potentiometer of the dump control lever (Ref.
08-40-500-DA).
Make sure the engine runs at idle speed.
Attach a pressure gauge to PG of the dump system actuator on the manifold
valve.
If the pressure indication at PG is 195 to 224 bar (2830 to 3250 psi),
T282B S/N 327 08-02-07

Closeout
08-02-08 T282B S/N 327

08-02-003 Dump System Pressure Check
T282B S/N 327 08-02-09

08-02-10 T282B S/N 327

Dump System Schematic
08-02-004 Dump System Schematic
T282B S/N 327 08-02-11

08-02-12 T282B S/N 327

Dump Pumps
08-10 Dump Pumps

There are two hydraulic pumps for the dump system of the haul truck.
System Operation
(Ref. Fig. 08-10-001)
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.
The dump pumps are set displacement gear type pumps. 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 (300 U.S. gal)per minute of hydraulic fluid oil at an engine speed of 1900
rotation per minute (rpm). A pump speed of 2171 rpm gives a dump time of 20 to 30
seconds.
Specifications
Dump cycle is approximately 34 seconds UP, and 14 seconds DOWN.
The usual operating temperature is 50 to 60 °C (122 to 140 °F) at 20 °C (68 °F) ambient
temperature.
The maximum system pressure is 207 bar (3000 psi) ±3.5 bar (50 psi).
The pump volume is 1140 L (300 U.S. gal) per minute at an engine speed of 1900 and a pump
speed of 2171 rpm.
T282B S/N 327 08-10-01

Dump Pumps
08-10-001 Dump Pumps
08-10-02 T282B S/N 327

Dump Pumps
08-10-100-DA - How to Remove the Dump Pumps

Setup

Use a safety harness when you do maintenance above the ground (Ref.
01-20-000-DA).
Close the shutoff valve for the dump system hydraulic tank(Ref. 07-20-000-DA).
If the brake and steering pump is attached to the dump pump,
remove the brake and steering pump (Ref. 09-10-100-DA).
If the gear oil cooling pump is attached to the dump pump,
remove the gear oil cooling pump (Ref. 10-20-100-DA).
Procedure
(Ref. Fig. 08-10-002)
Warning! The hydraulic fluid can cause a 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 (225 lb).

Use a jack or a lift device that can hold the weight.
Put a container below the dump pump (20) or (15) to collect the hydraulic fluid.
Put protective covers on the hoses (1), (11), and all open ports.
Remove the capscrews (19), lockwashers (18), washers (17), and bracket (16).
Remove the capscrews (5), washers (6), and pump (20).
Remove the locknut (14), lockwashers (22), and pump (15).
Remove the o-rings (7) and adapter (8).
Closeout
T282B S/N 327 08-10-03

Dump Pumps
08-10-002 Removal/Installation of the Dump Pumps
08-10-04 T282B S/N 327

Dump Pumps
08-10-200-DA - How To Install The Dump Pumps

Setup

01-20-000-DA).
08-10-100-DA).
Parts Table:

3 Washer 16 51035AW-26
4 Clamp halves 4 51035AW-26
7 O-ring 4 51542AJ-22
8 Adapter 2 51542AJ-36
9 Clamp halves 4 51035AW-24
10 O-ring 4 51035AW-24
13 Washer 16 51035AW-24
14 Locknut 4 51542AJ-1
15 Pump 1 51542AJ-28
16 Bracket 2 51542AJ-39
17 Washer 4 51542AJ-14
20 Pump 1 51542AJ-24
21 O-ring 4 51035AW-26
Procedure
(Ref. Fig. 08-10-002)
Warning! Hydraulic fluid can cause a skin irritation.

Notice! The weight of the dump pump is 101 kg (225 lb).

Use a jack or a lift device that can hold the weight.
T282B S/N 327 08-10-05

Dump Pumps
Install the o-rings (7) and adapter (8).

Install the pump (15) and the locknut (14).
Install the pump (20), capscrews (5), and washers (6).
Install the bracket (16), capscrews (19), lockwashers (18), and washers (17).
Remove the protective covers from the hoses (1), (11), and the ports.
Install the o-rings (10), hoses (11), capscrews (12), washers (13), and clamp
halves (9).
Install the o-rings (21), hoses (1), capscrews (2), washers (3), and clamp halves
(4).
Closeout
If the gear oil cooling pump is removed,

Install the gear oil cooling pump (Ref. 10-20-200-DA).
Open the shutoff valve for the dump system hydraulic tank (Ref. 07-20-000-DA).
08-10-06 T282B S/N 327

Dump Pumps
08-10-500-DA - Fault Isolation - Noisy Pump

This procedure is for the fault isolation of a dump pump that is unusually noisy.
Fault Isolation
Possible Causes
1. Low supply of oil.
2. Incorrect oil in system.
3. Dirty oil filter and clogged strainers.
4. Clogged strainers or blockage in suction line.
5. Air leakage in suction line.
6. Oil temperature very high.
7. Air suction through the shaft seal when pump is at idle.
Corrective Action
1. Fill the dump system hydraulic tank to the correct level (Ref. 07-20-705-AA).
2. Drain the system and fill with the correct oil (Ref. 07-20-700-DA)(Ref. 07-20-705-AA).
3. Clean strainers (Ref. 07-20-710-DA), replace filter elements (Ref. 08-60-700-DA), and get a
sample of oil and do an oil analysis.
4. Clean the strainers or remove blockage (Ref. 07-20-710-DA).
5. Do a check for loose connections or defective seals.
6. Examine system components and hoses to find source of heat.
7. Apply a spray of oil around the seal, replace seal if defective.
T282B S/N 327 08-10-07

Dump Pumps
08-10-505-DA - Fault Isolation - Unresponsive Pump

This procedure is for troubleshooting a dump pump that takes too long to respond or
fails to respond.
Fault Isolation
Possible Causes
1. Low supply of oil.
2. Relief valve pressure not sufficient .
3. Pump worn or damaged.
4. Cylinders worn (bypassing)
Corrective Action
1. Fill the dump system hydraulic tank to the proper level (Ref. 07-20-705-AA).
2. Make sure the pressure is set correctly (Ref. 08-02-405-DA).
3. Do an inspection of the pump, and repair or replace as necessary.
4. Do an inspection of the cylinders, and repair or replace as necessary.
08-10-08 T282B S/N 327

Dump Pumps
08-10-510-DA - Fault Isolation - Oil Overheating

This procedure is for troubleshooting a dump system with an oil overheat condition.
Troubleshooting
Possible Causes
1. Unwanted material does not let the relief valve close fully. The flow control valve inside the inlet
section of the dump valve is closed.
2. Incorrect oil for existing climate.
3. Contamination in the oil.
4. Low oil level.
5. Air in the system.
6. Contamination in the pilot valve.
7. Pump worn (slipping or bypassing).
8. Cylinders worn (bypassing).
Corrective Action
1. Clean, flush, or replace the relief valve or the pilot valve, and repair as necessary. Examine the
flow control valve.
2. Drain (Ref. 07-20-700-DA) and fill the system with the applicable oil (Ref. 07-20-705-AA).
3. Drain (Ref. 07-20-700-DA) and flush (Ref. 08-02-300-DA) the system, change the filters (Ref.
08-60-700-DA) and clean the strainers (Ref. 07-20-710-DA), (Ref. 07-20-710-DA), and fill the
system with the applicable oil (Ref. 07-20-705-AA).
4. Fill dump system hydraulic tank to proper level (Ref. 07-20-705-AA).
5. Do a check for leaks in the suction line. Make sure that there are no damages to the suction lines
and the lines are correctly sealed.
6. Clean, flush, or replace the pilot valve.
7. Repair or replace the pump.
8. Repair or replace the cylinders.
T282B S/N 327 08-10-09

Dump Pumps
08-10-515-DA - Fault Isolation- Oil Foaming

This procedure is for the fault isolation of a dump system with an oil foaming condition.
Fault Isolation
Possible Causes
1. Air leakage into the system between the tank and the pump.
2. Incorrect oil.
3. Oil level too low.
4. Tank baffles damaged or loose.
Corrective Action
1. Tighten all suction line connections and do an inspection of all the lines.
2. Drain (Ref. 07-20-700-DA) and fill the system with the applicable oil (Ref. 07-20-705-AA).
3. Fill dump system hydraulic tank to the correct level (Ref. 07-20-705-AA).
4. Repair the tank, and clean and flush the tank and system as necessary (Ref. 08-02-300-DA).
08-10-10 T282B S/N 327

Dump Valve
08-20 Dump Valve

The dump valve supplies the hydraulic fluid to extend and retract the dump cylinders.
System Operation
(Ref. Fig. 08-20-001)
The dump valve receives hydraulic fluid from the dump pumps through two high
pressure filters. The dump valve transmits hydraulic fluid to the dump cylinders and the
pilot control valve.
The pilot control valve sends an hydraulic signal to move the spools in the dump valve.
The flow of hydraulic fluid causes the dump cylinders to extend or retract.
When the dump valve receives no signals from the pilot control valve, hydraulic fluid
returns to the hydraulic tank.
T282B S/N 327 08-20-01

Dump Valve
08-20-001 Dump Valve
08-20-02 T282B S/N 327

Dump Valve
08-20-100-DA - Removal of the Dump Valve

Setup

Remove the pressure filters (Ref. 08-60-100-DA).
Procedure
(Ref. Fig. 08-20-002)

Notice! The weight of the dump valve without hydraulic fluid is 146 kg (320 lb).
Make sure that the lifting device or support is sufficient to hold the weight.
Put a container below the dump valve (18) to collect the hydraulic fluid.
Disconnect the hoses (17) from the dump valve (18) and install protective covers.
Remove the capscrews (13), washers (14), o-rings (11), and clamp halves (15).
Install protective covers on the hoses (12) and open ports.
Remove the capscrews (6), adapters (7), and o-rings (8).
Install protective covers on the hoses (1) and open ports.
Remove the capscrews (24), washers (23), o-rings (26), and clamp halves (22).
Install protective covers on the flange adapters (25) and open ports.
Remove the capscrews (21), nuts (20), and washers (19).
Use a lifting device or support and remove the dump valve (18).
Closeout
T282B S/N 327 08-20-03

Dump Valve
08-20-002 Removal/Installation of the Dump Valve
08-20-04 T282B S/N 327

Dump Valve
08-20-200-DA - Installation of the Dump Valve

Setup

Make sure that the haul truck is in the same configuration as the removal (Ref.
08-20-100-DA).
Parts List:
REF. NAME OF PART QTY DRAWING-ITEM NO.

2 O-ring 2 51035AW-25
4 Washer 8 51035AW-25
5 Clamp half 4 51035AW-25
7 Adapter 2 51035AW-65
8 O-ring 2 51035AW-29
10 Washer 4 51035AW-10
11 O-ring 2 51035AW-25
14 Washer 8 51035AW-25
16 Locknut 4 51035AW-2
18 Dump valve 1 51035AW-31
19 Washer 2 51035AW-71
20 Nut 2 51035AW-70
23 Washer 8 51035AW-25
25 Adapter flange 2 51035AW-35
26 O-ring 2 51035AW-25
Procedure
(Ref. Fig. 08-20-002)

Notice! The weight of the dump valve (dry) is 146 kg (320 lb).
Make sure that the lifting device or support is sufficient to hold the weight.
T282B S/N 327 08-20-05

Dump Valve
Use a lifting device or support and install the dump valve (18).
Install the capscrews (21), nuts (20), and washers (19).
Remove the protective covers from the ports on the dump valve (18).
Remove the protective covers from the flange adapters (25).
Install the capscrews (24), washers (23), o-rings (26), and clamp halves (22).
Remove the protective covers from the hoses (1).
Install the capscrews (6), adapters (7), and o-rings (8).
Remove the protective covers from the hoses (12).
Install the capscrews (13), washers (14), o-rings (11), and clamp halves (15).
Remove the protective covers and connect the hoses (17) to the dump valve
(18).
Closeout
Install the pressure filters (Ref. 08-60-200-DA).

08-20-06 T282B S/N 327

Dump Valve
08-20-500-DA - Fault Isolation - High Pressure in "HOLD"

This fault isolation is forto check the valve inlet section when pressure is too high with
the dump control lever in HOLD.
Fault Isolation
Possible Causes
1. Blockage in pilot flow.
2. Blockage in pilot return line.
3. Main control poppet stuck in closed positon.
4. Blockage in return line from main control valve.
Corrective Action
1. Flush out or replace the pilot valve supply line.
2. Flush out or replace the pilot valve return line.
3. Remove unwanted material. Make sure the poppet moves freely. Do an inspection of all o-rings
and backup rings, replace any damaged parts.
4. Flush out or replace the return line from the main control valve.
T282B S/N 327 08-20-07

Dump Valve
08-20-505-DA - Fault Isolation - High Operating Pressure

This fault isolation is for the dump valve inlet section when the pressure is unusually
high during operation.
Fault Isolation
Possible Causes
1. Malfunction of the main relief valve.
Corrective Action
1. Replace, or see OEM service instructions for maintenance of the main relief valve.
08-20-08 T282B S/N 327

Dump Valve
08-20-510-DA - Fault Isolation - High Operating Temperature

This fault isolation is for the dump valve inlet section when the temperature is
unusually high during operation.
Fault Isolation
Possible Causes
1. Incorrect operation of the main relief valve.
2. Malfunction of overload relief.
3. Too much oil bypassing in main control valve or pilot valve.
4. Cylinder bypassing.
5. Defective pump.
Corrective Action
2. Replace, or see OEM service instructions for maintenance of the overload relief.
3. Do an inspection of the spools and bores for wear or scores. Replace all worn or damaged
components.
4. Replace or repair the cylinder.
5. Replace or repair the pump.
T282B S/N 327 08-20-09

Dump Valve
08-20-515-DA - Fault Isolation- Loss of Power or Slow Reaction

This fault isolation is for the dump valve inlet section for loss of power or slow reaction
time.
Fault Isolation
Possible Causes
1. Blockage in the main flow control body pilot hole.
2. Anti-void poppet in the inlet section stuck in open position.
3. Ruptured or partially blocked pilot valve supply line.
4. Pilot valve spool not correctly positioned.
7. Defective pump.
8. Too much oil bypassing in the main control valve or pilot valve.
9. Void.
Corrective Action
1. Remove unwanted material from the pilot hole.
2. Do an inspection of poppet, poppet seat, and bore for unwanted material, wear, correct
installation, and make sure that poppet moves freely in bore. Replace the bias spring if bent or
distorted.
3. Flush or replace the supply line.
4. Do an inspection for dirty or damaged linkage. Do an inspection of spool and detent ball for
damage or wear. Replace all damaged or worn components.
5. Replace, or see OEM service instructions for maintenance of the main control and pilot valve.
6. Repair or replace the cylinder.
8. Do an inspection of spools and bores for wear or scores. Replace damaged components.
9. See void corrective action (Ref. 08-20-520-DA).
08-20-10 T282B S/N 327

Dump Valve
08-20-520-DA - Fault Isolation - Dump Body Movement Voids

This fault isolation is for the dump valve inlet section for voids in dump body movement
when the dump body is lowered.
Fault Isolation
Possible Causes
1. Relief valve poppet of the main flow control will not close.
2. Low pressure relief valve in the inlet section will not close.
3. Anti-void poppet in the inlet section will not open.
Corrective Action
1. Replace, or see OEM service instructions for maintenance of the main flow control relief poppet.
2. Do an inspection of poppet, poppet installation, and bore for unwanted material, wear, and make
sure that the poppet moves freely in bore. Replace the bias spring if bent or distorted.
3. Do an inspection of poppet, poppet installation, and bore for unwanted material, wear, and make
sure that the poppet moves freely in bore. Replace bias spring if bent or distorted.
T282B S/N 327 08-20-11

Dump Valve
08-20-525-DA - Fault Isolation - Dump Body Lifts Slowly (or

does not lift)
This fault isolation is for the dump valve plunger section for when the dump body does
not lift, or lifts slowly.
Fault Isolation
Possible Causes
1. Spools do not move freely in the main control valve.
2. Blockage in the pilot pressure line.
3. Broken bias springs in one of the two spools.
4. Ruptured pilot pressure line.
5. Pilot valve spool not in correct position.
7. Void in dump cylinders.
9. Defective pump.
10. Incorrect poppet restrictor, or the position of the poppet restrictor is incorrect.
Corrective Action
1. Do an inspection for unwanted material, wear and scores. Make sure that the spools move freely
in bores. Replace all worn or damaged components.
2. Flush or replace the pilot pressure line.
3. Replace the springs in pairs.
4. Replace the pilot pressure line.
5. Do an inspection for dirty or damaged linkage that does not let the spool move freely. Examine
the spools and detent balls. Replace all damaged components.
7. Examine the poppet restrictor in the rod spool and make sure spool is installed correctly.
10. Make sure the poppet restrictor is correctly installed.
08-20-12 T282B S/N 327

Dump Valve
08-20-530-DA - Fault Isolation - Decrease of Speed in "FLOAT"

This fault isolation is for the dump valve plunger section for a decrease of speed in
"float."
Fault Isolation
Possible Causes
1. Pilot valve spool not in the correct position.
2. Main control valve spools do not move freely.
3. Float poppet does not open.
4. Blockage between main and pilot valves.
5. Blockage in pilot valve return line.
6. Blockage in hole in spool.
7. Blockage in restrictor poppet.
8. Low pressure relief in inlet section does not open.
9. Blockage in return line of the main control valve.
10. Restrictor poppet in spools are not "seated" correctly.
Corrective Action
the spools and detent balls. Replace all damaged components.
2. Remove any unwanted material and make sure that the spools move freely in bores. Replace all
worn or damaged components.
3. Remove any unwanted material and make sure that the poppet moves freely.
4. Flush out or replace the main and pilot valve lines.
5. Flush out or replace the return line for the pilot valve.
6. Remove any unwanted material from the spool hole, and replace any worn or damaged parts.
7. Remove any unwanted material and make sure poppet moves freely. Replace any worn or
damaged components.
8. Remove any unwanted material and make sure the valve moves freely. Replace any worn or
damaged components.
9. Flush out or replace the return line of the main control valve.
10. Do an inspection of "seat" for damage. Lap to mating "seat" or replace.
T282B S/N 327 08-20-13

Dump Valve
08-20-535-DA - Fault Isolation- Void or Vibration when Dump

Body Lowered
This fault isolation is for the dump valve plunger section for void and/or vibrations when
the dump body is lowered.
Fault Isolation
Possible Causes
1. Broken spool bias spring.
2. Blockage in the hole of the restrictor poppet.
3. Blockage in the pilot flow or pressure return line.
4. Pilot valve not in the correct position.
5. Chatter (vibration) - malfunction of the external restrictor (when applicable).
Corrective Action
1. Replace the bias springs in pairs.
2. Remove all unwanted material from the hole of the restrictor poppet.
3. Flush out or replace the line.
4. Replace the pilot flow or pressure return line.
5. Do an inspection for dirty or damaged linkage that does let the spool move freely. Examine the
spools and detent balls. Replace all damaged components.
6. Do an inspection for blockage and make sure poppet is installed correctly. Replace if necessary.
08-20-14 T282B S/N 327

Dump Valve
08-20-540-DA - Fault Isolation - Dump Body Lowers Slowly

(engine not in operation)
This fault isolation is for the dump valve plunger section when the dump body slowly
lowers when engine not in operation.
Fault Isolation
Possible Causes
2. Spools do not move freely in main control valve.
3. Too much oil bypassing in valves.
4. Pilot valve spool not correctly centered.
Corrective Action
2. Remove any unwanted material and make sure that the spools move freely. Replace any worn or
damaged components.
3. Inspect the spools for unusual wear or scores. Replace all damaged parts.
the spools and detent balls. Do a check for correct linkage adjustment. Replace all worn or
damaged components.
T282B S/N 327 08-20-15

Dump Valve
08-20-16 T282B S/N 327

Pilot Control Valve and Manifold Assembly
08-30 Pilot Control Valve and Manifold 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.
08-30-001 Pilot Control Valve Assembly
System Operation
(Ref. Fig. 08-30-002)
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.
The dump control lever sends a signal to the applicable EHP valve. The EHP valve
sends the necessary hydraulic pressure to the applicable port on the pilot control valve.
This pressure moves the spool in the pilot valve.
There are four positions in the pilot control valve as follows:
Power up
Hold
Float
Power down
The spool inside the pilot control valve moves as a result of the selection on the dump
control lever. The pilot control valve sends the hydraulic fluid through the manifold
valve to the dump valve.
T282B S/N 327 08-30-01

08-30-002 Pilot Control Valve System
08-30-02 T282B S/N 327

08-30-100-DA - How to remove the Pilot Control Valve

Setup
Procedure
(Ref. Fig. 08-30-003)

Put a container below the pilot control valve (1) to collect the hydraulic fluid.
Disconnect the tube assemblies (5) and put protective covers on the tube
assemblies and open ports.
Remove the capscrews (2), locknuts (3), and washers (4).
Remove the pilot control valve (1).
Closeout
T282B S/N 327 08-30-03

08-30-003 Removal/Installation of the Pilot Control Valve
08-30-04 T282B S/N 327

08-30-105-DA - How to remove of the Manifold Valve

Setup
Procedure
(Ref. Fig. 08-30-004)

Put a container below the manifold valve (1) to collect the hydraulic fluid.
Disconnect the electrical connectors (6).
Disconnect the hoses (7) and put protective covers on the hoses (7) and open
ports.
Disconnect the tube assemblies (5) and put protective covers on the tube
assemblies (5) and open ports.
Remove the capscrews (2), locknuts (3), and washers (4).
Remove the manifold valve (1).
Closeout
T282B S/N 327 08-30-05

08-30-004 Removal/Installation of the Manifold Valve
08-30-06 T282B S/N 327

08-30-200-DA - How to install the Pilot Control Valve

Setup

Parts List:

1 Pilot Control Valve 1 53739-M-10
2 Capscrew 4 53739-M-20
3 Locknut 4 53739-M-23
4 Washer 8 53739-M-24
Procedure
(Ref. Fig. 08-30-003)

Install the pilot control valve (1).

Install the capscrews (2), locknuts (3), and washers (4).
Remove the protective covers and connect the tube assemblies (5).
Closeout
T282B S/N 327 08-30-07

08-30-205-DA - How to install the Manifold Valve

Setup

Parts List:

1 Manifold valve 1 53739-E-9
2 Capscrew 4 53739-E-20
3 Locknuts 4 53739-E-23
4 Washers 8 53739-E-24
Procedure
(Ref. Fig. 08-30-004)

Install the manifold valve (1).

Install the capscrews (2), locknuts (3), and washers (4).
Remove the protective covers and connect the tube assemblies (5).
Connect the electrical connectors (6).
Closeout
08-30-08 T282B S/N 327

08-30-500-DA - Fault Isolation Procedure - High Oil Temperature

This procedure is to find the cause of the fault of a pilot valve with high oil temperature.
Fault Isolation
Possible Causes
1. Too much oil bypassing in pilot valve.
Corrective Action
1. Do an inspection of the spool and bore for wear or scores. To examine the serviceability of the
pilot valve this procedure:
Slowly lower the dump body (Ref. 13-30-905-DA).
Stop the engine.
Remove the pilot cap of the pilot valve.
Remove the pilot valve spool.
Make sure that the spool moves freely in the bore of the pilot valve.
Replace the pilot valve as necessary.
T282B S/N 327 08-30-09

08-30-505-DA - Fault Isolation Procedure - Loss of Power

This procedure is to find the cause of the fault of a pilot valve for loss of power or slow
reaction.
Fault Isolation
Possible Causes
1. The manifold does not get 24 V current (RRV2 or RRV1).
2. The adjustment of the overload relief valve is too low.
3. Pilot valve spool not in correct position.
4. The spool of the dump valve is stuck (dump body does not go down).
Corrective Action
1. Make sure that the manifolds gets power.
2. Do a check for the correct relief valve adjustment. Increase the relief pressure if necessary.
3. Examine the serviceability of the pilot valve (Ref. 08-30-500-DA) or (Ref. 08-30-510-DA). Clean,
flush, or replace the pilot valve, and repair as necessary.
4. Measure with this procedure:
Find the test pressure ports on the extend and retract side of the dump cylinder (at the
flange tee).
Measure the pressure on the extend side.
If the pressure is 224 bar (3250 psi), (equal to the relief valve adjustment), repair the dump
valve as necessary. Make sure that the spool moves freely.
08-30-10 T282B S/N 327

08-30-510-DA - Fault Isolation Procedure - Dump Body Moves

Slowly
This procedure is to find the cause of the fault of a pilot valve when the dump body
does not move or move unusually slow.
Fault Isolation
Possible Causes
1. Pilot valve spool not in the correct position.
2. Main relief valve adjustment too low or valve stuck open.
Corrective Action
1. Examine the serviceability of the pilot valve with this procedure:
Slowly lower the dump body (Ref. 13-30-905-DA).
Remove the pilot hose connection from one of the pilot caps.
Install a rod in the end that contacts the spool end.
Pilot operate the opposite end cap.
Make sure that you feel the rod move.
Remove the rod.
Install the rod in the other end and repeat the whole procedure.
2. Replace the valve, or see OEM service instructions for main relief valve maintenance.
T282B S/N 327 08-30-11

08-30-515-DA - Fault Isolation Procedure - Dump Body

Movement in "HOLD"
This procedure is to find the cause of the fault of a pilot valve for when the dump body
moves and the dump control lever is in the HOLD position.
Fault Isolation
Possible Causes
1. Too much oil bypassing in pilot valve.
2. The float cartridge valve is not in the correct position.
Corrective Action
1. Do an inspection of the spool and bore for wear or scores. Examine the serviceability of the pilot
valve (Ref. 08-30-500-DA).
2. Do an inspection of the float cartridge valve in the manifold with this procedure:
Make sure that the manual override switch is not in the shifted position.
Examine the float cartridge valve for contamination and flush if necessary.
Make sure that the valve does not get 24 V. The valve only gets 24 V when the dump body
is in the float position, almost all the way down.
08-30-12 T282B S/N 327

Dump Body Control Lever
08-40 Dump Body Control Lever
08-40-001 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.
Operation
The four functions are:
Lower the dump body
Raise the dump body
Float
Hold
The three positions are:
Forward
Center
Back
The dump body control lever operations are:
1. Push and hold the dump control lever forward to fully lower the dump body. If the dump control
T282B S/N 327 08-40-01

lever is released before the proximity switch engages, the dump body stops and in that position.
As the dump body goes lower than 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.
Dump Body Override Switch

The function of the dump body override switch lets 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.
Maintenance Tips
08-40-02 T282B S/N 327

08-40-500-DA - Dump Body Control Lever Adjustment

Setup
Procedure
(Ref. Fig. 08-40-002)
valve.
Pull and hold the dump body control lever to the UP position.
Notice! The pressure set by the factory for PG1 and PG2 are 27 to 31 bar (390 to 450 psi), but
a pressure of 24 to 68 bar (350 to 990 psi) is satisfactory.
It is necessary to have 24 bar (350 psi) to fully shift the spool in the dump valve, and the
pilot caps are calibrated to 68 bar (990 psi).
Stop the movement of the dump cylinder and adjust the high range potentiometer
with this procedure:
Use a small flat screw driver to adjust the high range potentiometer.
Turn the adjustment screw to the right to increase the pressure, or to the left to
decrease the pressure.
If the dump body control lever is new, turn the adjustment screw to the right eight
full turns, to begin.
Pull the dump body control lever back and note if the pressure indication at PG1
goes up or down.
Repeat the adjustment procedures until the pressure indication at PG1 is 27 to 31
bar (390 to 450 psi).
After the pressure at PG1 is correct, do this procedure:
valve.
Push and hold the dump body control lever to the DOWN position.
the up and down pressures are too far apart, and it is necessary to adjust the
frequency potentiometer with this procedure:
Use a small flat screw driver to adjust the frequency potentiometer until PG2 is
T282B S/N 327 08-40-03

Notice! It is possible to have PG1 and PG2 pressures in the correct range, but have no
movement of the dump cylinder.
After the pressures are in range, but there is no dump cylinder movement, you must adjust
the frequency potentiometer.
Repeat the dump control lever adjustment procedure until PG1 and PG2 are
Closeout
08-40-04 T282B S/N 327

08-40-002 Dump Body Control Lever Adjustment
T282B S/N 327 08-40-05

08-40-06 T282B S/N 327

Dump Body Cylinders
08-50 Dump Body Cylinders

(Ref. Fig. 08-50-001)
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:
Frame (Ref. 13-10-000-DA)
08-50-001 Dump Body Cylinders
Operation
The dump body cylinders extend or retract with hydraulic pressure from the dump
valve. This causes the dump body to lift or lower.
Maintenance Tips
Adjustments to the dump body cylinders cannot be done after installation on the haul
truck.
T282B S/N 327 08-50-01

Dump Body Cylinders
08-50-100-DA - How to Remove the Dump Body Cylinders

Setup

01-20-000-DA).
For this procedure, it is necessary to have cover plates with o-rings for the
hydraulic ports.
Procedure
(Ref. Fig. 08-50-002)

Pull the dump body control lever in the UP position and lift the front of the dump
body (1) approximately 305 mm (12.008 in.) above the frame.
Put two safety supports between the top frame rails and the dump body beam
runners.
Lower the dump body until it is against the safety supports.
Release the dump control lever to let it return to the CENTER position.
Stop the engine (Ref. 05-10-905-DA) 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.
Attach an overhead hoist to the lift points on the dump body.

Tighten the tension on the cables of the overhead hoist.
Close the supply and return line valves on the hydraulic tank.
Put a container below the dump cylinder (23).
Remove the lubrication hoses (22) and install protective caps on the hoses and
open ports.
Notice! The weight of a dump body cylinder without hydraulic fluid is 2291 kg (5100 lb).
Make sure that the lift device or support can hold the weight.
Attach an applicable lift device to the dump cylinder (23).

08-50-02 T282B S/N 327

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.
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.
Slowly and carefully loosen the high pressure hoses to let the pressure and hydraulic fluid
release until there is no more pressure.
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 to prevent leakage
and contamination.
Install protective covers on the hoses (17).

Use the tool (Liebherr P/N 10025660 Ref. 02-00-000-DA) and an applicable
bottle jack to remove the axial force of the cylinder rod from the pin.
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.
Use a chain or hand hoist to install the cylinder shipping bracket (24) (Liebherr
P/N T-193-A Ref. 02-00-000-DA).
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! The weight of the pin (5) is 36 kg (79.4 lb).

Lift the dump cylinder (23) just enough to remove the weight of the pin (5).
Remove the pin (5).
T282B S/N 327 08-50-03

Dump Body Cylinders
Notice! Usually the pin can be removed manually.

If the pin is worn, it can be necessary to use a hydraulic pin puller.
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,
Install the retainer for the shipping bracket around the dump cylinder (23).
The dump cylinder (23) can be on an angle to the rear of the haul truck
approximately 15-20 degrees.
Remove the capscrews (8), washers (9), and bearing cover (10).
Remove the capscrews (11), lockwashers (12), and retainer plate (13).
Remove the lower eye of the cylinder and ball bushing (15) from the lower pin.
Notice! The ball bushing is installed with tightness.

Use a large pry bar to remove the lower eye of the cylinder and ball bushing from the pin.
Use an hydraulic puller if necessary.
Lower the dump cylinder (23) until it is clear of the dump body.
Remove the retaining rings (3) and (14), seals (1) and (16), and spacer (2).
If the ball bushings (7) and (15) are damaged,
Remove the ball bushings (7) and (15).
Closeout
08-50-04 T282B S/N 327

Dump Body Cylinders
08-50-002 How to Remove/Install the Dump Body Cylinders
T282B S/N 327 08-50-05

Dump Body Cylinders
08-50-200-DA - How to install the Dump Body Cylinders

Setup

01-20-000-DA).
(Ref. 08-50-100-DA).

Permatex® anti-seize See recommended lubricants (Ref.
03-12-000-DA)
Parts Table:

1 Seal 2 51005BT-22
2 Spacer 2 51005BT-20
3 Retaining ring 2 51005BT-9
4 Capscrew 1 51005BT-4
5 Pin 1 51005BT-18
6 Locknut 1 51005BT-1
7 Bushing 1 51005BT-12
9 Lockwasher 4 51005BT-7
10 Bearing cover 1 51005BT-15
12 Washer 3 51005BT-8
13 Retainer plate 1 51005BT-14
14 Retaining ring 2 51005BT-10
15 Bushing 1 51005BT-11
16 Seal 1 51005BT-21
18 O-ring (retract) 2 51035AW-23
18 O-ring (extend) 2 51035AW-24
19 Bolt (extend) 8 51035AW-23
19 Bolt (retract) 8 51035AW-24
20 Washer (extend) 8 51035AW-23
20 Washer (retract) 8 51035AW-24
21 Clamp (extend) 4 51035AW-23
21 Clamp (retract) 4 51035AW-24
23 Cylinder 2 51005BT-13
24 Bracket, shipping 1 51005BT-24
26 Lockwasher 4 51005BT-7
08-50-06 T282B S/N 327

Dump Body Cylinders

27 Washer 4 51005BT-6
Procedure
(Ref. Fig. 08-50-002)
If the ball bushings (15) and (7) are removed,

Install the ball bushings (15) and (7) to the dump cylinder (23).
Danger! The cylinder rod can move in and out of the dump cylinder if not held.
Make sure that you add cover plates and o-rings to the cylinder ports to hold the cylinder
rod. Make sure that there is no trapped air in the cylinder.
Notice! The weight of a dump body cylinder without hydraulic fluid is 2291 kg (5100 lb).
Attach an applicable lift device to the dump cylinder (23).

Lift and move the dump cylinder (23) into position.
Make sure that the lubrication port on the bottom eye of the dump cylinder (23)
points to the front of the haul truck.
Install the seals (1) and (16), retaining rings (3) and (14), and spacer (2).
Put the lower ball bushing and eye (15) in position on the pin.
Install the retaining plate (13).
Lubricate the capscrews (11) with permatex anti-seize.
Notice! The weight of the pin (5) is 36 kg (79.4 lb).

If necessary, install the tool (Liebherr P/N 10025660 Ref. 02-00-000-DA) and an
applicable bottle jack to help align the upper pin (5).

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.
T282B S/N 327 08-50-07

Dump Body Cylinders
Use a container to catch the fluid.
Put a container below the cylinder (23).

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.
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.
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).
Align the upper pin hole of the cylinder (23) and install the pin (5).
Make sure that the lubrication port on the top eye of the dump cylinder (23) points
to the rear of the haul truck.
Install the capscrews (4) and locknuts (6).
Remove the tool (Liebherr P/N 10025660 Ref. 02-00-000-DA), if it is installed.
Install the bearing cover (10), capscrews (8), and washers (9).
Remove the protective caps and connect the lubrication hoses (22).
Use a chain or hand hoist to remove the cylinder shipping brackets (24) (Liebherr
P/N T-193-A Ref. 02-00-000-DA), capscrews (25), washers (26), and
lockwashers (27).
At the hydraulic tank, open the supply and return line valves.
Pull the dump control lever in the UP position and lift the front of the dump body
enough to release the safety supports.
Remove the safety supports from between the top frame rails and the dump body
beam runners.
Fully lower and then lift the dump body to release all trapped air.
Fully lower the dump body and stop the engine (Ref. 05-10-905-DA).
Examine the dump cylinder (23) for leaks.
Closeout
Make sure that the dump system hydraulic fluid is at the correct level (Ref.
07-20-705-AA).
08-50-08 T282B S/N 327

Dump System Pressure Filters
08-60 Dump System Pressure Filters

(Ref. Fig. 08-60-001)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.
System Operation
Hydraulic fluid goes from the dump pumps through the pressure filters. The clean
hydraulic fluid goes from the pressure filters to the dump valve.(Ref. Fig. 08-60-002)
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.
The pressure filter goes into bypass at 3.5 bar (50 psi). The visual indicator pops up at
2.41 bar (35 psi). If the pressure differential pressure measurement is 3.5 bar (50 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 (Ref. 08-60-700-DA).
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.
08-60-001 Dump System Pressure Filters
T282B S/N 327 08-60-01

08-60-002 Dump System Pressure Filters
08-60-02 T282B S/N 327

08-60-100-DA - How to Remove the Pressure Filters

Setup

Drain the hydraulic fluid from the pressure filter (Ref. 08-60-700-DA).
Procedure
(Ref. Fig. 08-60-003)

Notice! The weight of the pressure filter is 47 kg (103.6 lb).

Make sure that the lift device can hold the weight.
Remove the capscrews (3), washers (4), and clamp halves (5).
Remove the o-ring (2) and put protective covers on the hose (1).
Remove the capscrews (6), flange (7), and o-ring (8).
Loosen the capscrews (19).
Loosen the clamp halves capscrews, on the dump valve side, for the adapter (20)
that connects the pressure filter to the dump valve .
Remove the capscrews (14), washers (13), clamp halves (12), and o-ring (15).
Put protective covers on the open ports.
Remove the capscrews (19), lockwashers (18), and the pressure filter (17).
If you must replace the pressure filter (17), do this procedure:
Remove the capscrews (9), lockwashers (10), elbow flange (11), and o-ring (16).
Put protective covers on the open ports.
Closeout
T282B S/N 327 08-60-03

08-60-003 How to remove/How to install the Pressure Filters
08-60-04 T282B S/N 327

08-60-200-DA - How to install the Pressure Filters

Setup

08-60-100-DA).
Parts Table:

2 O-ring 1 51035AW-24
4 Washer 4 51035AW-24
7 Flange 1 51035AW-36
8 O-ring 1 51035AW-28
11 Flange, elbow 1 51035AW-42
13 Washer 4 51035AW-25
15 O-ring 1 51035AW-25
16 O-ring 1 51035AW-28
17 Pressure filter 1 51035AW-33
Procedure
(Ref. Fig. 08-60-003)


Install the pressure filter (17).

Loosely install the capscrews (19) and lockwashers (18).
If the elbow flange (11) is removed,
T282B S/N 327 08-60-05

Install the elbow flange (11), o-ring (16), capscrews (9), and lockwashers (10).
Continue with these steps:
Install the o-ring (15).
Loosely install the capscrews (14), washers (13), and clamp halves (12).
Tighten the capscrews on the dump valve for the adapter (20) that connects the
pressure filter to the dump valve.
Install the o-ring (8), flange (7), and capscrews (6).
Install the o-ring (2), hose (1), clamp halves (5), capscrews (3), and washers (4).
Closeout
08-60-06 T282B S/N 327

08-60-700-DA - Service Procedure for the Dump System

Pressure Filter
Setup

Make sure that the engine is not in operation (Ref. 05-10-905-DA).
Make sure that the hydraulic fluid in the dump system is cool.
Close the supply and return shut-off valves for the dump system on the hydraulic
tank (Ref. 07-20-000-DA).
Procedure
(Ref. Fig. 08-60-004)
Check of the visual indicator (2) and record the result.

Put an applicable container below the pressure filter to collect the hydraulic oil.
Turn the bleed plug (1) one and a half turns to open.
Remove the port plug (9) and bleed plug (8) and let the hydraulic oil drain.
Install the port plug (9) and bleed plug (8).
Tighten the port plug (9), bleed plug (8), and bleed plug (1).
Remove the cap (7).
Loosen the set screw (4).
Remove the tube (6) and o-rings (3).
Remove the filter element (5).
If the visual indicator was out, or the dump pump has a catastrophic failure,
Replace the filter element (5) and flush the system (Ref. 08-02-300-DA).
If the haul truck is at the first 100 hour or the 1000 hour preventive maintenance,
Replace the filter element (5).
Inspect the pressure filter, filter element (5), and o-rings (3),
Replace any damaged parts.
Install the o-rings (3), filter element (5), and tube (6).
Install the cap (7) until it is over the o-ring.
Tighten the cap (7) to not more than 20 Nm (180 lbf in.).
Tighten the set screw (4).
Make sure that the visual indicator (2) is fully pushed in.
T282B S/N 327 08-60-07

Closeout
Open the supply and return shut-off valves for the dump system on the hydraulic
tank (Ref. 07-20-000-DA).
Start the engine (Ref. 05-10-900-DA) and let the engine operate until the dump
system temperature is 45 °C (113 °F).
Make sure there are no leaks.
08-60-08 T282B S/N 327

08-60-004 Dump System Pressure Filter Servicing
T282B S/N 327 08-60-09

08-60-10 T282B S/N 327

General Practices and Specifications..........................................................09-02-01
Brake and Steering System Pressure Setup.......................................09-02-02
Brake and Steering System Pressure Test......................................... 09-02-06
Brake and Steering System Schematic...............................................09-02-11
Brake and Steering Pump............................................................................. 09-10-01
How to Remove the Brake and Steering Pump.................................. 09-10-05
How to Install the Brake and Steering Pump...................................... 09-10-07
Brake and Steering Pressure Filter..............................................................09-20-01
How to Remove the Pressure Filter.................................................... 09-20-03
How to Install the Pressure Filter........................................................ 09-20-05
How to Do the Servicing Procedure for the Brake and Steering Pressure
Filter.................................................................................................................09-20-06
Brake and Steering Manifold........................................................................ 09-30-01
How to Remove the Brake and Steering Manifold.............................. 09-30-04
How to Install the Brake and Steering Manifold.................................. 09-30-06
Steering System.............................................................................................09-40-01
Toe-In Check...................................................................................... 09-40-03
Steering Encoder Test........................................................................ 09-40-05
Toe-In Adjustment...............................................................................09-40-06
Steering Accumulator................................................................................... 09-41-01
How to Remove the Steering Accumulator......................................... 09-41-03
How to Install the Steering Accumulator............................................. 09-41-05
Steering Accumulator System Bleed...................................................09-41-07
Steering Accumulator Precharge Check............................................. 09-41-09
Steering Accumulator Precharge Drain...............................................09-41-11
Steering Accumulator Precharge Replenishment............................... 09-41-13
Flow Amplifier Valve......................................................................................09-42-01
How to Remove the Flow Amplifier Valve........................................... 09-42-02
How to Install the Flow Amplifier Valve............................................... 09-42-05
Steering Control Valve.................................................................................. 09-43-01
How to Remove the Steering Control Valve........................................09-43-02
How to Install the Steering Control Valve............................................09-43-04
Steering Cylinders......................................................................................... 09-44-01
How to Remove the Steering Cylinders.............................................. 09-44-02
How to Install the Steering Cylinders.................................................. 09-44-04
How to Check the Steering Cylinder for Leaks................................... 09-44-06
Tie Rods..........................................................................................................09-45-01
How to Remove the Tie Rods............................................................. 09-45-02
How to Install the Tie Rods................................................................. 09-45-04
Idler Arm Assembly....................................................................................... 09-46-01
How to Remove the Idler Arm Assembly............................................ 09-46-02
How to Install the Idler Arm Assembly................................................ 09-46-05
How to Inspect the Idler Arm Pin and Bearing.................................... 09-46-08
Steering Arm.................................................................................................. 09-47-01
How to Remove the Steering Arm.......................................................09-47-02

How to Install the Steering Arm................................................................................09-47-04
Steering Stop Pads............................................................................................................. 09-48-01
How to Remove the Steering Stop Pads..................................................................09-48-02
How to Install the Steering Stop Pads......................................................................09-48-04
Brake System...................................................................................................................... 09-50-01
Brake Accumulators........................................................................................................... 09-52-01
How to Remove the Brake Accumulators.................................................................09-52-03
How to Install the Brake Accumulators.....................................................................09-52-05
Brake Accumulator System Bleed............................................................................09-52-06
Brake Accumulator Precharge Check...................................................................... 09-52-08
Brake Accumulator Precharge Drain........................................................................09-52-10
Brake Accumulator Precharge Replenishment........................................................ 09-52-12
Hand Brake Valve and Manifold........................................................................................ 09-54-01
How to Remove the Hand Brake Valve and Manifold.............................................. 09-54-02
How to Install the Hand Brake Valve and Manifold.................................................. 09-54-04
Buddy Steering and Braking Components.......................................................................09-60-01
Connection and Operation....................................................................................... 09-60-03

The brake and steering system has the systems that follow:
Steering System (Ref. 09-40-000-DA)
Operation
(Ref. Fig. 09-02-006)(Ref. Fig. 09-00-001)
The brake and steering hydraulic pump pushes hydraulic fluid through a filter and into
the accumulators through the valves in the manifold. The accumulators are charged
with a nitrogen gas to 125 bar (1810 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.
The brake and steering system operates at a pressure of 207 bar (3000 psi). The
brake and steering pump controls the hydraulic pressure to the brake and steering
system. The range of operation for the brake and steering system is 200 to 220 bar
(2900 to 3190 psi).
If the pressure in the brake and steering system goes near 220 bar (3190 psi), the
brake and steering pump de-strokes to keep the pressure at 207 bar (3000 psi).
If the pressure in the system goes near 200 bar (2900 psi), the pump comes back on
stroke, as necessary, to keep the pressure at 207 bar (3000 psi).
If the engine or brake and steering pump becomes unserviceable, the accumulators
supply pressure for the system. Check valves in the brake and steering system do not
let the pressure in the accumulators bleed.
There is a visual and an audio alarm if the pressure in the brake or steering system
goes below 172 bar (2490 psi). You must stop the haul truck as safely and quickly as
possible and shutdown the engine.
If the temperature of the hydraulic oil in the brake and steering system goes higher
than 93 °C (199 °F), an alarm shows on the display panel. After this overtemp alarm
shows, it is necessary to stop the haul truck as safely and quickly as possible and
shutdown the engine.
T282B S/N 327 09-00-01

Brake and Steering System Maintenance Manual
09-00-001 Brake and Steering System
09-00-02 T282B S/N 327

Maintenance Manual Brake and Steering System
General Practices and Specifications
09-02 General Practices and Specifications

The general section of the brake and steering system has the tests and checks that
follow:
Brake and Steering System Pressure Set-Up (Ref. 09-02-400-DA)
Brake and Steering System Pressure Test (Ref. 09-02-500-DA)
Operation
The general section of the brake and steering system has the system schematic that
follows:
Brake and Steering System Schematic (Ref. 09-02-990-DA)
Maintenance Tips
T282B S/N 327 09-02-01

09-02-400-DA - Brake and Steering System Pressure Setup

Setup
Procedure
(Ref. Fig. 09-02-001)
(Ref. Fig. 09-02-002)
Start the engine (Ref. 05-10-900-DA) .

Let the engine operate at idle speed for 15 minutes.
Make sure that the relief valve screw adjuster is fully to the left.
Turn the unloader and pressure compensator adjusters for the brake and steering
pump fully to the right.
Turn the relief valve screw adjuster in right direction until the pressure at G4
shows 275.8 bar (4000 psi).
Turn the unloader adjuster of the brake and steering pump fully to the left.
Use the manual override button of the steering accumulator valve (SV1) to
release the pressure at G4.
Turn the unloader adjuster of the brake and steering pump in right direction until
you hear the pump come on stroke.
The gauge at GPA stops at current setting of the unloader valve. Approximately
1/4 turn is equal to 13.8 bar (200 psi).
Attention! If the unloader adjuster is in too much (to the right) the current setting of the
unloader valve does not show.
Turn the unloader adjuster to the left a small quantity and turn the steering column. This
lets the pump come back on stroke and the current setting of the unloader valve to show.
Turn the unloader adjuster of the brake and steering pump to the right until 220.6
bar (3200 psi) shows at GPA when the pump comes back off stroke.
Compare the pressure at GPA with the pressure at G4.
The two values are usually the same for the time when the pump comes off
stroke.
If the pressures at GPA and G4 are not the same for when the pump comes off
stroke,
Set the pump to come off stroke when G4 is at 220.6 bar (3200 psi).
Read and record the outlet pressures like this:
Read and record the outlet pressure at the GPA port of the pump when the pump
is on stroke.
The GPA with the pump on stroke must be approximately 220 bar (3190 psi).
Read and record the outlet pressure at the GPA port of the pump when the pump
09-02-02 T282B S/N 327

is off stroke.
The GPA with the pump off stroke must be approximately 17 bar (250 psi).
Closeout
T282B S/N 327 09-02-03

09-02-001 Brake and Steering System Pressure Setup
09-02-04 T282B S/N 327

09-02-002 Brake and Steering System Pressure Setup
T282B S/N 327 09-02-05

09-02-500-DA - Brake and Steering System Pressure Test

Setup
Procedure
(Ref. Fig. 09-02-003)
(Ref. Fig. 09-02-004)
(Ref. Fig. 09-02-005)
Start the engine (Ref. 05-10-900-DA) and put the control lever of the haul truck in
the NEUTRAL position.
Set the park brake.
Make sure that the G4 shows 220 bar (3190 psi) when the pump comes off
stroke.
Install pressure gauges at TP1 and SVB.
Apply the brakes.
Record the indication on the pressure gauge at TP1.
The correct pressure at TP1 is 195 to 210 bar (2830 to 3050 psi).
Record the indication on the pressure gauge at SVB.
The correct pressure at SVB is 134 to 141 bar (1940 to 2040 psi).
If the pressures at TP1 and SVB are correct, do this procedure:
Apply the handbrake. and record the indication on the pressure gauges at TP1
and SVB.
Record the indication on the pressure gauge at TP1.
The correct pressure at TP1 is 195 to 210 bar (2830 to 3050 psi).
Record the indication on the pressure gauge at SVB.
The correct pressure at SVB is 134 to 141 bar (1940 to 2040 psi).
If the pressures at TP1 and SVB are correct, do this procedure:
Release the service brakes and use a 0-50 psi gauge to read and record the
pressure in the foot pedal pilot line (Px).
The maximum pressure at Px must be 0.69 bar (10 psi).
pressure for the front brakes (TP1).
The maximum pressure must be 0.34 bar (5 psi).
pressure for the rear brakes (SVB).
The maximum pressure must be 0.34 bar (5 psi).
Install a pressure gauge at PB.
09-02-06 T282B S/N 327

Move the park brake switch to the RELEASE position.

Record the pressure at PB.
The correct pressure at PB is 195 to 224 bar (2830 to 3250 psi),
If the pressure at PB is correct, do this procedure:
Install a pressure gauge on the P port of the flow amplifier valve.
Make sure the engine is at idle speed and record the pressures in this order:
wheels forward with engine at idle speed,
steering LEFT at approximately mid-stroke,
steering LEFT with steering cylinders bottomed out,
steering RIGHT at approximately mid-stroke,
steering RIGHT with steering cylinders bottomed out.
Shutdown the engine (Ref. 05-10-905-DA) , and record the time it takes to bleed
the steering accumulator.
The time to bleed the steering accumulator must be maximum 60 seconds.
Closeout
T282B S/N 327 09-02-07

09-02-003 Brake and Steering System Pressure Test
09-02-08 T282B S/N 327

T282B S/N 327 09-02-09

09-02-10 T282B S/N 327

Brake and Steering System Schematic
09-02-006 Brake and Steering System Schematic
T282B S/N 327 09-02-11

09-02-12 T282B S/N 327

Brake and Steering Pump
09-10 Brake and Steering Pump

(Ref. Fig. 09-10-001)(Ref. Fig. 09-10-002)
There is one brake and steering pump for the brake and steering system. The brake
and steering pump is installed on the dump pump on the driver's side. The brake and
steering pump is mechanically connected to the gears in one of the dump pumps. The
dump pump supplies the mechanical energy to operate the brake and steering pump.
The brake and steering pump takes hydraulic fluid from the brake and steering
hydraulic 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 auto lube
system.
T282B S/N 327 09-10-01

09-10-001 Brake and Steering Pump
09-10-02 T282B S/N 327

09-10-002 Brake and Steering Pump
The brake and steering pump has the components that follow:
Pressure Compensator
Unloader Valve
T282B S/N 327 09-10-03

The brake and steering pump connects to the components that follow:
Unloader Valve Accumulator
Check Valve for Unloader Control
The brake and steering pump is an in-line axial piston pump with a variable output. The
angle of the swashblock sets the output volume of the brake and steering pump. The
larger the angle of the swashblock, the more fluid the pump supplies. The swashblock
is internal to the brake and steering pump. The pistons move over the face of the
swashblock which causes them to move in and out of the pump.
If the pistons move out of the pump, it makes an empty space and atmospheric
pressure pushes fluid from the brake and steering hydraulic tank into the inlet of the
pump to fill the empty space. Then, if the pistons move in, hydraulic oil is pushed out of
pump into the brake and steering hydraulic system. Resistance to the flow of this fluid
causes pressure in the hydraulic system.
Pump Control
The pressure compensator and the unloader valve supply the pump control. They
control the variable output of the brake and steering pump. The pressure compensator
is attached to a control piston and to the swashblock by a control pin. The control pin
can change the angle of the swashblock which changes the output volume of the brake
and steering pump. The unloader valve decreases the output of the pump to about 17
bar (250 psi) when the pump is off stroke.
The unloader valve controls the hydraulic pressure to the brake and steering system. If
the system pressure increases to 220 bar (3190 psi), the brake and steering pump
comes off stroke, and stand by at 17 bar (250 psi). At the time the pump comes off
stroke, the pressure on the other side of the check valve for unloader control is 220 bar
(3190 psi). This pressure decreases because of leakage in the brake and steering
circuit. If the system pressure decreases to 200 bar (2900 psi), the brake and steering
pump comes on stroke until the system pressure increases back up to 220 bar (3190
psi).
The unloader valve accumulator is installed near the hydraulic tank. The function of the
unloader valve accumulator is to supply a precharge of 124 bar (1800 psi) for the
unloader valve.
09-10-04 T282B S/N 327

09-10-100-DA - How to Remove the Brake and Steering Pump

Setup

release the pressure from the steering system (Ref. 09-41-300-DA).
Put the shutoff valve for the brake and steering tank in the closed position (Ref.
07-20-000-DA).
Procedure
(Ref. Fig. 09-10-003)

Put a container below the brake and steering pump (14) to collect the hydraulic
fluid.
Disconnect the hoses (6) and (13) and put protective covers on the open ports.
Remove the capscrews (2), lockwashers (3), clamp halves (4), and o-ring (5).
Put protective covers on the hose (1) and open port.
Disconnect the hose (11).
Remove the capscrews (9), lockwashers (8), clamp halves (7), fitting (10), and
o-ring (12).
Put protective covers on the hose (11) and the open port.
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.
Use an applicable lift device or support to hold the pump (14).

Pull the brake and steering pump (14) away from the dump pump.
Closeout
T282B S/N 327 09-10-05

09-10-003 Removal/Installation of the Brake and Steering Pump
09-10-06 T282B S/N 327

09-10-200-DA - How to Install the Brake and Steering Pump

Setup
Follow the applicable haul truck safety precautions (Ref. 01-16-000-DA) .

Parts Table:

3 Lockwasher 4 53275AN-54
4 Clamp halves 1 53275AN-54
5 O-ring 1 53275AN-54
10 Fitting 1 53275AN-214
12 O-ring 1 53275AN-237
14 Pump 1 51542AJ-32
Procedure
(Ref. Fig. 09-10-003)

Notice! The weight of the pump without the hydraulic fluid is 50 kg (110 lb).
Use an applicable lift device or support to hold the pump (14).

Connect the drive shaft of the brake and steering pump (14) to the dump pump.
Remove the protective covers and connect the hoses (6) and (13).
Remove the protective covers from the hose (11) and the open port.
Install the fitting (10), o-ring (12), capscrews (9), lockwashers (8), and clamp
halves (7).
Connect the hose (11).
Remove the protective covers from the hose (1) and the open port.
Install the hose (1), o-ring (5), capscrews (2), lockwashers (3), and clamp halves
(4).
T282B S/N 327 09-10-07

Closeout
Put the shutoff valve for the brake and steering tank in the open position (Ref.
07-20-000-DA).
Do the brake and steering system pressure setup (Ref. 09-02-400-DA).
09-10-08 T282B S/N 327

Brake and Steering Pressure Filter
09-20 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.
09-20-001 Brake and Steering Pressure Filter
T282B S/N 327 09-20-01

(Ref. Fig. 09-20-001)
The pressure filter works together with the strainers to clean the hydraulic oil in the
brake and steering system. 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.
There are test points on the pressure filter to do a differential pressure check. The
pressure filter rate is 207 bar (3000 psi) maximum with bypass relief at 3.5 bar (50 psi).
If the pressure measurement is 3.5 bar (50 psi) across the test points, then the
hydraulic oil is going through the bypass and not going through the pressure filter.
There is an element in the pressure filter that cleans the hydraulic oil. The element can
be removed for inspection and replaced.
Maintenance Tips
To do a test of the pressure across the pressure filter, the temperature of the hydraulic
oil must be 40 to 65 °C (104 to 149 °F) and the engine at high idle, approximately 1650
rpm.
09-20-002 Brake and Steering Pressure Filter
09-20-02 T282B S/N 327

09-20-100-DA - How to Remove the Pressure Filter

Setup
Procedure
(Ref. Fig. 09-20-003)

Put a container below the pressure filter (8) to collect the hydraulic fluid.
Disconnect the hose (5) and put protective covers on the hose and open port.

Make sure that the lift device that can hold this weight.
Remove the capscrews (2), flange (1), pressure filter (8), and o-rings (9).
Closeout
T282B S/N 327 09-20-03

09-20-003 Removal/Installation of the Pressure Filter
09-20-04 T282B S/N 327

09-20-200-DA - How to Install the Pressure Filter

Setup

Parts Table:

1 Flange 1 53275AN-99
8 Pressure filter 1 53275AN-72
9 O-ring 2 53275AN-65
Procedure
(Ref. Fig. 09-20-003)

Remove all the protective caps from the pressure filter (8).

Install the o-rings (6), pressure filter (8), and capscrews (2).
Install the flange (1), capscrews (7) and lockwashers (6).
Remove the protective covers and connect the hose (5).
Closeout
T282B S/N 327 09-20-05

09-20-700-DA - How to Do the Servicing Procedure for the

Setup

Make sure that the engine is not in operation (Ref. 05-10-905-DA).
Bleed the brake accumulators (Ref. 09-52-300-DA).
Bleed the steering accumulator (Ref. 09-41-300-DA).
Make sure that the hydraulic fluid in the brake and steering system is cool.
Close the supply and return shutoff valves for the brake and steering system on
the hydraulic tank (Ref. 07-20-000-DA).
Procedure
(Ref. Fig. 09-20-004)
Do a visual check of the visual indicator (2) and record the result.
Put an applicable container below the pressure filter to collect the hydraulic oil.
Turn the plug (1) one and a half turns to open.
Remove the bleed plug (8) and let the hydraulic oil drain.
Tighten the plug (1).
Remove filter housing (6), and the filter element (5).
Examine the o-rings (3), (4), and (7) for damage or wear.
If the visual indicator is out, or the brake and steering pump has a catastrophic
failure,
Replace the filter element (5) and flush the system.
If the haul truck is at the first 100 hour or the 1000 hour preventive maintenance,
Replace the filter element (5).
Do an inspection of the pressure filter, filter element (5), and o-rings (3), (4), and
(7).
Replace any parts that have damage.
Install the o-rings (3) and (4), filter element (5), and filter housing (6).
Make sure that the o-rings (3) and (4) are correctly installed.
Tighten the filter housing (6) to not more than 20 Nm (180 lbf in.).
Make sure that the visual indicator (2) is pushed fully in.
Install the bleed plug (8) and o-ring (7).
Closeout
09-20-06 T282B S/N 327

Open the supply and return shutoff valves for the brake and steering system on
the hydraulic tank (Ref. 07-20-000-DA).
Start the engine (Ref. 05-10-900-DA) and let the engine operate until the brake
and steering system is at usual temperature of operation.
Make sure there are no leaks.
T282B S/N 327 09-20-07

09-20-004 Brake and Steering Pressure Filter Servicing
09-20-08 T282B S/N 327

Brake and Steering Manifold
09-30 Brake and Steering Manifold

The brake and steering manifold is installed on the left side of the haul truck on the
frame forward of the hydraulic tank. The brake and steering manifold is the junction
between the brake and steering pump and the brake and steering systems.
(Ref. Fig. 09-30-001)
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 TCU.(Ref. 05-20-000-DA) 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.
There are five test ports to apply hydraulic pressure:
G1 - front brake
G2 - rear brake
G3 - steering
G4 - system
G5 - park brake
The three bleed valves to bleed the brake and steering accumulators are:
NV1 and NV2 - for the brake system
SV1 - for the steering system
T282B S/N 327 09-30-01

09-30-001 Brake and Steering Manifold
The brake and steering manifold connects to the systems that follow:
09-30-02 T282B S/N 327

Auto Lube System (Ref. 10-10-000-DA)
09-30-002 Brake and Steering Manifold
The manifold also has pressure outputs to the auto lube system and 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.
T282B S/N 327 09-30-03

09-30-100-DA - How to Remove the Brake and Steering Manifold

Setup

Procedure
(Ref. Fig. 09-30-003)

Put a container below the manifold (7) to collect the hydraulic fluid.
Mark and disconnect the wires (6).
Mark and disconnect the electrical connector (8) from the park brake solenoid.
Mark and disconnect the electrical connector (9) from SV1.
Mark and disconnect the hoses (5) and put protective covers on the hoses and
open ports.
Notice! The weight of the brake and steering manifold is 31 kg (68.3 lb).
Use an applicable lifting device that can hold the weight.
Remove the capscrews (3), lockwashers (4), and manifold (7).
Closeout
09-30-04 T282B S/N 327

09-30-003 Removal/Installation of the Brake and Steering Manifold
T282B S/N 327 09-30-05

09-30-200-DA - How to Install the Brake and Steering Manifold

Setup

Parts Table:

7 Manifold 1 53275AN-207
Procedure
(Ref. Fig. 09-30-003)

Notice! The weight of the brake and steering manifold is 31 kg (68.3 lb).
Remove all protective caps from the manifold (7).

Install the manifold (7), capscrews (3), and lockwashers (4).
Connect the wires (6).
Connect the electrical connector (8) to the park brake solenoid.
Connect the electrical connector (9) to SV3.
Closeout
09-30-06 T282B S/N 327

Steering System
09-40 Steering System

The steering system has the components that follow:
Steering Accumulator (Ref. 09-41-000-DA)
Flow Amplifier Valve (Ref. 09-42-000-DA)
Steering Control Valve (Ref. 09-43-000-DA)
Steering Cylinders (Ref. 09-44-000-DA)
Tie Rod (Ref. 09-45-000-DA)
Idler Arm Assembly (Ref. 09-46-000-DA)
Steering Arm (Ref. 09-47-000-DA)
Steering Stop Pads (Ref. 09-48-000-DA)
Operation
(Ref. Fig. 09-40-001)
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 (Ref. 01-00-000-DA) that shows when the pressure in
the steering system goes below 172 bar (2490 psi). It is necessary to safely and
quickly stop the haul truck when this alarm shows.
T282B S/N 327 09-40-01

Steering System
09-40-001 Steering System
09-40-02 T282B S/N 327

Steering System
09-40-400-DA - Toe-In Check

Setup

Make sure that the suspensions are set to the parameters in the suspension
inspection check (Ref. 11-10-400-DA).
Make sure that the haul truck is empty.
Park the haul truck on a level surface and put chocks on the rear tires.
Procedure
(Ref. Fig. 09-40-002)
Adjust the steering to the center so that the idler arm is parallel with the center
line of the main frame.
-or-
So that the distance from the two sides of the idler arm to the steering stop pads is the
same.
Lift the front of the haul truck until the front tires are off the ground a small
distance (Ref. 12-02-000-DA).
Measure the pin to pin lengths of the two tie rods and record.
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,
Toe-in is correct.
-or-
If (X) is not equal to 254 mm (10 in.) less than (Y), or the pin to pin lengths of the
two tie rods are not the same,
Do a toe-in adjustment (Ref. 09-40-505-DA).
Closeout
T282B S/N 327 09-40-03

Steering System
09-40-002 Toe-In Check
09-40-04 T282B S/N 327

Steering System
09-40-500-DA - Steering Encoder Test

Setup

Take a measurement of both left and right steering cylinder rods and adjust the
front wheels to the center.
Procedure
Connect the computer to the Siemens communication port on the dash.

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:
Make the selection APPLICATION-OBSERVER from the pull-down menu and
push ENTER.
There is a command for CONNECTOR 1.
Use the keyboard to add the data "$WST".
Push the ENTER button continually until the values start to scroll down the
screen.
Push CONTROL C to stop the scrolling.
The values shown are the percentage values 0 to 100 percent.
Move the steering control fully left or fully right and repeat the test.
The values change. A value of zero percent equals zero degrees. A value of 100
percent equals 250 degrees.
To do the test without the values shown continuously, do this procedure:
Make the selection APPLICATION-CONNECTOR from the pull-down menu (do
not push ENTER).
Use the keyboard to add the data "$WST" AND PUSH enter.
Move the steering control fully left or fully right and repeat the test.
The values change. A value of zero percent equals zero degrees. A value of 100
percent equals 250 degrees.
To do a check of the voltage of the steering encoder, do this procedure:
Use a voltmeter to measure the voltage at 1XT-56, or Con B-89, or at the
steering encoder.
Closeout
T282B S/N 327 09-40-05

Steering System
09-40-505-DA - Toe-In Adjustment

Setup
Follow the applicable haul truck safety precautions (Ref. 01-16-000-DA) .

Make sure that the suspensions are set to the parameters in the suspension
inspection check (Ref. 11-10-400-DA).
Park the haul truck on a level surface and put chocks on the rear tires.
Procedure
(Ref. Fig. 09-40-003)
-or-
So that the distance from the two sides of the idler arm to the steering stop pads is the
same.
Lift the front of the haul truck until the front tires are off the ground a small
distance (Ref. 12-02-000-DA).
Loosen the tie rod clamps.
Turn the tie rods with a pipe wrench to adjust their length with this procedure:
Adjust the length so that (X) is 254 mm (10 in.) less than (Y).
Notice! The tie rods have opposite threads at opposite ends.

Turn the tie rods in the applicable direction to adjust their length.
Align the joint of the tie rod clamp with the compression relief of the tie rod tube.
The tie rod clamps will clear the frame when the haul truck turns fully or the
suspension is fully retracted.
Tighten the bolts of the rod clamps to 245 Nm (180 lbf ft).
Completely lower the front of the haul truck and remove the lift device.
Put a load in the haul truck.
Park the haul truck on a level surface and put chocks on the rear tires
Take a measurement of (X) and (Y).
Calculate (Z) = (Y) - (X).
If (Z) is between zero and ±25 mm (0.984 in.),
The toe-in is correct.
09-40-06 T282B S/N 327

Steering System
If (Z) is not between zero and ±25 mm (0.984 in.),

Adjust the toe-in.
If the toe-in cannot be adjusted correctly,
See your Liebherr service representative.
Closeout
09-40-003 Toe-In Adjustment
T282B S/N 327 09-40-07

Steering System
09-40-08 T282B S/N 327

Steering Accumulator
09-41 Steering Accumulator

There is one steering accumulator for the steering system. The steering accumulator is
installed forward of the fuel and hydraulic tank on the left side of the haul truck.
System Operation
(Ref. Fig. 09-41-001)
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 (1700 psi). The steering accumulator
has a 170 L (45 U.S. gal) capacity.
During operation, hydraulic fluid from the brake and steering pump keeps the pressure
in the accumulator at 200 to 220 bar (2900 to 3190 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 (Ref. 09-41-300-DA).
T282B S/N 327 09-41-01

09-41-001 Steering Accumulator
09-41-02 T282B S/N 327

09-41-100-DA - How to Remove the Steering Accumulator

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 09-41-002)

Put a container below the accumulator (1) to collect the hydraulic fluid.
Remove the capsrews (9), lockwashers (10), clamp halves (7), and o-ring (6).
Discard the o-ring (6).
Put protective covers on the hose (11) and open port.
Notice! The weight of the accumulator (dry) is 850 kg (1850 lb).

Attach an applicable lift device to the accumulator (1).

Remove the nut (5), washer (3), lockwasher (4), and the u-bolt (2).
Remove the accumulator (1).
Closeout
T282B S/N 327 09-41-03

09-41-002 Removal/Installation of the Steering Accumulator
09-41-04 T282B S/N 327

09-41-200-DA - How to Install the Steering Accumulator

Setup

01-20-000-DA).
09-41-100-DA).
Parts Table:

1 Accumulator 1 53275AN-75
2 U-bolt 2 53275AN-94
3 Washer 2 53275AN-18
5 Nut 2 53275AN-4
6 O-ring 1 53275AN-53
9 Capscrews 4 53275AN-53
10 Lockwashers 4 53275AN-53
Procedure
(Ref. Fig. 09-41-002)



Put the accumulator (1) in position on the haul truck.
Install the u-bolt (2), nut (5), washer (3), and lockwasher (4).
Remove the protective covers from the hose (11) and port.
Install the hose (8), o-ring (6), clamp halves (7), capscrews (9), and lockwashers
(10).
T282B S/N 327 09-41-05

Closeout
Make sure that the steering accumulator has the correct initial charge (Ref.
09-41-400-DA).
09-41-06 T282B S/N 327

09-41-300-DA - Steering Accumulator System Bleed

Setup
Procedure
(Ref. Fig. 09-41-003)

Make sure the engine is stopped.

The system automatically bleeds down in three to five minutes.
After three to five minutes, on the brake and steering manifold, push SV1 in and
turn counter clockwise a 1/4 turn to the OUT position.
Make sure that no pressure remains in the system.
Put the SV1 knob back to its initial position.
Closeout
T282B S/N 327 09-41-07

09-41-003 Steering Accumulator System Bleed
09-41-08 T282B S/N 327

09-41-400-DA - Steering Accumulator Precharge Check

Setup

The nitrogen charging and gauging kit (Liebherr P/N T-107-T Ref. 02-00-000-DA)
is necessary for this procedure.
Procedure
(Ref. Fig. 09-41-004)
Make sure the bleeder valve (1) is fully out in the closed position.
Disconnect the tank hose assembly (4) from the charging assembly (5).
Remove the valve cap (7).
Connect the adapter (3) to the valve stem (8).
Tighten the adapter (3) by hand securely enough to prevent gas leakage, but do
not tighten too much.
Danger! The nitrogen gas is pressurized in the accumulator.

The pressurized gas can cause serious injury and can force the valve stem assembly from the
accumulator if the valve assembly is turned before the pressure is released.
Make sure that only the small swivel nut turns and always put on protective clothing,
gloves, and face and eye shields when charging or discharging the system.
Put a 3/4 inch wrench on the swivel nut (9) of the valve stem (8).
Turn the swivel nut (9) counterclockwise four full turns, or until the initial charge
pressure shows on the gauge (6).
Record the pressure indication.
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).
If the accumulator pressure is more than 117.2 bar (1700 psi), do this procedure:
Decrease the steering accumulator initial charge (Ref. 09-41-700-DA).
If the accumulator pressure is less than 117.2 bar (1700 psi), do this procedure:
Increase the steering accumulator charge (Ref. 09-41-705-DA).
Closeout
T282B S/N 327 09-41-09

09-41-004 Steering Accumulator Precharge Check
09-41-10 T282B S/N 327

09-41-700-DA - Steering Accumulator Precharge Drain

Setup

Procedure
(Ref. Fig. 09-41-005)

Turn the swivel nut (9) counterclockwise four full turns, or until the charge
Carefully open and close the bleeder valve (1) until the necessary pressure is
shown on the gauge.
-or-
Open the bleeder valve (1) until all the pressure is released from the accumulator.
Closeout
T282B S/N 327 09-41-11

09-41-005 Steering Accumulator Precharge Drain
09-41-12 T282B S/N 327

09-41-705-DA - Steering Accumulator Precharge Replenishment

Setup


Type 1, Grade F Nitrogen CGA Specification G-10 or higher Commercially Available
Procedure
(Ref. Fig. 09-41-006)
Make sure the bleeder valve (1) and shutoff valve (2) are fully out in the closed
position.
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.
If can be necessary to replace the installed nipple with T-107-B and the installed nut with
T-107-A.


Turn the swivel nut (9) to the left four full turns, or until the initial charge pressure
shows on the gauge (6).
Slowly open the nitrogen tank valve and the shutoff valve (2), then close the two
valves to let the gauge (6) adjust.
If the accumulator pressure is more than 117.2 bar (1700 psi), do this procedure:
Reduce the precharge in the accumulator (Ref. 09-41-700-DA).
If the correct quantity of pressure, 117.2 bar (1700 psi), shows on the gauge (6),
T282B S/N 327 09-41-13

do this procedure:
Close the shutoff valve (2) and the nitrogen tank valve.
Disconnect the tank hose assembly (4) from the nitrogen tank.
Closeout
09-41-14 T282B S/N 327

09-41-006 Steering Accumulator Precharge Replenishment
T282B S/N 327 09-41-15

09-41-16 T282B S/N 327

Flow Amplifier Valve
09-42 Flow Amplifier Valve

The flow amplifier valve is installed on the lower, forward crossmember on the left side
of the haul truck.
09-42-001 Flow Amplifier Valve
The flow amplifier valve increases the flow of the hydraulic fluid from the steering
column to the steering cylinders.
T282B S/N 327 09-42-01

09-42-100-DA - How to Remove the Flow Amplifier Valve

Setup

Procedure
(Ref. Fig. 09-42-002)
(Ref. Fig. 09-42-003)
Remove the capscrews (15), lockwashers (16), and cover (17).

Put a container below the flow amplifier valve (13) to collect the hydraulic fluid.
Remove the capscrews (10), clamp halves (11), o-ring (12), and elbow (9).
Remove the capscrews (7), clamp halves (6), and o-ring (5).
Remove the capscrews (2), clamp halves (3), and o-ring (4).
Disconnect the hoses (14).
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 (63.9 lb).

Remove the capscrews (18), lockwashers (19), and flow amplifier valve (13).
Closeout
09-42-02 T282B S/N 327

09-42-002 Removal/Installation of the Flow Amplifier Valve
T282B S/N 327 09-42-03

09-42-003 Removal/Installation of the Flow Amplifier Valve
09-42-04 T282B S/N 327

09-42-200-DA - How to Install the Flow Amplifier Valve

Setup

Parts Table:

4 O-ring 3 53275AN-51
5 O-ring 1 53282AC-55
6 Clamp halves 1 53282AC-55
7 Capscrew 4 53282AC-55
12 O-ring 1 53275AN-52
13 Flow amplifier valve 1 53275AN-86
17 Cover 1 53275AN-139
Procedure
(Ref. Fig. 09-42-002)
(Ref. Fig. 09-42-003)

Notice! The weight of the flow amplifier valve is 29 kg (63.9 lb).
Install the flow amplifier valve (13), lockwashers (18), and capscrews (19).
Remove the protective covers from the hoses (1), (8), (9), (14), and ports.
Put the hoses (1) in position and install the o-rings (4), clamp halves (3), and
capscrews (2).
Put the hose (8) in position and install the o-ring (5), clamp halves (6), and
capscrews (7).
Put the hose (9) in position and install the o-ring (12), clamp halves (11), and
capscrews (10).
T282B S/N 327 09-42-05

Connect the hoses (14).

Install the cover (17), lockwashers (16), and capscrews (15).
Closeout
09-42-06 T282B S/N 327

Steering Control Valve
09-43 Steering Control Valve

The steering control valve is installed on the bottom of the steering column below the
floor of the cab.
09-43-001 Steering Control Valve
The steering control valve sends hydraulic fluid, in proportion to the movement of the
steering wheel, to the flow amplifier valve.
T282B S/N 327 09-43-01

09-43-100-DA - How to Remove the Steering Control Valve

Setup

Procedure
(Ref. Fig. )

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

Put protective covers on the hoses (3) and (4) and all open ports.
Remove the capscrews (1), lockwashers (2) and steering control valve (5).
Closeout
09-43-02 T282B S/N 327

09-43-002 Removal/Installation of the Steering Control Valve
T282B S/N 327 09-43-03

09-43-200-DA - How to Install the Steering Control Valve

Setup

Parts Table:

1 Capscrew 4 53273-B-6
2 Lockwasher 4 53273-B-12
5 Steering control valve 1 53273-B-13
Procedure
(Ref. Fig. 09-43-002)

Put the steering control valve in the correct position to the steering column.
Install the lockwashers (2) and capscrews (1).
Remove the protective covers from the hoses (3) and (4), and all ports.
Install the hoses (3) and (4), remove the identifying tags and make sure all hoses
go to the correct ports.
Closeout
09-43-04 T282B S/N 327

Steering Cylinders
09-44 Steering Cylinders

(Ref. Fig. 09-44-001)
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:
09-44-001 Steering Cylinders
Operation
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.
The steering cylinders operate with pistons and use rubber piston seals that are
resistant to synthetic oil.
Maintenance Tips
Defective rubber piston seals could cause a leak in the steering cylinders and the
steering to be slow.
T282B S/N 327 09-44-01

Steering Cylinders
09-44-100-DA - How to Remove the Steering Cylinders

Setup

Bleed the accumulators (Ref. 09-41-300-DA).
Procedure
(Ref. Fig. 09-44-002)
Disconnect the hydraulic lines (1) and lubrication hoses (11).

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 (430 lb).
Put an applicable support at the two ends of the cylinder (9).

Remove the lockwire from the capscrews (6).
Remove the lockwashers (18), locknuts (19), capscrews (13), washers (15), and
rotation stop (16).
Pull out the pin (17).
Remove the capscrews (6) and (8), cap(5), and pin (7).
Remove the steering cylinder (9).
Remove the seals (4), retainers (2), and spacers (3) and (10).
Remove the bushings (12).
Closeout
09-44-02 T282B S/N 327

Steering Cylinders
09-44-002 Removal/Installation of the Steering Cylinders
T282B S/N 327 09-44-03

Steering Cylinders
09-44-200-DA - How to Install the Steering Cylinders

Setup

Make sure the haul truck is in the same condition as the removal procedure (Ref.
09-44-100-DA).

Grease 2.5% or more Molybdenum Disulfide 5079-A
Liquid Nitrogen Commercially available
03-12-000-DA)
Lockwire 51014AE-10
Parts List:

2 Retainer 4 51014AE-14
3 Spacer 2 51014AE-27
4 Seal 4 51014AE-38
5 Cap 1 51014AE-20
6 Capscrew 2 51014AE-4
7 Pin 1 51014AE-33
9 Steering Cylinder 1 51014AE-17
10 Spacer 2 51014AE-59
12 Bushing 2 51014AE-15
15 Washer 2 51014AE-64
16 Rotation Stop 1 51014AE-61
17 Pin 1 51014AE-29
18 Lockwasher 1 51014AE-6
19 Locknut 1 51014AE-5
Procedure
(Ref. Fig. 09-44-002)
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.
Put the bushings (12) in an applicable container and fill with liquid nitrogen.
09-44-04 T282B S/N 327

Steering Cylinders
Install the lower retainers (2).

Install the bushings (12) and hold in position while the bushings (12) stabilize.
Install the upper retainers (2).
Notice! The weight of the steering cylinder without hydraulic fluid is 196 kg (430 lb).
Put an applicable support at the two ends of the cylinder (9).

Put the steering cylinder (9) in position on the haul truck.
Install the spacers (3) and (10), and seals (4).
Carefully align the retainers (2), spacers (3) and (10), and seals (4).
Apply a thin coat of ant-seize to the pins (17) and (7).
Install the pins (17) and (7).
Lubricate the capscrews (8), (13) and locknut (19) with permatex® anti-seize.
Install the capscrews (6), (8), (13), locknut (19), lockwasher (18), washers (15),
and rotation stop (16).
Tighten the locknuts (19) to 410 Nm (300 lbf ft).
Remove the protective caps and connect the hydraulic lines (1) and lubrication
hoses (11).
Lubricate the bushings (12) with grease.
Closeout
T282B S/N 327 09-44-05

Steering Cylinders
09-44-405-DA - How to Check the Steering Cylinder for Leaks

Setup
Procedure
Pressurize one end of the steering cylinder until it is fully extended or fully
retracted.
Put a flow meter in line at the other end of the steering cylinder.
Hold the steering cylinder in that position and do a flow check at the low pressure
port.
If the oil continues to flow,
Replace the piston seals.
Pressurize the opposite end of the steering cylinder until it is fully extended or
fully retracted.
Hold the steering cylinder in that position and do a flow check at the low pressure
port.
If the oil continues to flow,
Replace the piston seals.
If oil shows on the rod or rod head area,
Replace the extension rod seal.
Closeout
09-44-06 T282B S/N 327

Tie Rods
09-45 Tie Rods

(Ref. Fig. 09-45-001)
The tie rods connects to the assemblies that follow:
Kingpin, Spindle (Ref. 12-12-000-DA), and Steering Arm (Ref. 09-47-000-DA)
09-45-001 Tie Rods

If the idler arm moves, it causes the tie rods to move in opposite directions. The tie
rods push or pull on the steering arm to change the direction of the wheels.
The ends of the tie rod have threads. The only difference between the ends of the tie
rod is they have opposite threads. One end is left threads and the other end is right
threads.
The tie rods can be adjusted for toe-in to align the wheels.
Maintenance Tips
Incorrect wheel alignment wears the tires quickly. Regular maintenance to the wheel
alignment can increase tire life.
T282B S/N 327 09-45-01

Tie Rods
09-45-100-DA - How to Remove the Tie Rods

Setup
Procedure
(Ref. Fig. 09-45-002)
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.
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 (405 lb).

Make sure that the lifti device can hold the weight.
Put a support at the two ends of the tie rod (7).

Remove the lockwasher (13), locknut (14), capscrews (9), washers (11), and
rotation stop (12).
Notice! The weight of the pin is 16 kg (35.27 lb).

Pull out the pins (6).

Remove the tie rod (7).
Remove the seals (5), capscrews (3), retainers (2), and spacers (4) and (8).
Remove the bushings (1).
Closeout
09-45-02 T282B S/N 327

Tie Rods
09-45-002 Removal/Installation of the Tie Rods
T282B S/N 327 09-45-03

Tie Rods
09-45-200-DA - How to Install the Tie Rods

Setup

Make sure the haul truck is in the same condition as the removal procedure (Ref.
09-45-100-DA).

03-12-000-DA)
Parts Table:

1 Bushing 2 51014AE-15
4 Spacer 2 51014AE-26
5 Seal 4 51014AE-35
6 Pin 2 51014AE-28
7 Tie Rod 1 51014AE-31
8 Spacer 2 51014AE-58
11 Washer 2 51014AE-64
12 Rotation Stop 1 51014AE-61
14 Locknut 1 51014AE-5
Procedure
(Ref. Fig. 09-45-002)

Very cold liquids can cause serious personal injury.
Put the bushings (1) in an applicable container and fill with liquid nitrogen.
Install the lower retainers (2).
Install the bushings (1) and hold in position while the bushings (1) stabilize.
Install the upper retainers (2).
Lubricate the capscrews (3) with anti-seize and install.
09-45-04 T282B S/N 327

Tie Rods
Notice! The weight of the tie rod is 184 kg (405 lb).

Put an applicable support below the tie rod (7).

Put the tie rod (7) in position.
Install the spacers (8) and (4), and the seals (5).
Carefully align the spacers (4) and (8), seals (5), and bushings (1) with the tie rod
(7).

Install the pins (6).

Lubricate the capscrews (9) and locknuts (14) with anti-seize.
Install the capscrews (9) and the locknuts (14).
Install the lockwashers (13), washers (11), and rotation stop (12).
Tighten the locknuts (14) to 410 Nm (300 lbf ft).
Bend the tab of the lockwasher (13) into the slot of the locknut (14).
Lubricate the bushings (1) with grease.
Closeout
T282B S/N 327 09-45-05

Tie Rods
09-45-06 T282B S/N 327

Idler Arm Assembly
09-46 Idler Arm Assembly

(Ref. Fig. 09-46-001)
The idler arm assembly interfaces with the assemblies that follow:
Tie Rods (Ref. 09-45-000-DA)
Steering Cylinders (Ref. 09-44-000-DA)
Steering Stop Pads (Ref. 09-48-000-DA)
09-46-001 Idler Arm Assembly

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.
T282B S/N 327 09-46-01

Idler Arm Assembly
09-46-100-DA - How to Remove the Idler Arm Assembly

Setup

Put an applicable support below the idler arm assembly.
Remove the tie rods (Ref. 09-45-100-DA).
Remove the steering cylinders (Ref. 09-44-100-DA).
Procedure
(Ref. Fig. 09-46-002)
Disconnect the lubrication hoses (25).

Disconnect the steering encoder cable (7).
Remove the screws (5) and the retaining bracket (8).
Remove the capscrews (13), the lockwashers (14), and the drive plate (15).
Carefully remove the steering encoder (6) and the coupling (1).
Notice! The weight of the idler arm assembly is 376 kg (830 lb).
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.
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.

The pin can fall when the retainer is removed.
Support the pin if necessary.
Remove the capscrews (23), washers (24), and retainer (20).
09-46-02 T282B S/N 327

Idler Arm Assembly

Make sure that you are prepared to hold the weight.
Remove the key (21), and pin (16).

If the lower bearing (19) is not removed with the retainer (20),
Remove the lower bearing (19).
Attention! The idler arm assembly holds the upper spacer in position.
The upper spacer can fall when the idler arm assembly is removed.
Support the upper spacer if necessary.
Move the idler arm assembly (22) to the rear of the haul truck and out of the
crossmember.
Remove the seals (11) and (18), and the spacers (12) and (17).
Closeout
Do an inspection of the pins and bearings (Ref. 09-46-400-DA).

T282B S/N 327 09-46-03

Idler Arm Assembly
09-46-002 Removal/Installation of the Idler Arm Assembly
09-46-04 T282B S/N 327

Idler Arm Assembly
09-46-200-DA - How to Install the Idler Arm Assembly

Setup

(Ref. 09-46-100-DA).

03-12-000-DA)
Adhesive Loctite 277 5084-E
Parts Table:

1 Coupling 1 51014AE-50
2 Shims AR 51014AE-39, 40, 41, 53
3 Washer 8 51014AE-65
10 Bearing 1 51014AE-18
11 Seal 1 51014AE-16
12 Spacer 1 51014AE-37
15 Drive Plate 1 51014AE-49
16 Pin 1 51014AE-34
17 Spacer 1 51014AE-37
18 Seal 1 51014AE-16
19 Bearing 1 51014AE-18
21 Key 1 51014AE-12
22 Idler Arm Assembly 1 51014AE-23
24 Washer 8 51014AE-65
Procedure
(Ref. Fig. 09-46-002)
If the bearing (19) is removed from the retainer (20),

Put the bearing (19) into the retainer (20).
T282B S/N 327 09-46-05

Idler Arm Assembly
Notice! The weight of the idler arm assembly is 376 kg (830 lb).
Put an applicable support below the idler arm assembly (22).

Move the idler arm assembly (22) into position on the crossmember.
Align the pin boss with the upper and lower bearing ports in the frame.

Make sure that you are prepared to hold the weight.
Install the pin (16) in the hole so that it is centered from top to bottom.
Turn the pin (16) and install the key (21).
Install the lower spacer (17) and the lower seal (18).
Make sure the lower seal (18) is square with the crossmember bore and flush
with the top surface of the bottom of the crossmember.
Install the bearing (19) and retainer (20).
Lubricate the capscrews (23) with anti-seize.
Install the upper spacer (12) and the upper seal (11).
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.
Install the drive plate (15) and coupling (1).
Install the bearing (10) and the retainer (9).
Lubricate the capscrews (4) with permatex® anti-seize.
Install four of the capscrews (4) and washers (3).
Evenly, tighten the capscrews (4) to 53 Nm (39 lbf ft).
Loosen the capscrews (4) and then tighten to 14 Nm (120 lbf in.).
Measure the gap between the retainer (9) and the top surface of the upper
crossmember boss with a feeler gauge.
Take the average of the measurements and remove 0.254 mm (0.01 in.) to
determine the amount of shim necessary.
Install the necessary shims (2).
Install the retainer (9) and washers (3).
09-46-06 T282B S/N 327

Idler Arm Assembly
Apply Loctite 277 to the capscrews (4) and install.

Connect the auto-lube supply hoses (25).
Lubricate the bearings (10) and (19) with grease and make sure that the hole is
fully filled with grease.
Install the steering encoder (6), retaining bracket (8), and screws (5).
Make sure the split is away from the other spring pins.
Connect the steering encoder cable (7).
Closeout
Install the steering cylinders (Ref. 09-44-200-DA).

Install the tie rods (Ref. 09-45-200-DA).
Lubricate all the pivot points of the front end with grease.
T282B S/N 327 09-46-07

Idler Arm Assembly
09-46-400-DA - How to Inspect the Idler Arm Pin and Bearing

Setup
Remove the idler arm assembly (Ref. 09-46-100-DA).
Attention! The bearing is usually damaged during removal from the retainer.
Replace the bearing if it is damaged.
Remove the bearing from the retainer.
Procedure
(Ref. Fig. 09-46-003)
Measure the idler arm bore.

The original dimensions of a new idler arm bore are from 114.325 to 114.452 mm
(4.501 to 4.506 in.).
Measure the bearing bore in the retainer.
The original dimensions of a new bearing bore are from 164.950 to 164.975 mm
(6.494 to 6.495 in.).
Measure the diameter of the bearings.
The original dimensions of a new bearing are from 109.985 to 110.000 mm (4.33
to 4.331 in.),
Measure the diameter of the pin.
The original dimensions of a new pin are from 114.198 to 114.300 mm (4.496 to
4.5 in.).
Replace the components that are worn.
Closeout
09-46-08 T282B S/N 327

Idler Arm Assembly
09-46-003 Idler Arm Pin and Bearing Inspection
T282B S/N 327 09-46-09

Idler Arm Assembly
09-46-10 T282B S/N 327

Steering Arm
09-47 Steering Arm

(Ref. Fig. 09-47-001)
The steering arm connects to the assemblies that follow:
Tie Rod (Ref. 09-45-000-DA)
King Pins and Spindle (Ref. 12-12-000-DA)
09-47-001 Steering Arm

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.
T282B S/N 327 09-47-01

Steering Arm
09-47-100-DA - How to Remove the Steering Arm

Setup

Remove the tie rod from the steering arm (Ref. 09-45-100-DA).
Procedure
(Ref. Fig. 09-47-002)
Notice! The weight of the steering arm is 201 kg (445 lb).

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.
Remove and discard the capscrews (1).

Remove the spacers (2).
Remove and discard the capscrews (5).
Remove the washers (4).
Remove the steering arm (3).
Closeout
09-47-02 T282B S/N 327

Steering Arm
09-47-002 Removal/Installation of the Steering Arm
T282B S/N 327 09-47-03

Steering Arm
09-47-200-DA - How to Install the Steering Arm

Setup

(Ref. 09-47-100-DA).

Parts Table:

1 Capscrew 8 933523301-4
2 Spacer 8 933523301-11
3 Steering Arm 1 933523301-1
3A Steering Arm, opposite 1 933523401-1
4 Washer 8 933523301-3
5 Capscrew 8 933523301-2
Procedure
(Ref. Fig. 09-47-002)
Notice! The weight of the steering arm is 201 kg (445 lb).

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.
Lubricate the new capscrews (1) and (5) with anti-seize.

Install the steering arm (3) to the spindle with the capscrews (1), spacers (2),
capscrews (5), and washers (4).
Tighten the capscrews (1) and (5) to 3530 Nm (2600 lbf ft).
Closeout
Install the tie rod to the steering arm (Ref. 09-45-200-DA).

09-47-04 T282B S/N 327

Steering Stop Pads
09-48 Steering Stop Pads

(Ref. Fig. 09-48-001)
The steering stop pads interface with the assemblies that follow:
09-48-001 Steering Stop Pads

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.
T282B S/N 327 09-48-01

Steering Stop Pads
09-48-100-DA - How to Remove the Steering Stop Pads

Setup
Procedure
(Ref. Fig. 09-48-002)
Remove the capscrew (4).

Remove the stop pad (3).
Remove the plate (2) and shim (5).
Closeout
09-48-02 T282B S/N 327

Steering Stop Pads
09-48-002 Removal/Installation of the Steering Stop Pads
T282B S/N 327 09-48-03

Steering Stop Pads
09-48-200-DA - How to Install the Steering Stop Pads

Setup


03-12-000-DA)
Parts Table:

2 Plate 1 51014AE-43
3 Stop Pad 1 51014AE-42
5 Shim 2 51014AE-68
Procedure
(Ref. Fig. 09-48-002)
Install the shim (5).

Install the plate (2).
Lubricate the capscrews (1) with permatex® anti-seize and install.
Install the stop pad (3).
Install the capscrew (4).
Closeout
09-48-04 T282B S/N 327

Brake System
09-50 Brake System

The brake system connect to the components that follow:
Brake and Steering System (Ref. 09-00-000-DA)
Foot Pedal Controls
Operation
(Ref. Fig. 09-50-001)
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 (Ref. 01-00-000-DA) 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 (Ref. 01-00-000-DA). Wheel 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 (Ref. 01-00-000-DA) that shows when the pressure in
the brake system goes below 172 bar (2490 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.
T282B S/N 327 09-50-01

Brake System
09-50-001 Brake System
09-50-02 T282B S/N 327

Brake System
Brake System Components

(Ref. Fig. 09-50-002)
The brake system has the components that follow:
Brake Accumulators (Ref. 09-52-000-DA)
Brake Pedal (Ref. 04-40-000-DA)
Front Brake Calipers (Ref. 12-32-000-DA)
Rear Brake Calipers (Ref. 12-50-000-DA)
Hand Brake Valve and Manifold (Ref. 09-54-000-DA)
T282B S/N 327 09-50-03

Brake System
09-50-002 Brake System Components
09-50-04 T282B S/N 327

Brake Accumulators
09-52 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.
System Operation
(Ref. Fig. 09-52-001)
The brake accumulators have a 7.57 L (2 U.S. gal) capacity.
The brake and steering pump(s) supplies the brake accumulators with 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 (1800 psi).
During operation, hydraulic fluid from the brake and steering pump(s) keeps the
pressure in the accumulators at 200 to 220 bar (2900 to 3190 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 (Ref. 09-52-300-DA).
T282B S/N 327 09-52-01

Brake Accumulators
09-52-001 Brake Accumulators
09-52-02 T282B S/N 327

Brake Accumulators
09-52-100-DA - How to Remove the Brake Accumulators

Setup

01-20-000-DA).
Procedure

Put a container below the accumulator (1) to collect the hydraulic fluid.
Disconnect the hydraulic hoses (4) and put protective covers on the hoses and
open ports.


Remove the capscrews (2) and lockwashers (3) from the clamps.
Remove the accumulator (1).
Closeout
T282B S/N 327 09-52-03

Brake Accumulators
09-52-002 Removal/Installation of the Brake Accumulators
09-52-04 T282B S/N 327

Brake Accumulators
09-52-200-DA - How to Install the Brake Accumulators

Setup

01-20-000-DA).
09-52-100-DA).
Parts Table:

1 Accumulator 1 53275AN-74
Procedure
(Ref. Fig. 09-52-002)


Attach an applicable lift device to the brake accumulator (1).

Install the accumulator (1) in the clamps.
Connect the hydraulic hoses (4) to the accumulator (1).
Closeout
Make sure that the brake accumulator has the correct precharge (Ref.
09-52-400-DA).
T282B S/N 327 09-52-05

Brake Accumulators
09-52-300-DA - Brake Accumulator System Bleed

Setup
Procedure
(Ref. Fig. 09-52-003)

Make sure the engine is stopped.

Manually open the valves NV1 and NV2 on the brake and steering manifold.
Make sure that no pressure remains in the system.
Close the valves NV1 and NV2.
Closeout
09-52-06 T282B S/N 327

Brake Accumulators
09-52-003 Brake Accumulator System Bleed
T282B S/N 327 09-52-07

Brake Accumulators
09-52-400-DA - Brake Accumulator Precharge Check

Setup

Procedure
(Ref. Fig. 09-52-004)

The pressurized gas could cause serious injury and can force the valve stem assembly from the
Turn the swivel nut (9) counterclockwise four full turns, or until the initial charge
Turn the swivel nut (9) to the right to the fully closed position.
If the accumulator pressure is more than 124 bar (1800 psi), do this procedure:
Decrease the brake accumulator initial charge (Ref. 09-52-700-DA).
If the accumulator pressure is less than 124 bar (1800 psi), do this procedure:
Fill the brake accumulator initial charge (Ref. 09-52-705-DA).
Closeout
09-52-08 T282B S/N 327

Brake Accumulators
09-52-004 Brake Accumulator Precharge Check
T282B S/N 327 09-52-09

Brake Accumulators
09-52-700-DA - Brake Accumulator Precharge Drain

Setup

Procedure
(Ref. Fig. 09-52-005)

gloves, and face and eye shields when you charge or discharge the system.
Carefully open and close the bleeder valve (1) until the necessary pressure is
shown on the gauge.
-or-
Open the bleeder valve (1) until all the pressure is released from the accumulator.
Closeout
09-52-10 T282B S/N 327

Brake Accumulators
09-52-005 Brake Accumulator Precharge Drain
T282B S/N 327 09-52-11

Brake Accumulators
09-52-705-DA - Brake Accumulator Precharge Replenishment

Setup


Procedure
(Ref. Fig. 09-52-006)
Make sure the bleeder valve (1) and shutoff valve (2) are fully out in the closed
position.
Connect and tighten the tank hose assembly (4) from the charging assembly (5)
to the nitrogen tank.
hose assembly.
If can be necessary to replace the installed nipple with T-107-B and the installed nut with
T-107-A.


If the accumulator pressure is more than 124 bar (1800 psi), do this procedure:
Reduce the initial charge in the accumulator (Ref. 09-52-700-DA).
After the correct quantity of pressure, 124 bar (1800 psi), shows on the gauge
09-52-12 T282B S/N 327

Brake Accumulators
(6), do this procedure:

Closeout
T282B S/N 327 09-52-13

Brake Accumulators
09-52-006 Brake Accumulator Precharge Replenishment
09-52-14 T282B S/N 327

Hand Brake Valve and Manifold
09-54 Hand Brake Valve and Manifold

The hand brake valve and manifold is installed below the brake pedal below the floor of
the cab.
09-54-001 Hand Brake Valve and Manifold
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.
T282B S/N 327 09-54-01

09-54-100-DA - How to Remove the Hand Brake Valve and

Manifold
Setup

Procedure
(Ref. Fig. 09-54-002)

Disconnect the hoses (1) and (5).

Put protective covers on the hoses (1) and (5).
Remove the capscrews (4), lockwashers (3), washers (2), and the manifold
assembly hand brake (6).
Closeout
09-54-02 T282B S/N 327

09-54-002 Removal/Installation of the Hand Brake Valve and Manifold
T282B S/N 327 09-54-03

09-54-200-DA - How to Install the Hand Brake Valve and

Manifold
Setup

Parts Table:
REFERENCE TECHNICAL LABEL QUANTITY DRAWING.-ITEM

2 Washer 2 53274-N-58
3 Lockwasher 2 53274-N-57
4 Capscrew 2 53274-N-11
6 Manifold Assembly Hand 1 53274-N-2
Brake
Procedure
(Ref. Fig. 09-54-002)

Install the manifold assembly hand brake (6), capscrews (4), lockwashers (3),
and washers (2).
Remove the protective covers and connect the hoses (1) and (5).
Closeout
09-54-04 T282B S/N 327

Buddy Steering and Braking Components
09-60 Buddy Steering and Braking 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.
(Ref. Fig. 09-60-001)
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 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.
T282B S/N 327 09-60-01

09-60-001 Buddy Steering and Braking Components
There is also a connection for the case drain line. Some remote pumps, such as piston
pumps, use this connection.
09-60-02 T282B S/N 327

09-60-300-DA - Connection and Operation

Setup

Bleed the brake accumulators (Ref. 09-52-300-DA)
Bleed the steering accumulator (Ref. 09-41-300-DA)
Procedure
(Ref. Fig. 09-60-002)
Put the remote hydraulic pump in a safe position on the haul truck.
Connect the pressure hose to the pressure hookup (1) on the brake and steering
manifold.
Connect the suction hose to the suction hookup (2) on the fuel and hydraulic
tank.
If necessary, connect the case drain hose to the case drain hookup (3) on the
bottom of the fuel and hydraulic tank.
Put the battery disconnect switch to the ON position.
Turn the master switch to the ON position.
Start the remote hydraulic pump.
Do a check of the pressure and suction hookups to make sure there are no leaks.
If the case drain connection is connected,
Do a check of the case drain hookup to make sure there are no leaks.
Operate the remote hydraulic pump until the brake and steering accumulators are
fully charged.
Caution! The buddy steering and braking system is used to tow the haul truck to a safe place.
Do not use the steering and braking system more than necessary. Tow the haul truck
slowly.
Caution! The operator of the tow vehicle must be able to speak to the operator of the haul
truck.
Make sure that the operator of the tow vehicle is able to speak to the operator of the haul
truck while you tow the haul truck.
Make sure that you follow the cautions when you tow the haul truck.
Stop the remote hydraulic pump when the haul truck is safely stopped.
Bleed the brake accumulators (Ref. 09-52-300-DA) .
Disconnect the remote hydraulic pump from the haul truck.
T282B S/N 327 09-60-03

Closeout
09-60-04 T282B S/N 327

09-60-002 Connection and Operation
T282B S/N 327 09-60-05

09-60-06 T282B S/N 327

10 Auxilliary Systems
Auto Lube System......................................................................................... 10-10-01
How to Test the Auto Lube System.................................................... 10-10-06
Auto Lube Injector Adjustment............................................................ 10-10-08
Service Procedure for the Auto Lube System..................................... 10-10-11
Gear Oil Cooling Components..................................................................... 10-20-01
How to Remove the Gear Oil Cooling Pump.......................................10-20-05
How to Install the Gear Oil Cooling Pump...........................................10-20-07
Service Procedure for the Gear Oil Filter............................................ 10-20-08
Gear Oil Breather Replacement..........................................................10-20-10
Fire Control System.......................................................................................10-40-01
Liebherr Payload Weigh System.................................................................. 10-50-01
How to Install the Liebherr Payload Weigh System............................ 10-50-04
Description of the LPWS Assembly-Step 1.........................................10-50-08
Visual Check of the Suspensions....................................................... 10-50-16
WEIGH SYSTEM FAULT CODES...................................................... 10-50-17
SOFTWARE LOAD in the ECOPLUS-Step 1..................................... 10-50-19
SOFTWARE LOAD in the ECOPLUS-Step 10................................... 10-50-36
Payload Display Meter...................................................................................10-52-01
Visual Check of the Suspensions....................................................... 10-52-02
LPWS Display Meter Set-Up...............................................................10-52-03
Payload Data Collection Procedure.................................................... 10-52-05
INBOARD and OUTBOARD DISPLAY.......................................................... 10-54-01
LITES Truck Control System........................................................................ 10-60-01

SBS Computer.....................................................................................................................10-80-01
Compact Flash Disc Replacement........................................................................... 10-80-02
SBS Computer Setup with XP Embedded-Step 1....................................................10-80-04
SBS Computer Setup with XP Embedded-Alternate Method...................................10-80-06

10 Auxilliary Systems
Overview
The auxilliary systems on the haul truck are:
Auto Lube System (Ref. 10-10-000-DA)
Gear Oil Cooling System (Ref. 10-20-000-DA)
Fire Control System (Ref. 10-40-000-DA)
Liebherr Payload Weigh System (Ref. 10-50-000-DA)
LITES Truck Control System (Ref. 10-60-000-DA)
SBS Computer (Ref. 10-80-000-DA)
T282B S/N 327 10-00-01

Auxilliary Systems Maintenance Manual
10-00-02 T282B S/N 327

Maintenance Manual Auxilliary Systems
Auto Lube System
10-10 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)(Ref. 10-60-000-DA)
Brake and Steering System (Ref. 09-00-000-DA)
Operation
(Ref. Fig. 10-10-001)
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 controls the
operation time and frequency of the hydraulic lubrication pump. Liebherr Mining
Equipment personnel can adjust the time periods for the operations that follow:
The time between when the haul truck starts and the auto lube system operates
The time between lubrication cycles
The maximum period of time that the lubrication pump is energized.
Manual lube starts when the operator pushes the manual lube switch in the cab. The
manual lubrication operates for a period of 60 seconds but, the Liebherr Mining
Equipment personnel can adjust this time period.
The over flow from the steering and brake amplifier valve supplies the lubrication pump
((Ref. 09-43-000-DA)). The steering has priority on the lubrication pump. The
lubrication pump does not come on if the steering requirement is equal or more than
the brake and steering pump output.
The first auto lube cycle starts after the haul truck is in neutral gear for five minutes.
The lubrication pump stays on for a maximum of one and half minutes if the steering
system requirement is less than the brake and steering pump output. The supply line
reaches the maximum pressure in 15 to 20 seconds. The Ecomat turns off the
lubrication pump two seconds after the supply line got to 172 bar (2490 psi)at the
pressure switch.
After the initial lubrication cycle, the lubrication pump comes on each 20 minutes. 24
volts is sent to the solenoid vent valve when the lubrication pump operates. The pilot
line of the vent valve senses the hydraulic pressure, and the vent valve closes until the
pressure increases in the supply line.
The 24 volts is removed from the vent valve and the pressure in the vent valve pilot
line decreases to 0 bar (0 psi) when the lubrication pump stops. The vent valve opens.
The pressure in the supply line decreases to 0 bar (0 psi) when the vent valve opens.
If after two cycles the auto lube switch (end of line) does not close, the auto lube fault
indicator in the cab starts to flash.
Auto Lube Components

(Ref. Fig. 10-10-002)
The function of the auto lube system is to supply grease to the pivot points on the haul
truck.
The auto lube system has the components that follow:
T282B S/N 327 10-10-01

Auto Lube System
Grease Tank
Lubrication Pump
Vent Valve Assembly
Injectors
Pressure Switch
10-10-02 T282B S/N 327

Auto Lube System
10-10-001 Auto Lube Components
Grease Tank
The grease tank holds 90 kg (198 lb) of grease for the auto lube system.
T282B S/N 327 10-10-03

Auto Lube System
Lubrication Pump
The lubrication pump has a flow control valve, that is set by the factory. You must not
touch the flow control valve. 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 (350
psi) hydraulic pressure. At low inlet pressure of 20 to 25 bar (290 to 360 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 (3150 psi) with the pressure reducing valve set to 24 bar (350 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 11.7 to 31 bar (170 to 450
psi). It is very important that you set the pressure reducing valve and do not touch it
after it is set.
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.
Injectors
The injectors are manually adjusted and then set for the quantity of grease to supply.
The injector has an adjustment screw that controls the quantity of travel for the piston.
The output of grease is at a minimum when the adjustment screw is fully tightened.
Retraction of the adjustment screw increases the grease output .
Pressure Switch
The pressure switch is set to 172 bar (2490 psi). The function of the pressure switch is
to control the maximum supply line pressure.
10-10-04 T282B S/N 327

Auto Lube System
10-10-002 Auto Lube System
T282B S/N 327 10-10-05

Auto Lube System
10-10-500-DA - How to Test the Auto Lube System

Setup
Follow applicable haul truck safety precautions (Ref. 01-16-000-DA).

Do the auto lube servicing (Ref. 10-10-700-DA).
Procedure
Set the park brake.

Put the haul truck in the NEUTRAL position and start the engine.
Run the haul truck engine at idle speed.
The lubrication pump comes on after five minutes.
Let the lubrication pump operate for one minute.
Turn out the adjustment screws on all the injectors eight turns to set the injectors
for the maximum output.
After the first cycle, the lubrication pump comes on one time each 20 minutes.
During the test, monitor the auto lube system:
Make sure that the auto lube alarm does not operate.
Make sure that the test port at the axle box shows 172 to 207 bar (2490 to 3000
psi) at all times.
Do this pressure check with the pressure switch not connected and with the
pressure switch connected.
Make sure that not more than 24 bar (350 psi) shows at the lubrication pump
when the pump operates.
If the auto lube alarm operates,
see your Liebherr service person.
If the test port at the axle box shows less than 172 bar (2490 psi),
adjust the pressure switch at end of the line. See your Liebherr service person.
If the lubrication pump shows more than 24 bar (350 psi) during operation,
turn the pressure reducing valve (adjacent to the pressure port, identified
PR10-32...) of the lubrication pump counterclockwise until the hydraulic pressure
shows 24 bar (350 psi).
Make sure that when the lubrication pump comes on, all the visual indicators on
the injectors move out.
Make sure that when the lubrication pump goes off, all the visual indicators on the
injectors go back to their initial position.
Closeout
10-10-06 T282B S/N 327

Auto Lube System
Adjust the injectors as necessary (Ref. 10-10-505-DA).

T282B S/N 327 10-10-07

Auto Lube System
10-10-505-DA - Auto Lube Injector Adjustment

Setup
Procedure
Remove the plastic cap from the bottom of the injector.

Loosen the stop nut.
Loosen the adjustment screw from the body of the injector.
Tighten the stop nut to the bottom of the adjustment screw.
Push the indicator pin until you make sure that the piston is at the bottom of
stroke.
Tighten the adjustment screw back into the body of the injector five turns.
The injector is at this time adjusted to the full output of 0.75 cubic inch. The
indicator pin must be near the top opening of the adjustment. One turn into the
injector body decrease the output by approximately 0.015 cubic inch.
If there is not enough grease to the pivot point, do this procedure:
Turn the adjustment screw out of the injector to increase the quantity of grease
from the injector.
If there is a large quantity of grease at the pivot point, do this procedure:
Turn the adjustment screw into the injector to decrease the quantity of grease
from the injector.
Set the park brake.
Put the control lever of the haul truck in the NEUTRAL position and start the
engine (Ref. 05-10-900-DA).
Let the engine operate at idle speed.
The lubrication pump comes on after five minutes.
Let the lubrication pump operate for one minute.
Check the pivot points of the haul truck for clean grease.
After the injector is adjusted as necessary, tighten the stop nut, and install the
plastic cap on the injector.
Closeout
10-10-08 T282B S/N 327

Auto Lube System
10-10-003 Auto Lube Injector Adjustment
T282B S/N 327 10-10-09

Auto Lube System
10-10-004 Auto Lube Injector Adjustment
10-10-10 T282B S/N 327

Auto Lube System
10-10-700-DA - Service Procedure for the Auto Lube System

Setup


Grease more than 2.5% Molybdenum 5079-A
Disulfide
Procedure
Inspect the auto lube system.

Inspect all the grease points of the auto lube system for new grease.
If a grease point does not have sufficient grease, do this procedure:
Adjust the lubrication injector (Ref. 10-10-505-DA).
Fill the main reservoir with grease.
Flush all of the lubrication hoses with grease and remove all the air from the
hoses.
Closeout
T282B S/N 327 10-10-11

Auto Lube System
10-10-12 T282B S/N 327

Gear Oil Cooling Components
10-20 Gear Oil Cooling Components

(Ref. Fig. 10-20-001)(Ref. Fig. 10-20-002)(Ref. Fig. 10-20-003)
The cooling system for the gear oil has these components:
Oil Coolers
Oil Filters
Direct Acting Relief Valve
Pump with Hydraulic Motor
Gear oil Cooling Pump
The cooling system for the gear oil has two isolated circuits. One circuit is for the left
rear wheel motor, the other circuit is for the right rear wheel 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 wheel 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 than20.7 bar (300 psi) and the gear oil is released back to 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 206.8 bar (3000 psi). If the hydraulic
pressure is more than 206.8 bar (3000 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 wheel motors does not go through the gear
oil cooling system.
T282B S/N 327 10-20-01

10-20-001 Gear Oil Cooling Components
10-20-02 T282B S/N 327

T282B S/N 327 10-20-03

10-20-04 T282B S/N 327

10-20-100-DA - How to Remove the Gear Oil Cooling Pump

Setup

01-20-000-DA).
Close the dump shutoff valve(Ref. 07-20-000-DA).
Procedure
(Ref. Fig. 10-20-004)
Warning! The hydraulic fluid can cause skin irritation.

Always put on protective clothing and eye protection when you do procedures that involve
hydraulic fluid.
Put a container below the oil cooling pump (5) to collect the hydraulic fluid.
Put protective covers on the hoses (1) and open ports.
Notice! The weight of the oil cooling pump is 16 kg (35.27 lb).

Use an applicable lift device or support that can hold the weight.
Remove the capscrews (2), washers (3), and oil cooling pump (5).
Remove and discard the o-ring (4).
Closeout
T282B S/N 327 10-20-05

10-20-004 Removal/Installation of the Gear Oil Cooling Pump
10-20-06 T282B S/N 327

10-20-200-DA - How to Install the Gear Oil Cooling Pump

Setup

Parts Table:

5 Pump, gear oil cooling 1 51542AJ-30
Procedure
(Ref. Fig. 10-20-004)
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.
Install the o-ring (4).
Notice! The weight of the oil cooling pump is 16 kg (35.27 lb).

Use an applicable lift device that can hold the weight.
Install the oil cooling pump (5), capscrews (2), and washers (3).
Closeout
Put the shutoff valve for the dump tank in the open position (Ref. 10-20-000-DA).
T282B S/N 327 10-20-07

10-20-700-DA - Service Procedure for the Gear Oil Filter

Setup


Oil See recommended lubricants (Ref.
03-12-000-DA)
Parts Table:

1 Filter 2 53365AB-33
Procedure
(Ref. Fig. 10-20-005)
Remove and discard the filters (1).

Fill new filters with the applicable oil.
Install the new filters (1).
Start the haul truck (Ref. 05-10-000-DA).
Disconnect the electrical connector from the gear oil cooling pump to engage the
pump.
The pump moves the oil in the gear oil cooling system.
Do a check for leaks.
Stop the haul truck (Ref. 05-10-905-DA).
Closeout
10-20-08 T282B S/N 327

10-20-005 Gear Oil Filter Servicing
T282B S/N 327 10-20-09

10-20-705-DA - Gear Oil Breather Replacement

Setup

Parts Table:

1 Breather 1 53365AB-108
Procedure
(Ref. Fig. 10-20-006)

Install the new breather (1).
Closeout
10-20-10 T282B S/N 327

10-20-006 Gear Oil Breather Replacement
T282B S/N 327 10-20-11

10-20-12 T282B S/N 327

Fire Control System
10-40 Fire Control System

The fire control system is a dry chemical type. The fire control system protects the
engine compartment and the hydraulic system, the most dangerous areas of the haul
truck.
The fire control system has these functions:
Manual Operation
Automatic Operation (optional)
The fire control system has these components:
The System Control Module
The Console Installed Actuator
The Alarm LED
The Audio Alarm
The Battery Power Source (automatic operation)
Notice! The data that follows is a model of a fire control system.

Refer to the original equipment manufacturer (OEM) of your fire control system for
specified maintenance and operation data.
Operation
Caution! Operation of the fire control system immediately releases the dry chemical.
The system operation stops the engine and can lower the visibility.
Make sure that the haul truck is safely and fully stopped before operation of the fire control
system.
Automatic Operation
If the fire control system senses a fire, the alarm LED flashes and the audio alarm
operates each second. The fire control system is in operation.
After a very short interval, the alarm LED flashes quickly and the alarm operates
continuously. The fire control system is about to release the dry chemical and stop the
engine. After the dry chemical is released, the alarm LED and the audio alarm operate
every six seconds.
The operator must do these steps:
Stop the haul truck in a safe location.
Set the hand brake and park brake.
Stop the engine.
Get out of the haul truck quickly and safely.
Move away from the haul truck to a safe location.
Follow the site safety rules.
T282B S/N 327 10-40-01

Fire Control System
Manual Operation
Hit the plunger actuator installed on the console to put the manual fire control system
in operation. You can operate the fire control system from the ground level actuator.
If there is a fire in the safe area, the operator must do these steps:
Stop the haul truck in a safe location.
Set the hand brake and park brake.
Pull the ring pin and hit the red plunger on the console installed actuator.
Stop the engine.
Get out of the haul truck quickly and safely.
Move away from the haul truck to a safe location.
Follow all applicable site safety rules.
Maintenance Tips
The automatic fire detection system contains battery power source. The battery
module must be replaced when the yellow LOW BATTERY LED and audio alarm
operate at three second intervals.
See your fire control system documentation for more data.
10-40-02 T282B S/N 327

Liebherr Payload Weigh System
10-50 Liebherr Payload Weigh System

The LIEBHERR Payload Weigh System (LPWS) monitors the pressures in the
suspensions as the haul truck moves and records the payload data for download
analyses.
The improvements installed on the LPWS make the system stable. The LPWS can
provide better measures of the pressures in the haul truck suspensions when a loaded
or unloaded haul truck moves. The LPWS can give additional data for analyses when
the information is downloaded.
The payload weigh system has the components that follow:
Four transducers
Payload Display Meter (Ref. 10-52-000-DA)
Inboard and Outboard Display Meters (Ref. 10-54-000-DA)
Payload Weigh System Box
Operation
The four transducers in the suspensions send payload data to the LPWS. The LPWS
takes the suspension data to make the calculations of the payload weight. The payload
data analyses can be used to prevent wear and damage to the suspensions. Refer to
(Ref. Fig. 10-50-001).
The LPWS uses two methods to make the calculations of the payload weight data.
Method A
Method A calculations depend on the correct sequence and operation of the hand
brake. When the haul truck is loaded, internal communications tell the LPWS to start
the calculation of the payload data. Sixty seconds after the haul truck is loaded, the
operator released the hand brake, and the truck does not move, the LPWS records the
payload weight.
Method B
Method B begins payload data calculations when the hand brake is released. The
LPWS begins to receive stable readings from the transducers when the hand brake is
released. The LPWS takes data from the four transducers every tenth of a second
when the truck moves. These data is used to calculate a rolling average and variance
for the past 3 seconds of historical data. After the variance reaches a minimum point (
Minimum Variance = least signal noise), the tonnage calculation is determined. The
payload can be determined dynamically because of the filter algorithm.
Maintenance Tips
A difference between Load A and B is normal and is the result of the truck dynamics.
Load A is the most accurate value, and Load B is the alternative value if an error
occurs with Load A. Improper hand brake sequence and/or quick release of hand
brake before load settling occurs, can result in abnormal Load A values.
T282B S/N 327 10-50-01

Improved Fault Detection

Refer to (Ref. 10-50-405-DA) to know the descriptions of the fault codes.
The suspension parameters are monitored real time during travel to evaluate the state
of suspension charge. A low pressure/charge fault system with two levels is used to
allow assessment of the severity of the suspension fault.
The first level is the warning level. The warning level offers an indication that the
suspension pressures are below the recommended pre-charge specification, but not at
a dangerous level. A warning indicates the requirement to determine a possible
recharge operation at the next maintenance opportunity.
The second level is the fault condition. The fault condition shows that the suspension
requires immediate attention.
Liebherr Payload Weigh System Schematic

Refer to (Ref. Fig. 10-50-001) to know the schematic of the Liebherr Payload Weigh
System.
10-50-02 T282B S/N 327

10-50-001 Liebherr Payload Weigh System Schematic
T282B S/N 327 10-50-03

10-50-200-DA - How to Install the Liebherr Payload Weigh

System
Setup

Parts Table:

1 Assy Weigh System Can 1 53042-F
Procedure
To install the LPWS, do this procedure:

Find the location of the LPWS (Ref. Fig. 10-50-002).
Check and put in the OFF position the battery disconnect switch.
Danger! Failure to put the battery disconnect switch in the OFF position can cause injury to
personnel.
Keep the battery disconnect switch in the OFF position at all times.
Remove the brown wire from DB5-2 and attach to 3GB4-3 (Ref. Fig. 10-50-003).
Attach the brown wire with cable ties.
Add a brown wire from 3GB4-3 to DB5-2.
Mark and identify all terminals and connectors on TB4.
Remove all terminals and connectors from the current weigh system.
Remove the four capscrews (2).
Remove the box (3) of the current payload system.
Install the LPWS (1) with the four bolts (3) (Ref. Fig. 10-50-004).
Add a new brown wire from 3GB4-5 to TB4-F.
Fold the old offload connector in the harness.
Attach the old offload connector with cable ties.
Connect all connectors and terminals to the new LPWS (1).
Closeout
Disconnect the portable computer.

10-50-04 T282B S/N 327

10-50-002 Liebherr Payload Weigh System Installation
T282B S/N 327 10-50-05

10-50-06 T282B S/N 327

T282B S/N 327 10-50-07

10-50-300-DA - Description of the LPWS Assembly-Step 1

Setup
Procedure
(Ref. Fig. 10-50-005)
The Liebherr Payload Weigh System Assembly has the connectors that follow:
1. OFF-LOAD. This connector is used to download all information that is stored in the Weigh system
with a standard USB 2.0 Type A-B cable connected to your lap top computer.
2. ECO PROG. This connector is a 9 pin serial connector, DB9, female connector used to load the
program from your computer into the Weigh System and to debug and troubleshoot the Weigh
System.
3. RTC PROG. This connector is a 9 pin serial connector, DB9, female connector that can be used
to download the information that is stored in the Weigh System. It is recommended NOT to use
this because of high noise interference.
4. TB4. This connection is Terminal Board 4 and is used to connect the Weigh System Box to the
Haul Truck.
Closeout
10-50-08 T282B S/N 327

T282B S/N 327 10-50-09


Setup
Procedure
(Ref. Fig. 10-50-006)
The Liebherr Payload Weigh System Assembly has the connectors that follow
(from left to right):
1. PT3. This connector is used to display the tonnage on the inboard and outboard displays.
2. PT2. This connector is used to send the tonnage information to Modular Mining.
3. CAN OPEN. This connector, when in use, can sent live data to the Modular Mining. If not in use,
an RB10 connector must be installed.
Closeout
10-50-10 T282B S/N 327


Setup
Procedure
(Ref. Fig. 10-50-007)
1. LF. This is the connection that receives the signal from the Left Front Transducer.
2. RF. This is the connection that receives the signal from the Right Front Transducer.
3. LR. This is the connection that receives the signal from the Left Rear Transducer.
4. RF This is the connection that receives the signal from the Right Rear Transducer.
Closeout
T282B S/N 327 10-50-11


Setup
Procedure
(Ref. Fig. 10-50-008)
1. USB177X. This Module allows the CANopen network to store and retrieve data and the actual
time and date. Referred to as the Memory Module.
2. 6GB8 is a ground gang block. 12GB2 is a RS232 gang block. 12GB1 is a 24 V gang block.
3. CANRS01 is a Serial Gateway Module for the RS232 port. Referred to as the Serial Gateway
Module.
4. Weigh System ECOMAT Controller is the signal processor of the Weigh System, located below
the Serial Gateway module and the Memory Module.
Closeout
10-50-12 T282B S/N 327

T282B S/N 327 10-50-13


Setup
Procedure
(Ref. Fig. 10-50-009)
1. CAN LITE. This light starts to flash when it searches for the operating system and once the
Master is connected to the operating system it is solid GREEN.
2. NODE ADDRESS. This must be set to 0 4.
3. PORT 1. The TX or RX light flashes when information is sent or received out of PT3 connector.
4. PORT 2. The TX or RX light flashes when information is sent or received out of PT2 connector.
5. DATA RATE. This must be set to 0.
6. MOD LITE. This light is solid green when it is connected to the Can Bus system.
Closeout
10-50-14 T282B S/N 327

T282B S/N 327 10-50-15

10-50-400-DA - Visual Check of the Suspensions

Setup
Procedure
Do a visual check of the suspension or the suspensions for leakage.
Warning! Do not permit the haul truck to travel if the suspensions minimum charge pressure
has decreased below the preliminary charge specification.
Damage and wear to the suspensions and the haul truck frame can occur if haul truck travel is
permitted while the suspension charge pressures decrease below the preliminary charge
specifications.
If the charge pressures decrease below the preliminary charge specification, immediately
do servicing of the suspension.
Make sure that the transducers are connected correctly.

Do a visual comparison of the alignment of the opposite suspension. For
example, right front aligns with the left front strut.
If there are visual problems, refer to the suspensions chapter for service
procedures (Ref. 09-00-000-DA).
If there are no visual problems, download the LPWS data for further analyses
(Ref. 10-52-510-DA).
Closeout
10-50-16 T282B S/N 327

10-50-405-DA - WEIGH SYSTEM FAULT CODES

Know the fault codes of the Liebherr Payload Weigh System.
Description
Fault Code Low Pressure Low Pressure High High Load Load not used
Fault P<600 Warning Pressure Pressure Imbalance Imbalance
for front P<700 for Fault P>5800 warning Fault Warning
P<100 for front P<225 for front P>4800 for
51784AP Rear for small rear P>8000 for front P>7000
Suspension. P<125 for big small rear for small rear
P<150 for all rear no filter P>6500 for P>6200 for
other on signal big rear big rear
Suspensions condition condition
no filter on must be held must be held
signal for 3 seconds for 3 seconds
1 x
2 x
3 x x
4 x
5 x x
6 x x
7 x x x
8 x
9 x x
10 x x
11 x x x
12 x x
13 x x x
14 x x x
15 x x x x
16 x
17 x x
18 x x
19 x x x
20 x x
21 x x x
22 x x x
23 x x x x
24 x x
25 x x x
26 x x x
27 x x x x
28 x x x
29 x x x x
30 x x x x
31 x x x x x
32 x
T282B S/N 327 10-50-17

Fault Code Low Pressure Low Pressure High High Load Load not used
Fault P<600 Warning Pressure Pressure Imbalance Imbalance
for front P<700 for Fault P>5800 warning Fault Warning
P<100 for front P<225 for front P>4800 for
51784AP Rear for small rear P>8000 for front P>7000
Suspension. P<125 for big small rear for small rear
P<150 for all rear no filter P>6500 for P>6200 for
other on signal big rear big rear
Suspensions condition condition
no filter on must be held must be held
signal for 3 seconds for 3 seconds
33 x x
34 x x
35 x x x
36 x x
37 x x x
38 x x x
39 x x x x
40 x x
41 x x x
42 x x x
43 x x x x
44 x x x
45 x x x x
46 x x x x
47 x x x x x
48 x x
10-50-18 T282B S/N 327

10-50-500-DA - SOFTWARE LOAD in the ECOPLUS-Step 1

Setup

Load the software into Ecoplus.
Connect to the Weigh System Box.
Procedure
(Ref. Fig. 10-50-010)
Select ONLINE (on top).

Select LOGIN.
Select RUN.
Closeout
10-50-010 Software Load in the Ecoplus
T282B S/N 327 10-50-19


Setup

Do the previous procedure (Ref. 10-50-500-DA).
Procedure
Select the Visualization Tab. You see several sub-folder tabs (Ref. Fig.
10-50-011).
Visualization–Source Code Debug. These visualizations are only for development
purposes and are not supported.
Visualization–Truck Setup and Service. These visualizations are for Field use. All
necessary functionality are provided here.
1. Setup: Visualization associated with commissioning of the system are available here.
2. Debug: Visualizations associated with debugging system problems are provided here.
Do the next procedure (Ref. 10-50-510-DA).
Closeout
10-50-20 T282B S/N 327

T282B S/N 327 10-50-21


Setup

Procedure
(Ref. Fig. 10-50-012)
Double Click “Part A”.

Press Truck Type Button until the correct truck type is selected, ( T252, T262,
T272, T282).
Select appropriate transducer type for each transducer, (3000PSI, 4000PSI,
5000PSI).
LF is Left Front
RF is Right Front
LR is Left Rear
RR is Right Rear
Notice! If you use the 8000 PSI transducers, set them to the 5000 PSI.
The transducers are rated at 1V/1000psi same as the 5000 PSI transducers. The 4000 PSI are
rated 5V/400 PSI.
Set the transducers correctly.
Select Voltage type of Transducer. (0 to 5V, or 0 to 10V). Set to 0 to 5V.

Select Display units, (English Tons or Metric Tons).
Select Display Behavior.
Display Always: Outside display for shovel operator always displays load.
Display When Weighing: Displays only when the truck is stopped.
Notice! You must save the changes.

If you do not save the changes, you lose the information you just entered.
Save your changes.
Save the Changes.
Closeout
10-50-22 T282B S/N 327

T282B S/N 327 10-50-23


Setup

Procedure
(Ref. Fig. 10-50-013)
Press “PART B”.

This visualization is for the recording Reference Information.
Enter Truck Number (1 to 4 digits).
Enter Optional Comments (This is a place to enter a test message, it does not
appear in the download).

If you do not save the changes, you lose the information you just entered.
Save your changes.
Save the Changes.

Closeout
10-50-24 T282B S/N 327

T282B S/N 327 10-50-25


Setup

Procedure
Press “PART C” (Ref. Fig. 10-50-014).

This visualization is for the INPUT of the Empty Wheel Weight.
If CAN network has NOT initialized you must troubleshoot the system.
If the CAN network has initialized, set the empty weight by moving the truck to a
level surface with the dump body empty. Copy the Truck Tons Value to the
Empty Wheel Weight. This value can be changed slightly to compensate for any
system non-liniarity (Ref. Fig. 10-50-015).

If you do not save the changes, you will lose the information you just entered.
Save your changes.
Save the Changes.

Closeout
10-50-26 T282B S/N 327

T282B S/N 327 10-50-27

10-50-28 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-50-016)
Press “PART D”.

This visualization is intended to give the user the ability to fine tune some system
parameters.
Define Minimum Bucket Size: Usually set less then a full bucket. A good starting
point is half full bucket.
Truck Load Level: This is the load value set for a full truck. A good starting point
is half truck capacity.
Truck Overload Level: This is when the truck is overloaded and a signal is sent to
the Siemens system to lower the maximum speed the truck can travel.

If you do not save the changes, you will lose the information you just entered.
Save your changes.
Save the Changes.

Closeout
T282B S/N 327 10-50-29

10-50-30 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-50-017)
Press “Debug and then Part_A_IO_Monitor”.

This visualization is intended to give the user the ability to troubleshoot the
system by changing the inputs or outputs.
DISCRETE INPUTS:
Truck Moving: True or False
Hand Brake Engage: True or False
Dump Body is Up: True or False
DISCRETE OUTPUTS:
Truck Not Loaded: True or False
Truck is Overloaded: True or False
Green: True or False (Turns the Green Light ON)
Yellow: True or False (Turns the Yellow Light ON)
Red: True or False (Turns the Red Light ON)
ANALOG INPUTS (TRANSDUCER VOLTAGES):
This allows you to input individual values for the transducers and you will be able to see the read
out in Load tons.
Closeout
T282B S/N 327 10-50-31

10-50-32 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-50-018)
Press “Part_B_Transducer_Debug”.
This visualization is intended to help you to find problems with the transducers.
There is a bar graph above each transducer that you can examine as you correct
the system.
Closeout
T282B S/N 327 10-50-33


Setup

Procedure
Press “Part_C_Test Display” (Ref. Fig. 10-50-019).

This visualization is intended to help you to find problems with the Test Display
Mode.
Press TEST RS232 Connection PT2 from False to True. This will put the system
into a test display mode going to the Modular Mining output. Modular Mining
displays will change “111111” to “222222” until they go to “000000”.
Press TEST RS232 Connection PT3 from False to True. This will put the system
into a test display mode. All displays will change “111111” to “222222” until they
go to “000000”.
Closeout
10-50-34 T282B S/N 327

T282B S/N 327 10-50-35


Setup

Procedure
(Ref. Fig. 10-50-020)
Press “Part_D_Test_Memory_Module”.
The top portion of this Test Memory Module “send S/W Version to Memory
Module: True or False is used by the programmer to troubleshoot the system.
If the RED bar appears and reads“CAN NOT STARTED PLEASE WAIT:0”, then
you have a bus problem.
Closeout
10-50-36 T282B S/N 327

Payload Display Meter
10-52 Payload Display Meter

The LPWS display meter is installed on the accessory panel in the operator cab. The
meter has an LED six-digit display. The first three digits identify the payload weight in
tonnage. The first three digit combination is separated by a hyphen and the two digits
on the right identify the fault codes.
The payload meter shows the codes that follow:
Fault Codes
Operation
The LPWS has communication that shows the suspension or the suspensions where
the fault occurred. The two-digit numeric fault codes are shown on the LPWS display
while the faults occur.
The suspension parameters are monitored hen the haul truck moves and the
suspension charge can be calculated.
The first three numbers on the left of the payload meter show the weight of the load.
The weight is shown in tons or metric tons.
The last two numbers on the right of the payload display meter show the fault code.
Fault Codes
The fault code tells the operator of a problem in the suspension. The fourth and fifth
numbers from the left are the fault code numbers.
Code Suspension
00 no fault
01 left front
02 right front
03 left/right front
04 left rear
05 left front/rear
06 left rear/right front
07 left front/rear, right front
08 right rear
09 right rear/left front
10 right front/rear
11 right front/rear, left front
12 right/left rear
13 right/left rear, left front
14 right/left rear, right front
15 check all
For example: 190-00. This indicates a 190 ton payload with no fault codes. The
Tonnage is 190. The separator is (-). The Fault code is 00.
If a condition occurs where a fault code repeats continuously, do a visual check of the
related suspension, or suspensions. Refer to (Ref. 10-52-400-DA).
T282B S/N 327 10-52-01

10-52-400-DA - Visual Check of the Suspensions

Setup
Procedure
Do a visual check of the suspension or the suspensions for leakage.
Warning! Do not permit the haul truck to travel if the suspensions minimum charge pressure
decreased below the preliminary charge specification.
Damage and wear to the suspensions and the haul truck frame can occur if haul truck travel is
permitted while the suspension charge pressures have decreased below the preliminary charge
specifications.
If the charge pressures decrease below the preliminary charge specification, immediately
service of the suspension.
Make sure that the transducers are connected correctly.

Do a visual comparison of the alignment of the opposite suspension. For
example, right front aligns with the left front strut.
If there are visual problems, refer to the suspensions chapter for service
procedures (Ref. 09-00-000-DA).
If there are no visual problems, download the LPWS data for further analyses
(Ref. 10-52-510-DA).
Closeout
10-52-02 T282B S/N 327

10-52-500-DA - LPWS Display Meter Set-Up

Setup

Put the master ignition switch to the ON position.
Procedure
(Ref. Fig. 10-52-001)
(Ref. Fig. 10-52-002)
Remove the front cover from the LPWS.

Push the S1 and the S2 buttons at the same time to enter the setup mode.
Release the S1 and the S2 buttons.
Push S1 to get to the next function and push S2 or S3 to change the value of the
functions that follows:
dc 1 = OFF
ADD = 1
br = 1920
EH = ON
Just = r
Term =1
Push S1 to return to the ready mode.
Replace the front cover for the payload meter.
The Setup Messages read:
dc1=OFF. dc1 has an OFF position and an ON position value. The LDWS version
is not shown when you change the dc1 value to the OFF position.
ADD = 1. The ADD is the location that holds the address. If 1 is selected as the
address, the system responds to the queries that are sent to address 1. The
address ranges from 0 to 255.
br = 1920. Baud Rate Setup (Br). This message tells the count of the baud rate
for the RS-232/RS-485 output.
EH = ON. This line is used to set the echo command to automatic (ON) or
manual (OFF). The LPWD automatically retransmits all serial data when the echo
command is set to ON.
Just = r. f. This message location lets an input of a character strings without limit.
The six characters before the end of a string is shown and all other characters
are ignored when the right option is selected.
Term =1. Input String Terminator: This message location sets the count for the t
ENTER key can be operated before the termination of a string and change the
display.
T282B S/N 327 10-52-03

Closeout
10-52-001 LPWS Display Meter Set-Up
10-52-002 LPWS Display Meter Set-Up
10-52-04 T282B S/N 327

10-52-510-DA - Payload Data Collection Procedure

Setup

1. Connect a portable computer to the LPWS data port.
Procedure
(Ref. Fig. 10-52-003)
Start <PROGRAMS> + RTC_MemModule.

Continue to the next step (Ref. 10-52-515-DA).
Closeout
10-52-003 Payload Data Collection Procedure
T282B S/N 327 10-52-05


Setup

Complete the previous procedure (Ref. 10-52-510-DA).
Procedure
(Ref. Fig. 10-52-004)
Launch the RTC_MemModule and select interface tab.

Closeout
10-52-06 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-005)
Connect to the Memory Module.

Select Mode: USB
Select Access Point: 1
Select OK
Closeout
T282B S/N 327 10-52-07


Setup

Procedure
(Ref. Fig. 10-52-006)
Select “Connect” on the USB1792 – CANopen Memory Module, by INC,LLC

Closeout
10-52-08 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-007)
Select Download Path and Filename.

Closeout
T282B S/N 327 10-52-09


Setup

Procedure
(Ref. Fig. 10-52-008)
Select Data Path and Filename and Save.

Closeout
10-52-10 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-009)
(Ref. Fig. 10-52-010)
Verify the Configuration.

Press the Settings Tab.
Make sure the Settings the same as shown in the illustration.
Closeout
T282B S/N 327 10-52-11

10-52-12 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-011)
(Ref. Fig. 10-52-012)
Select Download Settings.

Make sure the Download Settings are as selected as shown in the illustration.
Closeout
T282B S/N 327 10-52-13

10-52-14 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-013)
(Ref. Fig. 10-52-014)
Verify Correct Time.

If the time is not correct, do this procedure:
Select Set Time/Date Tab.
Set Time as necessary.
Closeout
T282B S/N 327 10-52-15

10-52-16 T282B S/N 327


Setup

Procedure
(Ref. Fig. 10-52-015)
(Ref. Fig. 10-52-016)
(Ref. Fig. 10-52-017)
Select Upload Tab on the top.

Select Upload Memory.
Data Log will be uploaded.
Closeout
T282B S/N 327 10-52-17

10-52-18 T282B S/N 327

T282B S/N 327 10-52-19


Setup

Procedure
(Ref. Fig. 10-52-018)
Open the data log file from the saved location.

The downloaded data starts Microsoft Excel. The data file has the (.xls)
extension.
No headers will come into view, but columns A to AN fill with data.
Columns AA to AN are referred to as the Sandbox.
The information in columns AA to AN have no relevance to the information used
for analyses.
Data shown in column AA to AN are is referred t as the Sandbox Data and at this
time, the information in columns AA to AN have no use.
If an operator tells of continuous fault codes that show on the LPWS display, do a
download of the payload data for further diagnosis and to find the problem.
Closeout
10-52-20 T282B S/N 327

T282B S/N 327 10-52-21

10-52-22 T282B S/N 327

INBOARD and OUTBOARD DISPLAY
10-54 INBOARD and OUTBOARD DISPLAY

The inboard and outboard display panels serve the function of giving the shovel and
truck operator a real time value of the payload.
Operation
If the truck moves the value changes based on the rolling average calculation of Load
method B.
A general fault detection is provided on the inboard display utilizing a fault code
system.
The system records approximately 2887 load cycles, based on a 139 bytes/load with
392K memory available (372K X 1024 = 401408 bytes). If the memory is full, there are
2 settings to determine the action:
Ring Buffer Mode Not Selected-No more Data is recorded
Ring Buffer Mode is Selected- Approximately half of the Data (oldest Data) recorded is
overwritten.
T282B S/N 327 10-54-01

INBOARD and OUTBOARD DISPLAY
10-54-02 T282B S/N 327

LITES Truck Control System
10-60 LITES Truck Control System

The LITES truck control system is the Liebherr Integrated Truck Electronic System
(LITES). LITES is a programmable logic controller (PLC). The haul truck uses LITES to
control and test for specific conditions. LITES shows the operator these conditions on
the controls and indicators (Ref. 04-12-000-DA).
The PLC is referred to as the Ecomat on the electrical schematics.
The PLC has software, written by Liebherr Mining Equipment Co., specially for the
PLC. The PLC monitors and/or controls the devices/functions as follows:
AC Drive System fault indicator
Engine Hour Meter
Auto and Manual Lube
Power OFF sequence for the PLC and the SBS computer
Steering bleed down control
Internal and external park brake indicators
Indicator test on start-up
Ecomat alarm buzzer
Miscellaneous Controls
Operation
AC Drive System Fault Indicator
With the engine in operation and a fault input from the Siemens AC drive system, the
indications that follow will occur:
the drive system fault indicator will come on
the AC drive system alarm buzzer operates
The operator can push the fault reset switch to try to reset the AC drive system and the
drive system fault indicator. If the light stays on, there is a fault that cannot be reset.
Stop the engine and tell maintenance about the problem.
Engine Hour Meter

When the engine is in operation, the MDEC sends a signal to the PLC. The LITES
truck control system shows the hours of operation of the engine on the engine hour
meter.
Auto and Manual Lube

Liebherr Mining Equipment personnel have the software available to adjust the
constants for the timing of the auto lube algorithm.
There are four constants that can be adjusted for the auto lube system, as follows:
lube delay: the initial delay on start up
lube wait: the time between lube cycles
lube_sol_on: the time the auto lube system pumps grease
lube hysteresis: the time differential the grease takes to reach the end of the line switch
T282B S/N 327 10-60-01

LITES Truck Control System
The duration of time for the manual lube is set by the global constant, manual lube on.
The time is defaulted for 60 seconds.
Power OFF Sequence for the PLC and the SBS Computer.
The PLC uses an output to latch the coil of a relay on when the ignition switch is ON.
When the ignition switch is OFF, the relay stays on until the PLC de-energizes it. After
the correct shutdown sequence, the PLC de-energizes itself and the SBS computer.
Steering Bleed Down Control

The relay for the steering bleed down control operates when the master switch turns to
OFF and the engine ON indicator goes OFF.
Interior and Exterior Park Brake Indicators

The Ecomat receives a signal from the park brake pressure switch when the park
brake is activated. The park brake indicator light comes on when the park brake is ON.
Indicator Test on Start-Up

The indicator lights come on for three seconds and you hear the Ecomat buzzer when
the master switch is turned from OFF to IGNITION.
Ecomat Alarm Buzzer

The Ecomat alarm buzzer comes on when an indicator light stays ON and does not
flash. The Ecomat alarm buzzer is tested on start-up.
Miscellaneous Controls
The miscellaneous controls are as follows:
door proximity sensor and associated safety logic
wiper relay controlled by the washer ON switch
door alarm
A buzzer, with a periodic beeping, is an indication of an unsafe condition. For example,
if the cab door is open and the drive selector switch is in forward or reverse.
10-60-02 T282B S/N 327

SBS Computer
10-80 SBS Computer

The SBS computer is installed behind the main dash panel in the cab.
The SBS computer interfaces with the systems and components that follow:
Main Dash Panel (Ref. 04-10-000-DA)
Operation
The function of the SBS computer is to control the display panel. The SBS is the
interface between the Siemens AC drive system and the operator's display panel.
A DC to DC regulator supplies 12 VDC to the SBS computer.
The SBS is a PC7, Pentium III, 700MHz computer. The SBS is programmed at the
Liebherr factory in Newport News with all the necessary hardware and software
installed. Thus, the SBS can operate with minimal setup by service personnel. No
additional software is necessary.
The SBS has a 512 MB compact flash disc for a hard drive. The compact flash disc
has the operation system and the necessary software for the computer to operate. The
operator interface with the SBS is a standard 101/102-key PS/2 keyboard. You must
not install a mouse, thus all selections are done through the keyboard.
The table that follows supplies a small list of the keys to navigate within Microsoft
Windows with the keyboard:
KEY FUNCTION
Alt activate or inactivate the menu bar
Alt+Enter display property sheet for current selection
Alt+F4 close active windows
Alt+Spacebar display shortcut menu for the window
Arrow keys navigate fields within a group
Ctrl+Esc access the Start Menu on the Task bar
Enter activate
Esc cancel
Tab move to the next field of group of fields
The compact flash disc is pre-programmed with the Siemens dash program and the
Liebherr dash configuration (dashcfg). You must not add other software programs to
the SBS. Additional programs can cause a failure in the SBS and necessary
replacement of the compact flash disc.
The Liebherr dash configuration has options that can be configured with the Liebherr
dashcfg tool. The dashcfg tool permits the configuration of Metric or English units of
measure. It also permits the selection to use modular mining, and the selection of text,
such as English or Spanish.
Maintenance Tips
In order for the applications to operate correctly, the PC7 BIOS settings must be
correctly set (Ref. 10-80-500-DA). Settings that are not specified in this manual must
be set to their default value.
T282B S/N 327 10-80-01

SBS Computer
10-80-300-DA - Compact Flash Disc Replacement

Setup
Procedure
Caution! Electrostatic discharge (ESD) damages the computer.

Make sure that you use applicable ESD handling procedures.
Disconnect all cables and connectors from the computer.

Remove the computer and put it, bottom panel up, on a flat surface .
Attention! The screws and the screw holes are easily damaged.
Make sure that you remove the screws carefully.
Carefully remove the screws from the bottom panel.
Notice! There are two ribbon cables that connect the compact flash disc and a floppy drive to
the main board.
Do not remove the two ribbon cables, as the length of the cables is sufficient to permit
removal of the bottom panel.
Carefully lift the bottom panel off and keep the two ribbon cables attached.
Turn the bottom panel over to permit access to the compact flash disc.
Hold the compact flash disc by the sides and lift sufficiently to clear the tongue of
the groove.
Move the compact flash disc a small quantity side to side to disconnect it from the
connector pins.
Remove the compact flash disc.
Install a new pre-programmed compact flash disc from Liebherr Mining
Equipment.
Make sure that the connector pins are fully engaged into the compact flash disc.
Make sure that the tongue of the disc is in the groove.
Install the bottom panel.
Make sure that the front edge of the bottom panel fits in the groove in the front
panel, and that the back edge over hangs the bracket panel.
Carefully install the screws.
Install the computer.
10-80-02 T282B S/N 327

SBS Computer
Connect all cables and connectors to the computer.
Closeout
Send the removed compact flash disc to the Electrical R&D Department at
Liebherr Mining Equipment.
T282B S/N 327 10-80-03

SBS Computer
10-80-500-DA - SBS Computer Setup with XP Embedded-Step 1

Setup
To set the SBS Dash computer with XP Embedded, do this procedure:

Prepare a 3.5 in. Floppy disc with Ghost Installed.
Prepare a USB drive (1GB or larger).
Prepare a USB drive that has a ghost image of the software.
Prepare a keyboard with a PS2 connector.
Procedure
Attention! You need the latest files to do this procedure. The files can be downloaded from
Internet.
Download the latest files from the Liebherr FTP Server:
ftp://lmeprod:etl$7wwqc@ftp.lam.liebherr.com
To download the files from the Liebherr FTP Server with Windows Explorer, do
this procedure:
Press <Window+E> to open a Windows Explorer window.
Put the ftp address in the address field. The address is
ftp://lmeprod:etl$7wwqc@ftp.lam.liebherr.com.
Make sure that you see the window shown on the illustration (Ref. Fig.
10-80-001).
Copy the latest files to your hard drive.
Make sure that you have the documents that follow:
The "How to Document"
The "rawwritewin-0.7.zip" file. This file is used to apply the floppy image to the floppy disc.
The latest XP embedded floppy image (Ghost_Floppy_Image.img).
The XPe Ghost Image. When this procedure was created the latest image was
"XPeTest-17jul07.GHO".
If you are able to finish this procedure correctly, do this:
Continue to (Ref. 10-80-510-DA).
If you cannot finish this procedure and download the latest files, do this:
Closeout
10-80-04 T282B S/N 327

SBS Computer
10-80-001 SBS Computer Setup with XP Embedded-Step 1
T282B S/N 327 10-80-05

SBS Computer
10-80-505-DA - SBS Computer Setup with XP

Embedded-Alternate Method
Setup
Procedure
Notice! To do this procedure you must have access to the Internet.

If you do not have access to the Internet, do this:
Request the last files from LME Engineering.
Download and install the latest version of "Filezilla" from the Internet (Ref. Fig.
10-80-002).
Start "Filezilla" (Ref. Fig. 10-80-003).
Setup Your account (Ref. Fig. 10-80-004).
1. Select >>File>>Site Manager
2. Select >>New Site
3. Put the name "lme_Production_Software"
4. Host: ftp.lam.liebherr.com
5. ServerType: FTP-File Transfer Protocol
6. User: lmeprod
7. Password: etl$7wwqc
8. Press "OK"
Continue to the next procedure (Ref. 10-80-510-DA).
Closeout
10-80-06 T282B S/N 327

SBS Computer
10-80-002 SBS Computer Setup with XP Embedded-Alternate Method
T282B S/N 327 10-80-07

SBS Computer
10-80-08 T282B S/N 327

SBS Computer

Setup

Procedure
Notice! This procedure describes how to create a bootable floppy.

If you have a bootable copy, do not do this procedure.
If you do not have a bootable copy:
Do this procedure.
Create a new folder on your hard drive.

Extract the contents of rawwritewin-07.zip to this folder (Ref. Fig. 10-80-005).
Double-click on rawwritewin.exe (Ref. Fig. 10-80-006).
Insert a floppy disc into your floppy drive.
If you do not have a floppy disc use another computer or a USB to Floppy
adaptor.
Select the file "Ghost_Floppy_Image.img" (Ref. Fig. 10-80-007).
Select "Open".
Select "Write".
The software will apply the image to the floppy disc.
Closeout
T282B S/N 327 10-80-09

SBS Computer
10-80-10 T282B S/N 327

SBS Computer
T282B S/N 327 10-80-11

SBS Computer

Setup

Procedure
Notice! This procedure describes how to put the latest image on an USB Drive.
Do this procedure to know how to put the latest image on an USB Drive.
Copy the XP Embedded Ghost Image to your USB Drive, in the root directory.
When this procedure was created the latest image was "XPeTest-17-Jul07.GHO".
Closeout
10-80-12 T282B S/N 327

SBS Computer

Setup

Procedure
Notice! This procedure describes how to connect to the SBS Computer.

Do this procedure to know how to connect to the SBS Computer.
If you do this step on a truck you have to remove the truck keypad connector.
Connect a keyboard.
If the computer is already connected on the truck do not do this step.
Connect a display.
Apply power.
Closeout
T282B S/N 327 10-80-13

SBS Computer

Setup

Do the previous step (Ref. 10-80-520-DA).
Procedure
Notice! This procedure describes how to adjust the BIOS Settings of the PC7 SBS Computer.
These settings are required in the PC7 Computer for Flash Imaging.
All settings that are not described in this document must be set to its default.
Do this procedure to know how to adjust the BIOS Settings.
Shutdown the SBS PC7 computer.

Connect a standard 101/102-key PS/2 keyboard to the computer.
Start the SBS PC7 computer.
Use the "Auto Configuration with Optimal Settings" menu item on the main menu
and set the system configuration to the default factory values.
Set as follows for the advanced CMOS set-up:
1st boot device: 1st IDE-HDD
2nd boot device: floppy
3rd boot device: ATAPI CDROM
Try Other Boot Devices: Yes
Set as follows for peripheral set-up:
onboard serial port 1: 3F8h, IRQ4
onboard parallel port: Disabled
onboard serial port 3: 3E8h, IRQ11
onboard parallel port 2: Disabled
For the auto-detect hard disks, set as follows:
There are no options here. This will automatically adjust the system configuration for the attached
hard disc(s).
Save the settings and exit as follows:
Make a "Y" selection to save current settings and exit.
10-80-14 T282B S/N 327

SBS Computer
Closeout
T282B S/N 327 10-80-15

SBS Computer

Setup

Procedure
Notice! This procedure describes how to install the Ghost Image.

Do this procedure to know how to install the Ghost Image.
Insert the floppy disc and restart the computer.

The system will start to Norton Ghost with Thumb Drive Support.
Make sure that the screen reads "About Norton Ghost".
Select "Enter".
Use the arrow keys to select the option to restore an image to disc.
1. Local>>Disc>>From Image
2. Select "Enter"
An image selection window appears.
1. Use the Tab key to go to the "Look in" field.
2. Use the Down Arrow key to select "Drive D".
3. Press the Tab key one time.
4. Select the .GHO file. If the file name is very long, DOS will change the name automatically.
5. Select "Enter"
Caution! Use caution to select the Drive that is described in this step.
If you select a different drive, your USB Drive can de corrupted and you have to re-format it.
Select the Drive1.
Select Drive 1.
Press "ALT+O" keys.
Press "ALT+O" keys.
Press "ALT+Y" keys.
GHOST installs the image. You can see the progress indicator.
Remove the floppy when the installation is complete.
Press "ALT+R" keys. This will restart the computer.
10-80-16 T282B S/N 327

SBS Computer
Windows XP starts.
Closeout
T282B S/N 327 10-80-17

SBS Computer

Setup

Procedure
Notice! This procedure describes how to adjust the BIOS Settings of the SBS Computer. These
settings are required to the PC7 Computer so that the applications can operate correctly.
All settings that are not described in this document must be set to its default.
Do this procedure to know how to adjust the BIOS Settings of the SBS Computer.
Apply power to the SBS PC7 Computer .

Connect a standard 101/102-key PS/2 keyboard to the computer.
Start the SBS PC7 computer and press "Delete"at the same time.
Use the "Auto Configuration with Optimal Settings" menu item on the main menu
and set the system configuration to the default factory values.
Set as follows for the advanced CMOS setup:
1st boot device: 1st IDE-HDD
2nd boot device: floppy. The floppy drive is made 2nd boot device to prevent damage to this
drive.
3rd boot device: ATAPI CDROM
Try Other Boot Devices: Yes
Set as follows for peripheral setup:
onboard parallel port: Disabled
onboard parallel port 2: Disabled
For the auto-detect hard disks, do this procedure:
There are no options here. This automatically adjusts the system configuration for the attached
hard disc(s).
Save the settings and exit as follows:
Make a "Y" selection to save current settings and exit.
10-80-18 T282B S/N 327

SBS Computer
Closeout
T282B S/N 327 10-80-19

SBS Computer

Setup

Parts Table:

1 Licence Win XP 1 TI-3013AU-1
2 Licence Microsoft 1 TI-3013AU-2
Procedure
(Ref. Fig. 10-80-008)
Notice! This procedure describes how to correctly finish the setup of the XP Embedded.
Do this procedure to know how to correctly finish the setup of the XP Embedded.
Remove the floppy disc.

Restart the computer.
Check the correct operation of the truck.
Warning! After you check the correct operation of the truck you must cut the watchdog
connector.
The watchdog connector is not necessary. It can cause damage to the SBS PC7 Computer if it
is not inserted correctly.
Make sure that you cut the correct connector.
Identify the connectors correctly.

Cut the WDG I/O connector.
Closeout
10-80-20 T282B S/N 327

SBS Computer
T282B S/N 327 10-80-21

SBS Computer
10-80-22 T282B S/N 327

11 Suspensions
Front Suspension.......................................................................................... 11-10-01
How to Remove the Front Suspension............................................... 11-10-03
How to Install the Front Suspension................................................... 11-10-05
How to Drain the Oil from the Front Suspension.................................11-10-07
How to Fill the Front Suspension with Oil........................................... 11-10-10
How to Discharge the Gas from the Front Suspension.......................11-10-15
How to Charge the Front Suspension with Gas.................................. 11-10-18
How to Check the Front Suspension.................................................. 11-10-21
How to Check the Pressure of the Front Suspension......................... 11-10-22
How to Test the Front Suspension......................................................11-10-25
Front Suspension Specification and Maintenance Tables.................. 11-10-28
Rear Suspension........................................................................................... 11-20-01
How to Remove the Rear Suspension................................................ 11-20-03
How to Install the Rear Suspension.................................................... 11-20-05
How to drain the Oil from the Rear Suspension..................................11-20-07
How to Fill the Rear Suspension with Oil............................................ 11-20-10
How to Discharge the Gas from the Rear Suspension....................... 11-20-15
How to Charge the Rear Suspension with Gas...................................11-20-17
How to Check the Rear Suspension................................................... 11-20-20
How to Check the Pressure of the Rear Suspension..........................11-20-21
How to Test the Rear Suspension...................................................... 11-20-24
Rear Suspension Specification and MaintenanceTables....................11-20-28
Upper and Lower Control Arms................................................................... 11-30-01
How to Remove the Control Arms.......................................................11-30-02
How to Install the Control Arms...........................................................11-30-05
Control Arms Specification and MaintenanceTables.......................... 11-30-08


11 Suspensions
(Ref. Fig. 11-00-001)
The haul truck has an oil and nitrogen suspension system.
The suspension system has the components that follow:
Front Suspension (Ref. 11-10-000-DA)
Rear Suspension (Ref. 11-20-000-DA)
Control Arm Assembly (Ref. 11-30-000-DA)
Overview
The suspension is the support that holds the weight of the haul truck. The suspension
absorbs the vibrations when the haul truck moves over the ground. The suspension
adjusts the height of the haul truck and keeps it level.
T282B S/N 327 11-00-01

Suspensions Maintenance Manual
11-00-001 Suspensions
11-00-02 T282B S/N 327

Maintenance Manual Suspensions
Front Suspension
11-10 Front Suspension

The front suspension is attached to the frame and to the upper control arms (Ref. Fig.
11-10-001). There are lubrication hoses attached to the top and bottom of the
suspension from the auto lube system (Ref. 10-10-000-DA). The front suspension
connects to the assemblies that follow:
Control Arms (Ref. 11-30-000-DA)

There is one suspension for each front wheel. The front 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 and shocks.
T282B S/N 327 11-10-01

Front Suspension
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 holes in the suspension control the movement of the oil.
The suspension has an elastomer rebound pad to prevent damage to the suspension.
The function of the elastomer rebound pad prevents stress to 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.
Maintenance Tips
Usually, when all the pressure is released, then charged again in the suspension,
nitrogen gas goes into solution in the oil. This lowers the pressure after a period of
time. When the pressure is released from the suspensions (new or rebuilt suspensions,
or pressure released for oil fill), you must examine the pressure after 24 hours.
11-10-02 T282B S/N 327

Front Suspension
11-10-100-DA - How to Remove the Front Suspension

Setup

01-20-000-DA).
Remove the tire and rim assembly (Ref. 12-20-100-DA).
Release the nitrogen gas from the front suspension (Ref. 11-10-310-DA).
Procedure
(Ref. Fig. 11-10-003)
Notice! The weight of the lower control arm is 847 kg (1850 lb).
Put an applicable support below the lower control arm and lift the support until
you feel resistance.
Disconnect the lubrication hoses (5) and install protective caps on the hoses (5)
and open ports.
Warning! The suspension cylinder moves in the direction of the frame when the bottom pin is
pulled.
Make sure all personnel are at a safe distance.
Notice! The weight of the front suspension (dry) is 893 kg (1950 lb).
Safely attach an applicable lift device to the lift point on the suspension (6).
Remove the capscrews (1), washers (2), retainer (3), and pin (4).
Use pin puller (Liebherr P/N T-124-C Ref. 02-00-000-DA) to remove the pin (4), if
necessary.
Remove the suspension (6).
Closeout
T282B S/N 327 11-10-03

Front Suspension
11-10-003 Removal/Installation of the Front Suspension
11-10-04 T282B S/N 327

Front Suspension
11-10-200-DA - How to Install the Front Suspension

Setup

01-20-000-DA).
(Ref. 11-10-100-DA).

Parts Table:

2 Washer 6 51011AE-13
4 Pin 2 51011AE-20
6 Suspension 1 51784AW
Procedure
(Ref. Fig. 11-10-003)
Notice! The weight of the front suspension (dry) is 893 kg (1950 lb).
Attach an applicable lift device to the lift point on the suspension (6).
Put the suspension (6) in position.
Notice! The weight of the pin is 66 kg (146 lb).

Install the pin (4).

Apply a thin layer of permatex anti-seize to the capscrews (1).
Install the retainer (3), washers (2), and capscrews (1).
Tighten the the capscrews (1) to 920 Nm (680 lbf ft).
T282B S/N 327 11-10-05

Front Suspension
Closeout
Put oil in the suspension (Ref. 11-10-305-DA).

Pressurize the suspension (Ref. 11-10-310-DA).
11-10-06 T282B S/N 327

Front Suspension
11-10-300-DA - How to Drain the Oil from the Front Suspension

Setup
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.
Fully release the nitrogen gas from the suspension (Ref. 11-20-310-DA).
Procedure
(Ref. Fig. 11-10-004)
Warning! A 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.
To drain the oil from the suspension when the suspension is on the truck, do
this procedure:
Make sure that the suspension (1) is fully retracted against the internal rebound
pad.
Put an applicable container below the suspension to collect the oil.
Remove the drain plug (2).
Let the oil flow into the container.
Replace the drain plug (2).
Refer to the applicable environmental regulations to know how to safely discard
the oil.
Notice! The weight of the suspension is more than 800 kg (1750 lb).
To drain the oil from the suspension when the suspension is removed from the
truck, do this procedure:
Make sure that the suspension (1) is in a vertical position and fully retracted.
T282B S/N 327 11-10-07

Front Suspension

the oil.
Closeout
11-10-08 T282B S/N 327

Front Suspension
11-10-004 Front Suspension Oil Drain
T282B S/N 327 11-10-09

Front Suspension
11-10-305-DA - How to Fill the Front Suspension with Oil

Setup

The nitrogen charge and gauge kit (Liebherr P/N T-107-T Ref. 02-00-000-DA) is
necessary for this procedure.

Fully bleed the nitrogen from the suspension (Ref. 11-20-310-DA).


Oil Mobil Fluid 424 5081-B
Procedure
Caution! Lift the haul truck and install a device that can hold the chassis weight.
When the suspension is retracted fully, enough oil pressure remains in the suspension to create
a hydraulic lock that can prevent metal-to-metal contact.
Remove and keep the haul truck weight from the suspensions.
Notice! This procedure gives the oil fill procedures for the front suspensions that are on the
truck, or removed from the truck.
Know the part number of your front suspension.
You must release the nitrogen from the suspension before you do this procedure.
To fill the front suspension with oil when the suspension is on the truck, do this
procedure:
Lift the haul truck and install a device that can hold the chassis weight.
Keep the chassis supported at all times.
Attention! The suspension oil capacity is 17 L (4.5 U.S. gal).

More oil than specified can cause the suspension to fail.
Measure and add 17 L (4.5 U.S. gal) of oil. Do not add more than the specified amount.
Make sure the nitrogen charge is removed from the suspension.
11-10-10 T282B S/N 327

Front Suspension
Attention! When the suspension is on the truck it is not vertical. This procedure calculates the
angle that the suspension is installed on the haul truck.
The correct dimension "X" determines the correct position of the suspension and you can add
17 L (4.5 U.S. gal) of oil.
Carefully follow this procedure.
To check the oil level, do this procedure:

Lift and hold the haul truck and the control arms to have the correct dimension
“X” shown in the graphic (Ref. Fig. 11-10-005).
X = 53.34 mm (2.1 in.).
Remove the oil fill plug (3) and the oil level plug (1).
Add oil until the oil runs from the oil level port (1).
Warning! When you do this procedure, air cushions can occur in the suspensions.
Release the trapped air from the suspensions.
Lift and lower the control arms to fully extend and retract the suspension and
remove the air.
Make sure that you keep the oil fill port (3) open when you do this step.
Do this a minimum of two times.
Check the oil level at the oil level port (1).
If the oil level is lower, do this procedure:
Add oil until it flows from the oil level port (1).
Lift and lower the control arms to fully extend and retract the suspension,
(minimum two times), remove the air, and check the oil level again.
Repeat all the steps until the oil level is correct.
If the oil level is correct, do this procedure:
Install the plugs in the oil level port (1) and oil fill port (3).
Caution! Suspensions must be extended fully for this step.

If you do not extend the suspensions fully you cannot charge the suspension correctly.
Extend the suspensions correctly (the wheels must not touch the ground).
Lift the haul truck until the suspension is extended fully.

Gas charge the front suspension (Ref. 11-10-315-DA) from 53.46 bar (780 psi) to
56.86 bar (820 psi).
Install the charge/discharge valve cap (5).
T282B S/N 327 11-10-11

Front Suspension
Lower the truck to the ground until the weight of the haul truck is on the
suspensions.
Check the pressure of the suspension on the Liebherr Payload Weigh System.
Return the haul truck to service.
If the suspension is new or repaired and empty of oil, and is NOT on the truck,
do this procedure:
Lift the suspension with a device that can hold the suspension in a vertical
position.
Make sure that the nitrogen pressure is fully released from the suspension.
Attention! The suspension oil capacity is 17 L (4.5 U.S. gal).

Measure and add 17 L (4.5 U.S. gal) of oil. Do not add more than the specified quantity.
fully extend the suspension (Ref. Fig. 11-10-006) and measure 17 L (4.5 U.S.
gal) of Mobil fluid 424 or the LME approved equivalent.
Remove the plug from the oil fill port (3) and add the correct quantity of oil.
Install the plug in the oil fill port (3).
Install the suspension on the truck (Ref. 11-10-200-DA).
Caution! Suspensions must be extended fully for this step.

If you do not extend the suspensions fully you cannot charge the suspension correctly.
Extend the suspensions correctly (the wheels must not touch the ground).
Lift the haul truck until the suspension is extended fully.

Gas charge the front suspension (Ref. 11-10-315-DA) from 53.46 bar (780 psi) to
56.86 bar (820 psi).
Install the charge/discharge valve cap (5).
suspensions.
Check the charge of the suspension on the Liebherr Payload Weigh System.
Closeout
11-10-12 T282B S/N 327

Front Suspension
11-10-005 Front Suspension Oil Fill Procedure
T282B S/N 327 11-10-13

Front Suspension
11-10-006 Front Suspension Oil Fill Procedure
11-10-14 T282B S/N 327

Front Suspension
11-10-310-DA - How to Discharge the Gas from the Front

Suspension
Setup

Procedure
(Ref. Fig. 11-10-007)
To release the pressure from the suspensions when the suspensions are on the
Lift the haul truck to fully extend the applicable suspensions (the wheels must not
touch the ground) (Ref. 12-02-000-DA).
Turn and fully close the bleed valve (1) on the nitrogen charge and gauge kit.
Disconnect the tank hose assembly (4) from the nitrogen charge assembly (5).
Remove the valve cap (7) from the discharge valve on the front suspension.
Use your hand to tighten the adapter (3) to prevent gas leakage.

The pressurized gas can cause injury and can remove the valve stem assembly from the
suspension if the valve assembly is turned before the pressure is released.
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).
Carefully open and close the bleed valve (1) until the necessary pressure is
shown on the gauge.
-or-
Open the bleed valve (1) until all the pressure is released from the suspension.
Open the bleed valve (1).
T282B S/N 327 11-10-15

Front Suspension
Closeout
11-10-16 T282B S/N 327

Front Suspension
11-10-007 Front Suspension Gas Discharge Procedure
T282B S/N 327 11-10-17

Front Suspension
11-10-315-DA - How to Charge the Front Suspension with Gas

Setup

Use a jack to hold the frame of the haul truck (Ref. 12-02-000-DA).
Bleed the nitrogen from the suspension (Ref. 11-10-310-DA).
Check that the oil is at the correct level (Ref. 11-10-305-DA).

Procedure
(Ref. Fig. 11-10-008)
To charge the front suspensions when the suspensions are on the truck, do this
procedure:
Make sure that the applicable suspensions are fully extended.
Turn and fully close the bleed valve (1) and the shutoff valve (2).
Connect and tighten the tank hose assembly (4) from the charge assembly (5) to
the nitrogen tank.
hose assembly.
You can replace the installed nipple with T-107-B and the installed nut with T-107-A.


Use a 3/4 inch wrench to turn the swivel nut (9) left four full turns, or until the
charge pressure shows on the gauge (6).
11-10-18 T282B S/N 327

Front Suspension
Caution! The different types of suspensions have different gas charge pressures.
Know the pressure for your type of suspension.
Pressurize a front suspension on an unloaded haul truck to the value shown in

this table:
Part Number Bar PSI

51784-Y 53.46-56.86 775-825
51784AR 53.46-56.86 775-825
51784AW 53.46-56.86 775-825
9636974 53.46-56.86 775-825
If more pressure than necessary goes into the suspension,

Do the gas discharge procedure (Ref. 11-10-310-DA).
When the correct pressure is shown for the suspension, do this procedure:
Turn the swivel nut (9) right to the fully closed position.
suspensions.
Check the empty weight suspension charge that is shown on the Liebherr
Payload Weigh System (Ref. 10-50-000-DA).
Closeout
Attention! After the pressure is released from a suspension, some gas goes into solution into
the oil.
This condition lowers the pressure in the suspension after a period of time.
Make sure the pressure is correct after 24 hours.
Do a pressure check (Ref. 11-10-405-DA) after 24 hours.
T282B S/N 327 11-10-19

Front Suspension
11-10-008 Front Suspension Gas Charge Procedure
11-10-20 T282B S/N 327

Front Suspension
11-10-400-DA - How to Check the Front Suspension

Setup
Procedure
Examine the suspension for oil leaks.

If there is an oil leak,
Contact your Liebherr service representative.
If there is no oil leak,
Examine the chrome on the suspension.
The parameter(s) must be as shown in this table:
Suspension Condition Parameter(s)

Front Truck is empty 205 to 230 mm (8.071 to 9.055 in.)
Front Truck is loaded 75 to 100 mm (2.953 to 3.937 in.)
Check the nitrogen pressure on the front suspension ( Ref. 11-10-405-DA).

Make sure that the pressure is correct.
If one or more of the values are out of a serviceable parameter, contact your
Liebherr service representative.
Closeout
T282B S/N 327 11-10-21

Front Suspension
11-10-405-DA - How to Check the Pressure of the Front

Suspension
Setup

Procedure
(Ref. Fig. 11-10-009)
Notice! The different trucks have different types of suspensions.

The different types of suspensions have different charge pressures.
Know the type of suspension on your truck.
To check the front suspensions when they are on the truck, do this procedure:
Make sure the bleed valve (1) is fully out in the closed position.
Disconnect the tank hose assembly (4) from the charge assembly (5).
Remove the valve cap (7) from the discharge valve on the rear suspension.
Use your hand to correctly tighten the adapter (3) to prevent gas leakage.

Turn the swivel nut (9) to the left four full turns, or until the charge pressure
11-10-22 T282B S/N 327

Front Suspension
If the front suspension pressure is not in the specified limits, do this procedure:
Pressurize the front suspension (Ref. 11-20-315-DA).
Closeout
T282B S/N 327 11-10-23

Front Suspension
11-10-009 Front Suspension Pressure Check
11-10-24 T282B S/N 327

Front Suspension
11-10-500-DA - How to Test the Front Suspension

Setup
Attention! This test procedure applies to these types of front suspensions- 51784-Y, 51784AR,
51784AW, and 9636974.
Know the type of your suspension.
Procedure
Warning! This is a test procedure only for new or rebuilt suspensions when the suspensions
are removed from the truck.
You must not do this procedure when the suspensions are on the truck.
Carefully follow the steps in the procedure.
position.
Attention! The different types of suspensions have different oil capacities.

Refer to the table at the end of the procedure to know the correct quantity of oil for your
suspension.
Fully retract the suspension and measure the correct quantity of Mobil fluid 424
or the LME recommended equivalent.
Remove the oil fill plug (3).
Fill the suspension with 14 L (3.7 U.S. gal) of oil. This is approximately 80% of
the capacity of the suspension.
Remove the charge valve (2).
Extend and retract the suspension to release the trapped air.
Repeat this step until all air is released from the suspension.
Attention! The total capacity of the suspension is 17 L (4.5 U.S. gal).

Measure the quantity correctly.
Fill the suspension with the oil that remains.

Install the oil fill plug (3) and charge valve (2).
Prepare the nitrogen charge and gauge kit (Liebherr P/N T-107-T (Ref.
02-00-000-DA).
Charge the suspension until the charge pressure on the gauge shows 37.4 bar
(540 psi).
T282B S/N 327 11-10-25

Front Suspension
Close the charge valve (2).

Check the pressure after for 24 hours.
Caution! The pressure must not fall more than 1.4 bar (20 psi).
Make sure that all valves are fully closed.
If the pressure falls more than 1.4 bar (20 psi) you must repair the suspension.
If the pressure is more than 36.1 bar (520 psi) after 24 hours, continue with the
next steps.
Open the charge valve and release the pressure from the suspension.
Make sure that the nitrogen is fully removed from the suspension.
Attention! The next two steps require caution.

The steps must be done quickly.
Retract the suspension until the oil flows from the charge valve.
Stop to retract the suspension and close the charge valve.
Clean the suspension.
Warning! Suspensions must be free of gas pressure before you move the suspensions.
Know the requirements how to move the suspensions.
Prepare the suspension for installation.

To know the quantity of oil for your suspension, refer to this table:
Use the correct quantity of oil specified in this table.
Part Number Liters Quarts Oil. Specification

51784-Y 17 L (4.5 U.S. gal) 18 MOBIL 424
51784AR 17 L (4.5 U.S. gal) 18 MOBIL 424
51784AW 17 L (4.5 U.S. gal) 18 MOBIL 424
9636974 17 L (4.5 U.S. gal) 18 MOBIL 424
Closeout
11-10-26 T282B S/N 327

Front Suspension
11-10-010 Suspension Test Procedure
T282B S/N 327 11-10-27

Front Suspension
11-10-900-DA - Front Suspension Specification and

Maintenance Tables
Setup
Notice! There a different types of suspensions on the different trucks.

Make sure that you know the correct part number of your suspension.


Procedure
Table A is for the oil capacity of the front suspensions.

51784-Y 17 L (4.5 U.S. gal) 18 MOBIL 424
51784AR 17 L (4.5 U.S. gal) 18 MOBIL 424
51784AW 17 L (4.5 U.S. gal) 18 MOBIL 424
9636974 17 L (4.5 U.S. gal) 18 MOBIL 424
Table B is for the value of the dimension "X".
Part Number Millimeter Inch

51784-Y 53.34 2.10
51784AR 53.34 2.10
51784AW 53.34 2.10
9636974 53.34 2.10
Table C is for the gas charge pressure of the front suspensions.
Part Number Bar PSI

51784-Y 53.46-56.86 775-825
51784AR 53.46-56.86 775-825
51784AW 53.46-56.86 775-825
9636974 53.46-56.86 775-825
Closeout
11-10-28 T282B S/N 327

Rear Suspension
11-20 Rear Suspension

The rear suspension is attached to the frame and to the axle box (Ref. Fig. 11-20-001).
There are lubrication hoses attached to the top and bottom of the suspension from the
auto lube system (Ref. 11-10-000-DA). The rear suspension connects to these
assemblies:
Axle Box (Ref. 13-40-000-DA)
T282B S/N 327 11-20-01

Rear Suspension

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 holes
in the suspension control the movement of the oil.
The suspension has an elastomer rebound pad to prevent damage to the suspension.
The elastomer rebound pad prevents stress to 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.
Maintenance Tips
When all the pressure is released, then charged again in the suspension, nitrogen gas
goes into solution in the oil. This condition lowers the pressure after a period of time.
When the pressure is released from the suspensions (new or rebuilt suspensions, or
pressure released for oil fill), you must examine the pressure after 24 hours.
11-20-02 T282B S/N 327

Rear Suspension
11-20-100-DA - How to Remove the Rear Suspension

Setup

01-20-000-DA).
Release the nitrogen gas from the suspension (Ref. 11-20-310-DA).
Procedure
(Ref. Fig. 11-20-003)
Warning! The rear suspension comes down a few inches when the nitrogen gas is released.
Make sure all personnel are at a safe distance.
Put jacks (Ref. 12-02-000-DA) on each side of the frame below the main frame
near the lower dump cylinder anchors.
Lift the frame until the weight is not on the upper suspension pin.
Notice! The weight of the rear suspension without fluids is 722 kg (1600 lb).
Use a lift device that can hold that weight.
Put a safety block below the frame.

Attach an applicable lift device to the suspension (1).

Remove the pin (2) with the suspension removal tool (T-175-A Ref.
02-00-000-DA).
Remove the suspension (1).
Closeout
T282B S/N 327 11-20-03

Rear Suspension
11-20-003 Removal/Installation of the Rear Suspension
11-20-04 T282B S/N 327

Rear Suspension
11-20-200-DA - How to Install the Rear Suspension

Setup

01-20-000-DA).
Make sure that the haul truck is in the same configuration as the removal
procedure (Ref. 11-20-100-DA).

03-12-000-DA)
Parts Table:

1 Suspension 1 51784AX
2 Pin 2 51019-Z-24
3 Retainer 2 51019-Z-25
4 Washer 6 51019-Z-16
5 Capscrew 6 51019-Z-8
Procedure
(Ref. Fig. 11-20-003)
Notice! The weight of the rear suspension without fluids is 722 kg (1600 lb).
Attach an applicable lift device to the suspension (1).

Install the suspension (1).

Install the pin (2).

Install the retainer (3), washers (4), and capscrews (5).
T282B S/N 327 11-20-05

Rear Suspension
Closeout
Put oil in the suspension (Ref. 11-20-305-DA).

Pressurize the suspension (Ref. 11-20-310-DA).
11-20-06 T282B S/N 327

Rear Suspension
11-20-300-DA - How to drain the Oil from the Rear Suspension

Setup

Fully release the nitrogen gas from the suspension (Ref. 11-20-310-DA).
Procedure
(Ref. Fig. 11-20-004)
Warning! A 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.
To drain the oil from the suspension when the suspension is on the truck, do
this procedure:
Make sure that the suspension (1) is in a vertical position and fully retracted
against the rebound pad.
the oil.
Notice! The weight of the suspension is more than 800 kg (1750 lb).
To drain the oil from the suspension when the suspension is removed from the
Make sure that the suspension (1) is in a vertical position and fully retracted.
T282B S/N 327 11-20-07

Rear Suspension

the oil.
Closeout
11-20-08 T282B S/N 327

Rear Suspension
11-20-004 Rear Suspension Oil Drain
T282B S/N 327 11-20-09

Rear Suspension
11-20-305-DA - How to Fill the Rear Suspension with Oil

Setup


Fully bleed the nitrogen from the suspension (Ref. 11-20-310-DA).


Procedure
Notice! This procedure gives the oil fill procedures for all suspensions that are on the truck, or
removed from the truck.
Know the type of your rear suspension.
Before you do this procedure, you must release the nitrogen from the suspension.
To fill the rear suspension with oil when the suspension is on the truck, do this
procedure:
Lift the haul truck and install a device that can hold the chassis weight.
Lift the haul truck and extend the rear suspension until the dimension "X" is equal
to 100 mm (3.937 in.) (Ref. Fig. 11-20-005).
X = 100 mm (3.937 in.).
Connect the gas charge lines to the gas charge valve (2).
Put the ends of the gas charge lines in a container on the ground.
Open the charge valve (2) and release the pressure from the suspension.
Oil can flow in the container when you do this procedure.
Remove the oil fill plug (1).
Install an applicable fill adapter in the oil fill port (1) and connect to an applicable
low-pressure pump.
Make sure that the charge valve (2) is open.
11-20-10 T282B S/N 327

Rear Suspension
Caution! Slowly add the oil to the suspension .

If you add the oil fast you can cause the suspension to extend and lift the truck from the support
that holds the chassis.
Use caution when you add oil to the suspension.
Refer to (Ref. 11-20-900-DA) to know the correct amount of oil.
Use the pump to add oil in the suspension until oil starts to come out of the
charge valve (2) in the container.
Disconnect the pump and the oil fill line from the suspension.
Install the plug in the oil fill port (1).
Keep the gas charge valve (2) open.
Lift the chassis until you fully extend the two rear suspensions to separate
nitrogen from the suspension oil.
Notice! The dimension "X" is measured differently for the different types of suspensions (Ref.
Fig. 11-20-005).
Know how to measure the dimension "X" for your suspension.
Lower the chassis slowly until the dimension "X" on each rear suspension is
equal to the value shown in this Table A:

51784-Z 54 to 60 2 1/4 to 2 1/8
51784-AK 48 to 54 1 7/8 to 2
51784-AX 48 to 54 1 7/8 to 2
51784-AP 25 to 31 1 to 1 1/8
9614138 20 to 26 3/4 to 7/8
The excessive oil flows in the container.

Close the gas charge valve (2).
suspensions.
Make sure that the oil is separated from nitrogen.
Measure the dimension "X".
Attention! The dimension "X" gives information about the correct quantity of oil in the
suspension.
If the dimension "X" is less than the specified value, add oil to the suspension.
Refer table B to know how to calculate the additional quantity of oil.
If the dimension "X" is more than 6 mm (0.236 in.)below the minimum value
shown in Table A, do this:
T282B S/N 327 11-20-11

Rear Suspension
Lift the chassis until the rear suspensions are fully extended.
Refer to the Table B to calculate the quantity of oil to add to the suspension.
Part Number Millimeters per liter Inches per quart

51784-Z 13 1/2
51784-AK 13 1/2
51784-AX 13 1/2
51784-AP 10 3/8
9614138 10 3/8
Remove the weigh system transducer (4).

Add the correct quantity of oil to the suspension.
Inspect the O-ring of the transducer and install the transducer.
Lower the truck to the ground.
If the dimension"X" is less than 6 mm (0.236 in.)below the minimum value shown
in table A, do this:
Remove the gas charge lines from the container and connect the nitrogen charge
and gauge kit (Liebherr P/N T-107-T (Ref. 02-00-000-DA)).
Correctly connect the nitrogen charge and gauge kit.
Adjust the gas charge regulator to 3.44 bar (50 psi) and open the gas charge
valve (2).
Lift the chassis until the suspensions are fully extended.
Attention! If you charge the suspensions, you must refer to (Ref. 11-20-315-DA).
Know how to correctly charge the suspensions with nitrogen.
Table C gives the correct charge pressures for the different types of suspensions.
Charge the suspension with nitrogen to the correct pressure (Ref.

11-20-315-DA). Refer to this Table C:
Part Number Bar PSI

51784-Z 20.7-22.4 300-325
51784-AK 20.7-22.4 300-325
51784-AX 20.7-22.4 300-325
51784-AP 11-12 160-175
9614138 12-13 175-190
Close the charge valve (2).

Remove the nitrogen charge and gauge kit.
Lower the truck to the ground.
Return the truck to service.
11-20-12 T282B S/N 327

Rear Suspension
Closeout
T282B S/N 327 11-20-13

Rear Suspension
11-20-005 Rear Suspension Oil Fill Procedure
11-20-14 T282B S/N 327

Rear Suspension
11-20-310-DA - How to Discharge the Gas from the Rear

Suspension
Setup

Procedure
(Ref. Fig. 11-20-006)
To release the pressure from the suspensions when the suspensions are on the
Lift the haul truck to fully extend the applicable suspensions (Ref. 12-02-000-DA).
Turn and fully close the bleed valve (1).

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).
Carefully open and close the bleed valve (1) until the necessary pressure is
shown on the gauge.
-or-
Open the bleed valve (1) until all the pressure is released from the suspension.
Closeout
T282B S/N 327 11-20-15

Rear Suspension
11-20-006 Rear Suspension Gas Discharge Procedure
11-20-16 T282B S/N 327

Rear Suspension
11-20-315-DA - How to Charge the Rear Suspension with Gas

Setup

Use a jack to hold the frame of the haul truck (Ref. 12-02-000-DA).
Bleed the nitrogen from the suspension (Ref. 11-20-310-DA).
Check that the oil is at the correct level (Ref. 11-20-305-DA).

Procedure
(Ref. Fig. 11-20-007)
To charge the rear suspensions when the suspensions are on the truck, do this
procedure:
Make sure that the applicable suspensions are fully extended.
Turn and fully close the bleed valve (1) and the shutoff valve (2).
Connect and tighten the tank hose assembly (4) from the charge assembly (5) to
the nitrogen tank.
hose assembly.
You can replace the installed nipple with T-107-B and the installed nut with T-107-A.


Use a 3/4 inch wrench to turn the swivel nut (9) left four full turns, or until the
charge pressure shows on the gauge (6).
T282B S/N 327 11-20-17

Rear Suspension
Caution! The different types of suspensions have different gas charge pressures.
Know the pressure for your type of suspension.
Pressurize a rear suspension on an unloaded haul truck to the value shown in

this table:
Part Number Bar PSI

51784-Z 20.7-22.4 300-325
51784-AK 20.7-22.4 300-325
51784-AX 20.7-22.4 300-325
51784-AP 11-12 160-175
9614138 12-13 175-190
If more pressure than necessary goes into the suspension,

Do the gas discharge procedure (Ref. 11-20-310-DA).
When the correct quantity of pressure is shown for the suspension, do this
procedure:
Turn the swivel nut (9) right to the fully closed position.
Lower the haul truck. You can see that the empty weight of the haul truck
compresses the suspension.
Check the empty weight suspension charge that is shown on the Liebherr
Payload Weigh System (Ref. 10-50-000-DA).
Closeout
Attention! After the pressure is released from a suspension, some gas goes into solution into
the oil.
This condition lowers the pressure in the suspension after a period of time.
Make sure the pressure is correct after 24 hours.
Do a pressure check (Ref. 11-20-405-DA) after 24 hours.
11-20-18 T282B S/N 327

Rear Suspension
11-20-007 Rear Suspension Gas Charge Procedure
T282B S/N 327 11-20-19

Rear Suspension
11-20-400-DA - How to Check the Rear Suspension

Setup
Procedure
Examine the suspension for oil leaks.

If there is an oil leak,
Contact your Liebherr service representative.
If there is no oil leak,
Examine the chrome on the suspension.
The parameter(s) must be as shown in this table:
Suspension Condition Parameter(s)

Rear Truck is empty 255 to 280 mm (10.039 to 11.024 in.)
Rear Truck is loaded 76 to 100 mm (2.992 to 3.937 in.)
On the rear suspension, make sure that the nitrogen pressure is correct (Ref.
11-20-405-DA).
If one or more of the values are out of a serviceable parameter, contact your
Closeout
11-20-20 T282B S/N 327

Rear Suspension
11-20-405-DA - How to Check the Pressure of the Rear

Suspension
Setup

Procedure
(Ref. Fig. 11-20-008)
Notice! The different trucks have different types of suspensions.

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, do this procedure:
Make sure the bleed valve (1) is fully out in the closed position.
Use your hand to correctly tighten the adapter (3) to prevent gas leakage.

Turn the swivel nut (9) to the left four full turns, or until the charge pressure
If the rear suspension pressure is not in the specified limits, do this procedure:
T282B S/N 327 11-20-21

Rear Suspension
Pressurize the rear suspension (Ref. 11-20-315-DA).
Closeout
11-20-22 T282B S/N 327

Rear Suspension
11-20-008 Rear Suspension Pressure Check
T282B S/N 327 11-20-23

Rear Suspension
11-20-500-DA - How to Test the Rear Suspension

Setup
Attention! This test procedure applies to all types of rear suspensions.

Know the type of your suspension.
Procedure
Warning! This is a test procedure only for new or rebuilt suspensions when the suspensions
are removed from the truck.
You must not do this procedure when the suspensions are on the truck.
Carefully follow the steps in the procedure.
alignment.
Attention! The different types of suspensions have different oil capacities.

Refer to the table at the end of the procedure to know the correct quantity of oil for your
suspension.
fully extend the suspension and measure the correct quantity of Mobil fluid 424 or
the LME approved equivalent.
Use the weigh system transducer port to add the correct quantity of oil to the
suspension (Ref. Fig. 11-20-009).
Prepare the nitrogen charge and gauge kit (Liebherr P/N T-107-T (Ref.
02-00-000-DA).
Install an applicable plug in the weigh system transducer port and connect the
nitrogen charge and gauge kit to the charge valve (Ref. Fig. 11-20-010).
Charge the suspension until the charge pressure on the gauge shows 37.4 bar
(540 psi).
Close the charge valve.
Check the pressure after for 24 hours.
Caution! The pressure must not fall more than 1.4 bar (20 psi).
Make sure that all valves are fully closed.
If the pressure falls more than 1.4 bar (20 psi) you must repair the suspension.
If the pressure is more than 36.1 bar (520 psi) after 24 hours, continue with the
next steps.
11-20-24 T282B S/N 327

Rear Suspension
Open the charge valve and release the pressure from the suspension.
Make sure that the nitrogen is fully removed from the suspension.
Attention! The next two steps require caution.

The steps must be done quickly.
Retract the suspension until the oil flows from the charge valve.
Stop to retract the suspension and close the charge valve.
Clean the suspension.
Warning! Suspensions must be free of gas pressure before you move the suspensions.
Know the requirements how to move the suspensions.
Prepare the suspension for installation.

To know the quantity of oil for your suspension, refer to this table:
Use the correct quantity of oil specified in this table.

51784-Z 18.5 L (4.9 U.S. gal) 19.5 MOBIL 424
51784AK 18.5 L (4.9 U.S. gal) 19.5 MOBIL 424
51784AX 18 L (4.8 U.S. gal) 19 MOBIL 424
51784AP 37 L (9.8 U.S. gal) 39 MOBIL 424
9614138 44.5 L (11.8 U.S. gal) 47 Liebherr P/N 10330278
Closeout
T282B S/N 327 11-20-25

Rear Suspension
11-20-26 T282B S/N 327

Rear Suspension
T282B S/N 327 11-20-27

Rear Suspension
11-20-900-DA - Rear Suspension Specification and

MaintenanceTables
Setup
Notice! There a different types of suspension on the different trucks.

Make sure that you know the correct part number of your suspension.


Procedure
Table A is for the oil capacity of the rear suspensions.

51784-Z 18.5 L (4.9 U.S. gal) 19.5 MOBIL 424
51784AK 18.5 L (4.9 U.S. gal) 19.5 MOBIL 424
51784AX 18 L (4.8 U.S. gal) 19 MOBIL 424
51784AP 37 L (9.8 U.S. gal) 39 MOBIL 424
9614138 44.5 L (11.8 U.S. gal) 47 Liebherr P/N 10330278
Table B is for the value of the dimension "X".

51784-Z 54 to 60 2 1/4 to 2 1/8
51784-AK 48 to 54 1 7/8 to 2
51784-AX 48 to 54 1 7/8 to 2
51784-AP 25 to 31 1 to 1 1/8
9614138 20 to 26 3/4 to 7/8
Table C gives information how to calculate the quantity of oil to add to the
suspension.
Part Number Millimeters per liter Inches per quart

51784-Z 13 1/2
51784-AK 13 1/2
51784-AX 13 1/2
51784-AP 10 3/8
9614138 10 3/8
Table D is for the gas charge pressure of the rear suspensions.
11-20-28 T282B S/N 327

Rear Suspension
Part Number Bar PSI

51784-Z 20.7-22.4 300-325
51784-AK 20.7-22.4 300-325
51784-AX 20.7-22.4 300-325
51784-AP 11-12 160-175
9614138 12-13 175-190
Closeout
T282B S/N 327 11-20-29

Rear Suspension
11-20-30 T282B S/N 327

Upper and Lower Control Arms
11-30 Upper and Lower Control Arms

(Ref. Fig. 11-30-001)
The upper and lower control arms connects to the assemblies that follow:
Front Suspension (Ref. 11-10-000-DA)
Kingpin, Spindle, and Steering Arm (Ref. 12-12-000-DA)
11-30-001 Upper and Lower Control Arms
Operation
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 allow the front wheel assemblies to move vertically.
T282B S/N 327 11-30-01

11-30-100-DA - How to Remove the Control Arms

Setup

01-20-000-DA).
Remove the front wheel assembly (complete) (Ref. 12-10-100-DA).
Remove the front suspension (Ref. 11-10-100-DA).
Procedure
(Ref. Fig. 11-30-002)
Disconnect the lubrication hoses (12) and put protective caps on the hoses (12)
and all open ports.
Notice! The weight of the upper control arm is 976 kg (2150 lb)
Attach an applicable lift device to the upper control arm (11).
Notice! The weight of the lower control arm is 847 kg (1850 lb)
Put an applicable support below the lower control arm (10).
Notice! The capscrews are tightened to approximately 8135 Nm (6000 lbf ft)
Use a wrench with a multiplier to loosen the capscrews.

Remove the washers (2), retaining plates (3), bearing washers (5), shims (4), and
dowel pins (14) and (15).
Remove and discard the o-rings (13).
Use a pin puller to pull the pins (7) with the spacers (6) (Liebherr P/N T-075-B
Ref. 02-00-000-DA).
Remove the shims (8) and the bearing washers (9).
Remove the control arms (10) and (11).
Examine the bushings, pins (7), dowel pins (13) and (14), and pivot points.
Replace the parts that are worn or show signs of damage.
Fully clean the pin holes in the frame.
11-30-02 T282B S/N 327

Closeout
T282B S/N 327 11-30-03

11-30-002 Removal/Installation of the Control Arms
11-30-04 T282B S/N 327

11-30-200-DA - How to Install the Control Arms

Setup

01-20-000-DA).
(Ref. 11-30-100-DA).

Permatex® anti-seize See recommnded lubricants (Ref.
03-12-000-DA)
Parts Table:

2 Washer 2 51011AE-3
3 Retaining Plate 2 51011AE-31
4 Shims AR 51011AE
5 Bearing Washer 2 51011AE-34
6 Bearing Sleeve 2 51011AE-33
7 Pin 2 51011AE-26
8 Shims AR 51011AE
9 Bearing Washer 2 51011AE-34
10 Control Arm, Lower LH 1 51011AE-15
11 Control Arm, Upper LH 1 51011AE-14
13 O-ring 2 51011AE-10
14 Pin, Dowel 16 51011AE-8
15 Pin, Dowel 4 51011AE-7
Procedure
(Ref. Fig. 11-30-002)
Notice! The weight of the upper control arm is 976 kg (2150 lb) and the weight of the lower
control arm is 847 kg (1850 lb).
Notice! You can only install one control arm at a time.

Fully install one of the control arms and then the other.
T282B S/N 327 11-30-05

Move the control arms (10) or (11) into position on the frame.
Align the pinholes.
Install the bearing washers (9).
Push the control arm (10) or (11) fully against the frame in one direction.
Measure the gap between the bearing washer (9) and the frame.
Divide the measurement by two to get the quantity of shims necessary for both
ends of the control arm.
Add shims (8) equally, on both ends of the control arm, to center the control arm
to ±1 mm (0.039 in.)in relation to the frame.
The control arm is permitted to move up and down, but not forward and rearward.
Put the shims (8) between the bearing washer (9) and the control arm (10) and
(11).
Make sure that the gap between the bearing washer (9) and the frame is equal to
or less than 1 mm (0.039 in.).

Very cold liquids can cause injury.
Put the pins (7) in an applicable container and fill with liquid nitrogen.
Loosely, cover the container.
Let the pins (7) stay in the liquid nitrogen until they become stable, or the liquid
nitrogen stops to boil.
Install the pins (7) through the control arms (10) or (11) and into the frame.
If you cannot install the pins (26) easy into the control arms, do this step:
Put the pins (7) in the liquid nitrogen again and apply heat to the boss in the
frame.
Attention! You can damage the pins if you use too much force to push the pins in position.
The pins can be tapped with a Dead Blow hammer, but do not use a Dead Blow hammer if
the pin is stuck.
Make sure that the pins (7) are fully seated against the retainer plate inside the
frame.
Install the spacers (6).
Align the center grease groove on the spacer (6) with the grease port in the
control arms (10) and (11).
Install the bearing washers (5) and the dowel pins (14) and (15).
Measure from the outer face of the bearing washer (5) to the end face of the pin
(7). Use one of these procedures:
11-30-06 T282B S/N 327

To use a depth micrometer or dial calipers, do this procedure:

Measure the distance (X) from the outer face of the bearing washer (5) to the end face of the pin
(7).
(X) plus 0.13 mm (0.005 in.) is equal to the amount of shims necessary.
Install the shim pack (4).
Install the retainer plates (3), new o-rings (13), and washers (2).
Lubricate the capscrews (1) with anti-seize and install.
Make sure that the control arms (10) and (11) move up and down without
interference.
Closeout
Install the front suspension (Ref. 11-10-200-DA).

Install the front wheel assembly (complete) (Ref. 12-10-200-DA).
T282B S/N 327 11-30-07

11-30-900-DA - Control Arms Specification and

MaintenanceTables
Setup
Notice! There a different types of control arms on the different trucks.

Make sure that you know the correct part number of your control arm.
Procedure
Table A is for the specifications of the control arms.
Part Number Weight

10468050 847 kg (1850 lb) 19.5
10339761 847 kg (1850 lb) 19.5
10468051 976 kg (2150 lb) 19
10339762 976 kg (2150 lb) 39
Closeout
Not applicable
11-30-08 T282B S/N 327

12 Wheel Assemblies
How to Lift the Truck..................................................................................... 12-02-01
Front Wheel Assembly.................................................................................. 12-10-01
How to Remove the Front Wheel (Complete)..................................... 12-10-03
How to Install the Front Wheel (Complete)......................................... 12-10-07
How to Inspect the Bearing Assemblies..............................................12-10-10
How to Check the Oil Level of the Front Wheel Bearings................... 12-10-12
How to Disassemble the Front Wheel.................................................12-10-14
How to Assemble the Front Wheel......................................................12-10-18
How to Drain the Oil from the Front Wheel Bearings.......................... 12-10-23
How to Fill the Front Wheel Bearings with Oil.....................................12-10-25
King Pins and Spindle...................................................................................12-12-01
How to Remove the Kingpins..............................................................12-12-02
How to Install the Kingpins..................................................................12-12-04
How to Check the Kingpin...................................................................12-12-06
How to Inspect the Ball of the Kingpin................................................ 12-12-07
How to Check the Kingpin Bushing for Wear...................................... 12-12-08
How to Inspect the Spindle................................................................. 12-12-10
How to Inspect the Hub.......................................................................12-12-12
Tire and Rim Assembly................................................................................. 12-20-01
How to Remove the Front Tire and Rim Assembly from the Wheel....12-20-03
How to Install the Front Tire and Rim Assembly on the Wheel...........12-20-06
How to Replace the Studs of the Front Wheel.................................... 12-20-08
How to Inspect the Studs of the Front Wheel..................................... 12-20-10
Front Brakes...................................................................................................12-30-01
How to Bleed the Front Brakes........................................................... 12-30-03
How to Burnish the Front Brakes........................................................ 12-30-04
Front Brake Caliper....................................................................................... 12-32-01
How to Remove the Front Brake Caliper............................................ 12-32-03
How to Install the Front Brake Caliper................................................ 12-32-06
How to Inspect the Brake Lining......................................................... 12-32-08
How to Inspect the Caliper Parts........................................................ 12-32-09
How to Disassemble the Front Brake Caliper..................................... 12-32-11
How to Assemble the Front Brake Caliper.......................................... 12-32-13
How to Clean the Caliper Parts...........................................................12-32-16
Front Brake Disc............................................................................................ 12-36-01
How to Inspect the Brake Disc............................................................ 12-36-02
Rear Wheel Assembly................................................................................... 12-40-01
How to Remove the Rear Wheel Assembly........................................ 12-40-03
How to Install the Rear Wheel Assembly............................................ 12-40-05
How to Check the Oil Level of the Rear Wheel Assembly.................. 12-40-07
How to Disassemble the Rear Wheel................................................. 12-40-09
How to Assemble the Rear Wheel...................................................... 12-40-11
How to Disassemble the Wheel Motor Coupling.................................12-40-13
How to Assemble the Wheel Motor Coupling......................................12-40-15
How to Disassemble the Gearbox Coupling....................................... 12-40-17

How to Assemble the Gearbox Coupling................................................................. 12-40-19
How to Assemble the Gear Box Shaft Seals............................................................12-40-21
How to Drain the Oil from the Rear Wheel Assembly.............................................. 12-40-23
How to Fill the Rear Wheel Assembly with Oil......................................................... 12-40-25
Rear Tire and Rim Assembly............................................................................................. 12-42-01
How to Remove the Rear Tire and Rim Assembly...................................................12-42-03
How to Install the Rear Tire and Rim Assembly.......................................................12-42-06
How to Replace the Studs of the Rear Wheel..........................................................12-42-09
How to Inspect the Studs of the Rear Wheel........................................................... 12-42-11
Rear Brakes......................................................................................................................... 12-50-01
How to Remove the Rear Brakes.............................................................................12-50-03
How to Install the Rear Brakes.................................................................................12-50-06
How to Bleed the Rear Brake...................................................................................12-50-10
How to Burnish the Rear Brake................................................................................12-50-12
How to Inspect the Brake Lining...............................................................................12-50-13
How to Inspect the Brake Disc................................................................................. 12-50-14
How to Inspect the Caliper Parts..............................................................................12-50-15
How to Disassemble the Rear Brake Caliper........................................................... 12-50-16
How to Assemble the Rear Brake Caliper................................................................12-50-18
Rear Disc Brake Hub.......................................................................................................... 12-52-01
How to Remove the Rear Disc Brake Hub............................................................... 12-52-02
How to Install the Rear Disc Brake Hub................................................................... 12-52-05
Park Brake (Carlisle)........................................................................................................... 12-60-01
How to Remove the Park Brake............................................................................... 12-60-03
How to Install the Park Brake (Carlisle)....................................................................12-60-06
Mechanical Release of the Park Brake.................................................................... 12-60-07
Inspection of the Caliper Parts................................................................................. 12-60-10
How to Disassemble the Park Brake Caliper........................................................... 12-60-11
How to Assemble the Park Brake Caliper................................................................ 12-60-13

12 Wheel Assemblies
(Ref. Fig. 12-00-001)
The wheels support the haul truck and supply a rolling, load bearing link between the
haul truck and the ground. The haul truck has six tires, two on each rear wheel
assembly and one on each front wheel assembly.
The wheel assemblies have these systems:
Front Wheel Assembly (Ref. 12-10-000-DA)
Tire and Rim Assembly (Ref. 12-20-000-DA)
Rear Wheel Assembly (Ref. 12-40-000-DA)
Park Brake (Ref. 12-60-000-DA)
The wheel assemblies have a section that follows:
Jacking Points (Ref. 12-02-000-DA)
Overview
The rear wheel assembly uses the rear wheel motors to operate. The movement of the
rear wheels causes the haul truck to move.
The front wheel assembly receives turn signals from the steering system and moves
only when the haul truck moves.
The front and rear brakes stop the wheels of the haul truck when you apply the service
brakes. The park brake is applied when hydraulic pressure is removed from the park
brake caliper.
T282B S/N 327 12-00-01

Wheel Assemblies Maintenance Manual
12-00-001 Wheel Assemblies
12-00-02 T282B S/N 327

Maintenance Manual Wheel Assemblies
How to Lift the Truck
12-02 How to Lift the Truck

(Ref. Fig. 12-02-001)
Location
12-02-001 Jacking Points
T282B S/N 327 12-02-01

How to Lift the Truck
12-02-02 T282B S/N 327

12-10 Front Wheel Assembly

(Ref. Fig. 12-10-001)
The front wheel assembly connects to these assemblies:
Front Brake Assembly (Ref. 12-30-000-DA)
Kingpin, Spindle, and Steering Arm (Ref. 12-12-000-DA)
The front wheel assembly has these components:
Wheel Bearings
Wheel Bearing Retainer
Axial Face Seals
O-ring
Shims
12-10-001 Front Wheel Assembly

Each wheel assembly has two wheel bearings. Oil lubricates the wheel bearings. A
wheel bearing retainer holds the wheel bearings in position against the wheel. Shims
are necessary to correctly install the bearing retainer to the spindle.
Each wheel has two axial face seals that are installed as a pair. The axial face seal is a
precision component made of chilled cast iron. Each axial face seal has an axial face,
an o-ring, and a face ring.
T282B S/N 327 12-10-01

There are four fill ports around each wheel to fill or drain the wheel bearing oil. The
correct oil level mark is on the bearing retainer. The center of the hub cap is
plexi-glass. The clear plexi-glass lets you see the oil level in relation to the oil level
mark.
The front wheel assembly is installed on the spindle. The tire and rim assembly is
installed on the front wheel assembly. The tires turn and cause the wheels to turn
when the haul truck moves. The wheel moves around the spindle smoothly because of
the wheel bearings.
The brake disc is attached to the wheel assembly. The wheel stops movement when
the brakes are applied.
Maintenance Tips
You can remove the wheel separately from the spindle, the kingpin, or steering arm.
You can remove the complete wheel unit.
The removal of the wheel is not necessary to remove the brake calipers. You must
remove the wheel to remove the brake disc.
Warning! Face seals have very sharp edges.

If you touch the face seals you can get an injury.
Put on gloves to clean, lubricate, remove and install the face seals.
Oil that contains contamination, for example small metal pieces or a change in color,
shows that there is a problem that you must repair. Refer to the maintenance schedule
(Ref. 03-30-000-DA) to know when to get a sample of oil from the wheel for inspection.
See Technical Data/Maintenance Guidelines for instructions and specifications (Ref.
03-00-000-DA) about the wheel bearing lubricant type, capacity and check/fill
procedures.
12-10-02 T282B S/N 327

12-10-100-DA - How to Remove the Front Wheel (Complete)

Setup

01-20-000-DA).
Make sure that the suspension is installed (Ref. 11-10-200-DA).
Remove the tie rod from the steering arm (Ref. 09-45-100-DA).
Drain the oil from the wheel (Ref. 12-10-700-DA).
Procedure
(Ref. Fig. 12-10-002)
Notice! The weight of the front wheel (complete) without oil is 4168 kg (9200 lb).
Install the front wheel lift tool (Liebherr P/N T-103-E Ref. 02-00-000-DA) and
attach an applicable lift device to the lift tool.
Disconnect the lubrication hoses (1) and the brake lines (18).
Put protective caps on the lubrication hoses (1), brake lines (18), and open ports.
Remove the clamp (7) and move the rubber seal (6).
Notice! The weight of the lower control arm is 847 kg (1850 lb).
Put support blocks 250 to 300 mm (9.842 to 11.811 in.) below the lower control
arm.
Attach an applicable chain come-a-long, 5 ton or more, (Ref. 02-00-000-DA) from
the upper 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! The weight of the bushing retainer is 57 kg (126 lb).

T282B S/N 327 12-10-03

Attach an applicable lift device or support to the bushing retainer (13).

Use 3/4-10NC all-thread bolts to remove the bushing retainer (13).
Remove the bushing (15), and split ring (16).
Remove the o-rings (14), set screw (9), and washer (10).
Lower the control arm until the kingpin ball is free.
Remove the clamp (7) and move the rubber seal (6).
Caution! The retainer holds the outside bushing and shims.

The outside bushings and shims can fall when you remove the retainer.
Do not let the outside bushing and shims fall.
Remove the capscrews (19) and retainer (5), outside bushing (3), and shims (4).
Caution! The inside bushing is securely installed in the bushing socket, but haul truck operation
can loosen it.
The inside bushing can fall when the kingpin ball is free from the upper control arm.
Do not let the inside bushing fall.
Notice! The weight of the inside bushing is 49 kg (108 lb).

Use an applicable lift device or support to hold the inside bushing (2).
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.
The inside bushing can be difficult to remove from the upper control arm.
Apply pressure down to remove the inside bushing. If necessary, apply heat to the bushing
socket.
Remove the inside bushing (2) with three 3/8-16NC all-thread bolts.
Lower the lower control arm against the support.
Put the wheel assembly (17) in a safe location.
Closeout
Do a check of the kingpin (Ref. 12-12-400-DA).

Do an inspection of the kingpin ball (Ref. 12-12-405-DA).
12-10-04 T282B S/N 327

T282B S/N 327 12-10-05

12-10-002 Removal/Installation of the Front Wheel (Complete)
12-10-06 T282B S/N 327

12-10-200-DA - How to Install the Front Wheel (Complete)

Setup

01-20-000-DA).
Make sure that the haul truck is in the same configuration as the removal
procedure (Ref. 12-10-100-DA).

03-12-000-DA)
Parts Table:

3 Outside bushing 1 51011AE-23
4 Shim AR 51011AE-30
6 Seal 1 51011AE-28
7 Clamp 1 51011AE-9
8 Seal 1 51011AE-27
9 Set screw 1 51011AE-47
10 Washer 1 51011AE-48
12 Washer 16 51011AE-46
13 Bushing Retainer 1 51011AE-37
14 O-ring 2 51011AE-11
15 Bushing 1 51011AE-25
16 Split ring 1 51011AE-38
Procedure
(Ref. Fig. 12-10-002)
Notice! The weight of the front wheel (complete) without oil is 4168 kg (9200 lb).
Install the front wheel lift tool (Liebherr P/N T-103-E Ref. 02-00-000-DA) and
attach an applicable lift device to the lifting tool.
T282B S/N 327 12-10-07

Notice! The weight of the upper control arm is 976 kg (2150 lb) and the weight of the lower
control arm is 847 kg (1850 lb).
Lift the wheel assembly (17) and align the kingpin with the upper and lower
control arms.
Install the rubber seal (6), small end first, over the upper kingpin ball.
Apply grease to the upper kingpin ball.

Wear approved protective clothing, gloves, and eye protection applicable for the service
and repair operation that includes liquid nitrogen.
Put the bushings (2) in an applicable container and fill the container with liquid
nitrogen.
Notice! The weight of the inside bushing is 49 kg (108 lb).

Install the bushings (2) into the upper control arm and hold in position while the
bushings (2) stabilize.
Install the inside upper bushing (2) into the upper control arm.
Lift the wheel assembly (17) and install the kingpin ball into the upper control arm
socket.
Install the outside upper bushing (3) and retainer (5).
Lubricate the capscrews (19) with permatex anti-seize and install.
Install the rubber seal (8) into the lower control arm socket, small end first.
Lift the lower control arm until the lower kingpin ball is through the control arm
socket.
Apply grease to the lower kingpin ball.
Install the split ring (16) into the lower control arm socket.
Install the bushing (15) into the lower control arm socket with the grease groove
at the bottom.
Install the o-rings (14)
Notice! The weight of the bushing retainer is 57 kg (126 lb).

12-10-08 T282B S/N 327

Make sure that the set screw (9) pin hole is in line for the position of the bushing
retainer (13).
Lower the control arm enough to lock the split ring (16) and bushing (15) in place.
Lubricate the set screw (9) and the flange of the bushing retainer (13) with
permatex anti-seize.
Apply grease in the bore of the bushing retainer (13).
Install the set screw (9), washer (10), and bushing retainer (13).
Put the lower rubber seal (8) into the grooves on the lower kingpin.
Make the upper control arm level.
Tighten again the capscrews (19) to 55 Nm (41 lbf ft).
Take four measurements 90 degrees apart of the gap between the retainer (5)
and the control arm face.
Get the average value of the measurements.
Remove the capscrews (19) and retainer (5).
Add shims (4) equal to the average measurement plus 0.13 mm (0.005 in.).
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.
Install the retainer (5) and capscrews (19).

Put the upper rubber seal (6) into the grooves on the upper kingpin.
Remove the protective caps and connect the lubrication hoses (1) and brake
lines (18).
Apply grease to all the pivot points.
Make sure that the grease goes out to the seals (6) and (8).
After 50 hours of haul truck operation, tighten the capscrews (19) to 380 Nm (280
lbf ft).
Closeout
Install the tie rod to the spindle steering arm (Ref. 09-45-200-DA).
Fill the oil in the wheel (Ref. 12-10-705-DA).
T282B S/N 327 12-10-09

12-10-400-DA - How to Inspect the Bearing Assemblies

Setup
Procedure
(Ref. Fig. 12-10-003)
(Ref. Fig. 12-10-004)
Examine all the parts of each bearing assembly for wear, pits and cracks.
If the bearings show wear,
Replace the two bearings, races, and rub ring.
Attention! It is a good maintenance precaution to replace all related parts when you replace a
bearing.
Replace face seals, rub rings, races, and the opposite bearing when it is necessary to
replace one of the bearings .
Warning! The face seals have very sharp edges.

You can get an injury when you touch the face seals.
Put on gloves to clean, lubricate, remove and install the face seals.
Replace the face seals.
Closeout
12-10-10 T282B S/N 327

12-10-003 Possible formation of pit-shaped corrosion
12-10-004 Possible formation of pittings
T282B S/N 327 12-10-11

12-10-410-DA - How to Check the Oil Level of the Front Wheel

Bearings
Setup
Procedure
(Ref. Fig. 12-10-005)
Attention! The oil must be at room temperature to give a correct indication.

You can get an incorrect indication if you check the oil level when it is at the temperature of
operation.
Make sure the oil is at room temperature.
Inspect the oil level in relation to the oil level mark on the Lexan hub cab.
If the oil is below the oil level mark, add oil to the wheel (Ref. 12-10-705-DA).
If you cannot see the oil through the hub cap, do this procedure:
Turn the front wheel until two of the oil screw plugs are at the 9 o'clock and 3
o'clock positions.
Remove one of the oil level plugs.
If no oil comes out of the port, add oil to the wheel (Ref. 12-10-705-DA).
Install and tighten the oil level plug to 165 Nm (120 lbf ft).
Closeout
Clean all oil from the surface of the wheel.

12-10-12 T282B S/N 327

12-10-005 Front Wheel Bearings Oil Level Check
T282B S/N 327 12-10-13

12-10-600-DA - How to Disassemble the Front Wheel

Setup
Remove the front brake calipers (Ref. 12-32-100-DA).

Remove the steering arm (Ref. 09-47-100-DA).
Remove the front wheel assembly (complete) (Ref. 12-10-100-DA).
Remove the kingpins (Ref. 12-12-100-DA).
Procedure
(Ref. Fig. 12-10-006)
(Ref. Fig. 12-10-007)
Install two eye bolts in the threaded holes of the cover (16) 180 degrees apart,
and attach an applicable lift device.
Notice! The weight of the cover is 69 kg (152 lb).

Remove the capscrews (18), lockwashers (17), and cover (16).

Install two eye bolts in the holes with a thread of the bearing retainer (14).
Install the two eye bolts 180 degrees apart and attach an applicable lift device.
Notice! The weight of the bearing retainer (14) is 55 kg (121 lb).

Attention! A load that is not equal can cause the bearing retainer to change shape.
Remove the capscrews in a star pattern.
Remove the capscrews (15), bearing retainer (14), shims (12), and o-ring (13).
Remove the temperature sensor nuts (23), cable joint (24), tube clamp (25),
screws (26), washer (27), and lockwasher (28).
Loosen and remove the temperature sensors (20), and remove the plastic coils
(21) and (22), and the clamping box (19).
Install four eye bolts in the holes with a thread of the wheel hub (9).
Install four eye bolts 90 degrees apart, and attach an applicable lift device.
Notice! The weight of the wheel hub is 1600 kg (3500 lb).

Remove the outboard screw plug R 1/4 (2), and connect a high pressure pump
12-10-14 T282B S/N 327

assembly to R 1/4 (2) port.

Pressurize R 1/4 to 100 bar (1450 psi) minimum, and remove the internal bearing
race of the outboard bearing (11).
Release the pressure and remove the high pressure pump from R 1/4 (2) port.
Remove screw plugs (10) and outboard screw plug R 1/4 (8).
Connect a high pressure pump assembly to R 1/4 (8) port, and pressurize to 100
bar (1450 psi) minimum.
Remove the external bearing race of the outboard bearing (11).
Release the pressure and remove the high pressure pump from R 1/4 (8) port.
Remove the inboard screw plug R 1/4 (8).
Remove the external bearing race of the inboard bearing (7).
Remove the capscrews (3) and brake disc (4).
Remove the inboard screw plug R 1/4 (2).
Remove the internal bearing race of the inboard bearing (7) and rub ring (6).

If you touch the face seals you can get injured.
Put on gloves to clean, lubricate, remove, and install the face seals.
Remove the face seals (5) from the wheel hub (9) and the spindle (1).
Closeout
Do an inspection of the bearing assemblies (Ref. 12-10-400-DA).
T282B S/N 327 12-10-15

12-10-006 Removal/Installation of the Front Wheel
12-10-16 T282B S/N 327

12-10-007 Removal/Installation of the Front Wheel
T282B S/N 327 12-10-17

12-10-605-DA - How to Assemble the Front Wheel

Setup
Before the installation, apply a thin layer of oil to all contact surfaces in the wheel
unit and the bearings.
Apply a thin layer of oil or grease to the o-rings.

Oil Mobilgear SHC 680 5087-B
Parts Table:

1 Spindle 1 933523501-1
2 Screw plug 2 933523501-52
3 Capscrew 48 933523501-18
4 Brake disc 1 933523501-30
5 Face seal 1 933523501-2
6 Rub ring 1 933523501-5
7 Bearing, inboard 1 933523501-6
8 Screw plug 2 933523501-54
9 Wheel hub 1 933523501-10
10 Screw plug 4 933523501-12
11 Bearing, outboard 1 933523501-11
12 Shim package 1 933523501-90
13 O-ring 1 933523501-17
14 Bearing retainer 1 933523501-15
15 Capscrew 24 933523501-18
16 Cover 1 933523501-20
17 Lockwasher 24 933523501-17
18 Capscrew 24 933523501-18
19 Clamping box 1 933526601-1
20 Temperature sensor 3 933526601-4
21 Plastic coil -- 933526601-5
22 Plastic coil -- 933526601-6
23 Hex nut 3 933526601-11
24 Cable joint 2 933526601-2
25 Tube clamp 1 933526601-7
26 Screw, hex head 1 933526601-8
27 Washer 1 933526601-9
28 Lockwasher 1 933526601-10
12-10-18 T282B S/N 327

Procedure
(Ref. Fig. 12-10-006)
(Ref. Fig. 12-10-007)

If you touch the face seals you can get injured.
Put on gloves to clean, lubricate, remove, and install the face seals.
Caution! The face seals must be clean and free of lubricant to operate correctly.
Do not lubricate the rubber mount surfaces of the face seals. Use contact cleaner or
isopropyl alcohol, if necessary, during the installation.
To install the face seals, do this procedure:

Clean the faces of the face seals (5) with a lint free cloth.
Lightly lubricate the faces of the face seals (5) with wheel bearing oil.
Push the lower part of the face seal (5) into the fit on the spindle (1).
Push the upper part of the face seal (5) into the wheel hub (9).
To install the bearings, do this procedure:
Put the rub ring (6) in position on the spindle (1).
Caution! The bearings must be clean and free of damage to operate correctly.
High strength steel bars or bronze bars can leave unwanted pieces of metal on the bearing.
Always use a non-metallic hammer during the installation of the bearings. Replace the
bearing if it becomes damaged during the installation.
Use an oven to increase the temperature of the internal bearing race of the
inboard bearing (7) to 120 °C (248 °F), and install on the spindle (1).
Warning! Liquid nitrogen is a very cold liquid.

Always put on protective gloves, clothing, and eye protection.
Freeze the external bearing race of the inboard bearing (7) with nitrogen and
install on the wheel hub (9).
Install the inboard screw plug (8).
Lubricate the capscrews (3) with Loctite 242.
Install the brake disc (4) and capscrews (3).
Tighten the capscrews (3) in a star pattern to 1060 Nm (780 lbf ft).
Carefully turn the wheel hub (9) on the other side.
T282B S/N 327 12-10-19

Freeze the external bearing race of the outboard bearing (11) with nitrogen and
install on the wheel hub (9).
Install the screw plugs (10) and the outboard screw plug (8).
Install four eye bolts in the holes with a thread of the wheel hub (9).
Install the four eye bolts 90 degrees apart, and attach an applicable lift device.
Notice! The weight of the wheel hub is 1600 kg (3500 lb).

Lower the wheel hub (9) onto the spindle (1).

Use an oven to increase the temperature of the internal bearing race of the
outboard bearing (11) to 120 °C (248 °F), and install on the spindle (1).
Install the inboard and outboard screw plugs (2) on the spindle (1), and lock with
Loctite 242.
To install the temperature sensors, do this procedure:
Lubricate the outboard and inboard (not the center) temperature sensors (20)
with heat-conductive paste T12 on the front surface.
Install the inboard and outboard temperature sensors (20) completely, and then
turn one full turn to the left and lock with Loctite 242.
Install the center temperature sensor (20) 30 mm (1.181 in.) deep into wheel hub
(9), and lock with Loctite 242.
Install the nuts (23), and wrap plastic coil (21) around cables between
temperature sensors (20).
Install plastic coil (22) around cable between inboard temperature sensor (20)
and clamping box (19), and install clamping box (19).
Install the tube clamp (25), screws (26), washer (27), and lockwasher (28) to the
spindle (1).
From inside the spindle (1), attach the cable joint (24) to the spindle.
Pass the cable through the cable joint () and into the clamping box () and connect
them.
Attention! If you get measurements when the bearings are hot, you can get errors.
Make sure that the bearing is at room temperature before you do the measurements.
To get the wheel bearing measurements, do this procedure:

Turn the wheel five turns.
Install two eye bolts in the holes with a thread of the bearing retainer (14).
Install the two eye bolts 180 degrees apart, and attach an applicable lift device.
12-10-20 T282B S/N 327

Notice! The weight of the bearing retainer (14) is 55 kg (121 lb).

Install the bearing retainer (14) with eight capscrews (15), 45 degrees from each
other.
Attention! A load that is not equal can cause the bearing retainer to change shape.
Install the capscrews in a star pattern.
Tighten the eight capscrews (15) in a star pattern to 60 Nm (44 lbf ft).
Turn the wheel two turns and tighten the capscrews (15) to 200 Nm (150 lbf ft).
Turn the wheel two more turns and tighten the capscrews (15) to 200 Nm (150 lbf
ft).
Repeat this step until you cannot tighten the capscrews (15) more with 200 Nm
(150 lbf ft).
Measure the gap (X) between the bearing retainer (14) and the spindle (1).
X minus 0.1 mm (0.004 in.) equals the shim necessary.
To install the shim package, do this procedure:
Remove the bearing retainer (14) and capscrews (15).
Install the shim package (12).
Install the o-ring (13) to the bearing retainer (14).
Install the bearing retainer (14) with the oil level mark in the correct location.
Use Loctite 242 to install the capscrews (15) and tighten to 1060 Nm (780 lbf ft)
in a star pattern.
To install the cover, do this procedure:
Install two eye bolts in the holes with a thread of the cover (16).
Install the two eye bolts 180 degrees apart, and attach an applicable lifting
device.
Notice! The weight of the cover is 69 kg (152 lb).

Install the cover (16), capscrews (18), and lockwashers (17).
Closeout
Install the kingpins (Ref. 12-12-200-DA).

Install the front wheel assembly (complete) (Ref. 12-10-200-DA).
Install the steering arm (Ref. 09-47-200-DA).
T282B S/N 327 12-10-21

Install the front brake calipers (Ref. 12-32-200-DA).

Replenish the oil in the wheel (Ref. 12-10-705-DA).
12-10-22 T282B S/N 327

12-10-700-DA - How to Drain the Oil from the Front Wheel

Bearings
Setup

o'clock positions.
Procedure
(Ref. Fig. 12-10-008)
Put an applicable container below the oil drain plug at the bottom center position.
The oil capacity for the front wheel hub is 60 L (16 U.S. gal).
Remove the oil drain plug at the bottom center.
Remove the oil fill plug at the top center and let the oil drain.
Install the oil fill and oil drain plugs when you drain all the oil.
Closeout

T282B S/N 327 12-10-23

12-10-008 Front Wheel Bearings Oil Drain
12-10-24 T282B S/N 327

12-10-705-DA - How to Fill the Front Wheel Bearings with Oil

Setup

o'clock positions.

Oil Mobilgear SHC 680 5087-B
Procedure
(Ref. Fig. 12-10-009)

operation.
Remove the top oil fill plug.

Slowly pour or pump the specified oil into the oil fill port.
The oil capacity for the front wheel hub is 60 L (16 U.S. gal).
Give time for trapped air to come out from the front wheel hub.
Continue to pour or pump until oil is at the oil level mark or oil begins to flow from
the oil level port.
Install the oil fill and oil level plugs and tighten to 165 Nm (120 lbf ft).
Operate the haul truck for a half an hour and add oil to the wheel (Ref.
12-10-705-DA).
Closeout
T282B S/N 327 12-10-25

12-10-009 Front Wheel Bearings Oil Fill
12-10-26 T282B S/N 327

King Pins and Spindle
12-12 King Pins and Spindle

(Ref. Fig. 12-12-001)
The king pin and spindle connects to these assemblies:
Steering Arm (Ref. 09-47-000-DA)
Upper and Lower Control Arms (Ref. 11-30-000-DA)
Front Wheel Assembly (Ref. 12-10-000-DA)
12-12-001 Upper and Lower King Pins and Spindle

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.
T282B S/N 327 12-12-01

12-12-100-DA - How to Remove the Kingpins

Setup

Remove the front wheel assembly (Ref. 12-10-100-DA).
Procedure
(Ref. Fig. 12-12-002)
Notice! The weight of the front wheel assembly without fluids is 4168 kg (9200 lb).
Make sure that the front wheel assembly is in an applicable lift device.
Notice! The weight of the upper kingpin is 238 kg (525 lb).

Install an eye bolt to the upper kingpin (1) and attach an applicable lift device.
Remove the capscrews (2) and upper kingpin (1).
Carefully turn the spindle 180 degrees, and correctly hold in an upright position.
Notice! The weight of the lower kingpin is 238 kg (525 lb).

Install an eye bolt to the lower kingpin (4) and attach an applicable lifting device.
Remove the capscrews (3) and lower kingpin (4).
Closeout
12-12-02 T282B S/N 327

12-12-002 Removal/Installation of the Kingpins
T282B S/N 327 12-12-03

12-12-200-DA - How to Install the Kingpins

Setup

(Ref. 12-12-100-DA).

Lubricant Loctite 573
Parts Table:

1 Kingpin, upper 1 933523501-35
2 Capscrew 24 933523501-18
3 Capscrew 20 933523501-18
4 Kingpin, lower 1 933523501-40
Procedure
(Ref. Fig. 12-12-002)
Notice! The weight of the front wheel assembly without fluids is 4168 kg (9200 lb).
Make sure that the front wheel assembly is in an applicable lift device and in an
upright position.
Notice! The weight of the lower kingpin is 238 kg (525 lb).

Install an eye bolt to the lower kingpin (4) and attach an applicable lift device.
Lubricate the contact surface between the lower kingpin (4) and the spindle with
Loctite 573.
Put the lower kingpin (4) in position on the spindle.
Install the capscrews (3) with Loctite 242.
Carefully turn the spindle 180 degrees, and correctly hold in an upright position.
Notice! The weight of the upper kingpin is 238 kg (525 lb).

12-12-04 T282B S/N 327

Install an eye bolt to the upper kingpin (1) and attach an applicable lift device.
Lubricate the contact surface between the upper kingpin (1) and the spindle with
Loctite 573.
Put the upper kingpin (1) in position on the spindle.
Install the capscrews (2) with Loctite 242.
Closeout
Assemble the front wheel assembly completely (Ref. 12-10-605-DA).

Install the front wheel assembly (Ref. 12-10-200-DA).
T282B S/N 327 12-12-05

12-12-400-DA - How to Check the Kingpin

Setup
Procedure
Push the upper seal up into the ball neck area.
-or-
Remove the clamp and pull down the upper seal.
Clean the ball neck area with a lint free cloth.
Examine the ball neck area for cracks, gouges, abrasions or signs of damage.
If it is necessary to replace the kingpin, do this procedure:
Replace the king pin (Ref. 12-12-100-DA).
If the kingpin is serviceable, do this procedure:
Pull down the seal to the correct position.
-or-
Pull the seal up to the correct position and install the clamp.
Closeout
12-12-06 T282B S/N 327

12-12-405-DA - How to Inspect the Ball of the Kingpin

Setup
Not applicable.
Procedure
Measure the diameter of the upper kingpin ball.

If the measurement is less than the wear limit of 328.40 mm (12.929 in.),
Replace the kingpin.
Measure the diameter of the lower kingpin ball.
If the measurement is less than the wear limit of 281.16 mm (11.069 in.),
Replace the kingpin.
Closeout
Not applicable.
T282B S/N 327 12-12-07

12-12-410-DA - How to Check the Kingpin Bushing for Wear

Setup

Lift the front wheels off the ground until you can turn the tire by hand (Ref.
12-02-000-DA).
Procedure
(Ref. Fig. 12-12-003)
Install a jack below the lower control arm.

Measure the distance (X1) between the casting of the lower control arm and the
mount flange of the kingpin.
Lift the lower control arm with the jack only until the tire starts to lift further off the
ground.
Measure the distance (X2) between the casting of the lower control arm and the
mount flange of the kingpin.
Calculate (Z) = X1 - X2.
If (Z) is equal or less than 1.27 cm (0.5 in.),
The kingpin bushing is serviceable.
If (Z) is more than 1.27 cm (0.5 in.), but less than 1.905 cm (0.75 in.),
Repeat the kingpin bushing wear check every 250 hours.
If (Z) is equal or more than 1.905 cm (0.75 in.),
Replace the lower kingpin bushing.
Closeout
12-12-08 T282B S/N 327

12-12-003 King Pin Bushing Wear Check
T282B S/N 327 12-12-09

12-12-415-DA - How to Inspect the Spindle

Setup
Procedure
(Ref. Fig. 12-12-004)
Carefully inspect the specified areas for cracks.
-or-
Measure the dimensions.
Make sure that all dimensions are in the limits.
Closeout
12-12-10 T282B S/N 327

12-12-004 Inspection of the Spindle
T282B S/N 327 12-12-11

12-12-420-DA - How to Inspect the Hub

Setup
Procedure
(Ref. Fig. 12-12-005)
Carefully inspect the hub for cracks.
-or-
Measure the dimensions.
Make sure that all dimensions are in the limits.
Closeout
12-12-12 T282B S/N 327

12-12-005 Inspection of the Hub
T282B S/N 327 12-12-13

12-12-14 T282B S/N 327

Tire and Rim Assembly
12-20 Tire and Rim Assembly

The tires initially installed on the haul truck are 55/80-R63 E3R (41x63 in. rims). For
more information refer to the tire manufacturer maintenance guide or see your local
(Ref. Fig. 12-20-001)
The weight of the tire and rim assembly is 7750 kg (17100 lb), and has a height of
3.912 m (12.8 ft), and a width of 1.4 m (4.6 ft).
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.
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.
12-20-001 Tire and Rim Assembly
T282B S/N 327 12-20-01

Maintenance Tips
If you change the tire size you must change the setting in the electronic control. See
your Liebherr service representative.
12-20-02 T282B S/N 327

12-20-100-DA - How to Remove the Front Tire and Rim

Assembly from the Wheel
Setup

Park the haul truck on a level surface and put chocks on the tires.
Procedure
(Ref. Fig. 12-20-002)
Put the jack in position at the jacking point (Ref. 12-02-000-DA) near the tire to be
removed.
Lift the tire a small distance off the ground.
If the air in the tire is not released, the assembly can break apart when you remove the nuts
with enough force to cause injury or death.
Release the air from the tire before you do maintenance.
Remove the valve core and deflate the tire to approximately 69 to 103 kPa
(10.013 to 14.947 psi).
Notice! It is necessary to keep some pressure in the tire so that the bead seal does not break.
Keep approximately 69 to 103 kPa (10.013 to 14.947 psi) pressure in the tire.
Lift the jack until the tire is clear of the ground.
Notice! The weight of the tire and rim assembly is 7750 kg (17100 lb).
Use an applicable tire handler that can hold this weight. See the instructions of the
manufacturer for the correct tools.
Move the tire machine into position and hold the tire.
Remove the nuts (2).
Attention! The valve stem and diffuser valve can get damaged during the removal of the tire
and rim assembly.
Be careful when you remove the tire and rim assembly.
Remove the tire and rim (1) from the wheel.
T282B S/N 327 12-20-03

Closeout
Inspect the studs (Ref. 12-20-400-DA).

12-20-04 T282B S/N 327

12-20-002 Removal/Installation of the Front Tire and Rim Assembly
T282B S/N 327 12-20-05

12-20-200-DA - How to Install the Front Tire and Rim Assembly

on the Wheel
Setup

(Ref. 12-20-100-DA).

03-12-000-DA)
Parts Table:

2 Nut 58 53157AC-13
Procedure
(Ref. Fig. 12-20-002)
Clean the rim and the area on the wheel where you install the rim.
The surfaces must be free of unwanted material and lubricant.
Move the tire and rim (1) into position and align the valve stem carefully.
Attention! The valve stem and diffuser valve can get damaged during installation of the tire and
rim assembly.
Be careful when you install the tire and rim assembly.
Lubricate the threads of the nuts (2) with a small quantity of oil.
Install the nuts (2).
Make sure that the rim is fully against the circumference of the wheel and
gradually tighten all nuts (2).
Tighten the nuts (2) to 1850 Nm (1360 lbf ft).
Check the recommendations of the tire manufacturer for correct 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
12-20-06 T282B S/N 327

controls. Use a safety cage if the unit is off the haul truck.
Inflate the tire.

Make sure that the valve stem is correctly attached to the rim as necessary.
Carefully lower the jack until the tire is fully on the ground.
Warning! Movement of the haul truck with a load can cause the rim clamp nuts to loosen.
It is necessary that you tighten the rim nuts again after the haul truck does one load.
Make sure that the next operation of the haul truck is not longer than one hour
and then tighten all the nuts to 1850 Nm (1360 lbf ft).
Repeat the previous step three to four times, or until all nuts keep a torque value
of 1850 Nm (1360 lbf ft).
Closeout
T282B S/N 327 12-20-07

12-20-300-DA - How to Replace the Studs of the Front Wheel

Setup

Remove the front tire and rim assembly (Ref. 12-20-100-DA).

Adhesive Loctite, medium duty
Parts Table:

4 Stud, front wheel 58 933523501-50
Procedure
(Ref. Fig. 12-20-003)
To replace the front wheel studs, do this procedure:

Push out the applicable stud (4) and discard the stud.
Push the new stud (4) into the wheel hub
Closeout
12-20-08 T282B S/N 327

12-20-003 Replacement of the Studs
T282B S/N 327 12-20-09

12-20-400-DA - How to Inspect the Studs of the Front Wheel

Setup

Remove the front tire and rim assembly (Ref. 12-20-100-DA).
Procedure
(Ref. Fig. 12-20-004)
Inspect the items for missing or damaged studs:

mount studs for the tire and rim on the front wheel assembly
If there are more than four studs that miss or are damaged in the bolt circle,
Replace the missing or damaged bolts or studs (Ref. 12-20-300-DA).
If there are two or more missing or damaged studs adjacent to the other,
If there are less than four serviceable studs between each missing or damaged
stud,
Closeout
12-20-004 Inspection of the Studs
12-20-10 T282B S/N 327

Front Brakes
12-30 Front Brakes

The front brake assembly has these components:
Front Brake Calipers (Ref. 12-32-000-DA)
Front Brake Disc (Ref. 12-36-000-DA)

(Ref. Fig. 12-30-001)
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 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.
Braking performance increases when the brakes are burnished. If you burnish the
brakes correctly, the temperature of the disc becomes 205 °C (400 °F). 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.
T282B S/N 327 12-30-01

Front Brakes
12-30-001 Front Brakes
Maintenance Tips
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.
12-30-02 T282B S/N 327

Front Brakes
12-30-300-DA - How to Bleed the Front Brakes

Setup

Make sure that all of the hydraulic connections and fittings are correctly tightened
(Ref. 12-32-200-DA).
Two maintenance personnel are necessary to do the bleed procedure.
Procedure

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.
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.
Start the engine.
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.
Close the bleeder screw when there are no air bubbles in the fluid.
Tighten the bleeder screw to 11 to 20 Nm (95 to 180 lbf in.).
Repeat this procedure for all the caliper pieces.
Make sure that there are no hydraulic leaks.
Closeout
Correctly discard all the hydraulic fluid collected from the bleed procedure. Follow
the environmental regulations when you discard the fluid.
Make sure that the brake and steering hydraulic tank is at a serviceable level
(Ref. 07-20-705-AA).
T282B S/N 327 12-30-03

Front Brakes
12-30-305-DA - How to Burnish the Front Brakes

Setup
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 (2970 psi).
Move the haul truck to a safe area.
Remove the hub caps (Ref. 12-20-100-DA).
Disconnect the rear brake line, SVB, at the axle box, and install protective covers
on the brake line and open ports (Ref. Fig. 12-30-002).
Procedure
Press the override switch on the dump control lever during the time the service
brake is applied.
Drive the haul truck 8 to 15 km/h (5 to 9.3 mph) for approximately 135 m (442.9
ft) and at the same time apply the service brakes at 30-50% effort.
The brakes become hot and some smoke can show as the temperature
increases.
Stop the haul truck and measure the temperature of the disc.
If the disc temperature is less than 205 °C (400 °F), do this procedure:
Repeat the procedure.
If the disc temperature is equal to or more than 205 °C (400 °F), do this
procedure:
Let the disc become cool to 125 °C (255 °F).
Release the service and park brakes and repeat the procedure one time.
Closeout
Inspect for leaks or other unsatisfactory conditions.

Connect the rear brake line, SVB, in the axle box (Ref. Fig. 12-30-002).
Install the hub caps (Ref. 12-20-200-DA).
12-30-04 T282B S/N 327

Front Brakes
12-30-002 Front Brake Burnish Procedure
T282B S/N 327 12-30-05

Front Brakes
12-30-06 T282B S/N 327

Front Brake Caliper
12-32 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
12-32-001 Front Brake Caliper

(Ref. Fig. 12-32-001)
Each caliper piece has a brake lining that moves freely between the end 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
T282B S/N 327 12-32-01

Front Brake Caliper
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.
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.
Maintenance Tips
Do not use compressed air to remove pistons from the caliper housing. Compressed
air can remove a piston with a dangerous force.
12-32-02 T282B S/N 327

Front Brake Caliper
12-32-100-DA - How to Remove the Front Brake Caliper

Setup

Procedure
(Ref. Fig. 12-32-002)

Bleed the oil from the bleeder valves (3) on all five calipers.
Disconnect the hydraulic supply (12) and jumper lines (7).
Remove the hex nuts (1) and hardened washers (2) from the brake caliper to be
removed.
Correctly hold the inboard caliper piece (4).
Notice! The weight of the front brake caliper is 122 kg (270 lb).
Attach an applicable lift device to the inboard caliper half (4).

Move in the inboard caliper piece (4) on the capscrews (11) approximately 50 to
70 mm (1.968 to 2.756 in.).
Carefully remove the inboard brake lining (5) from behind the caliper piece (4) .
Do not let the brake lining (5) fall.
Remove the inboard caliper piece (4).
Correctly hold the outboard caliper piece (8) and attach an applicable lift device
to the caliper piece (8).
Remove the capscrews (11) and hardened washers (10).
Attention! The outboard brake lining comes out when the outboard caliper is removed.
Be careful when you remove the capscrews and hold the outboard brake lining.
Remove the outboard caliper piece (7) and the outboard brake lining (6).
Do not let the outboard brake lining (6) fall.
Closeout
T282B S/N 327 12-32-03

Front Brake Caliper
Inspect the brake lining (Ref. 12-32-400-DA).

12-32-04 T282B S/N 327

Front Brake Caliper
12-32-002 Removal/Installation of the Front Brake Caliper
T282B S/N 327 12-32-05

Front Brake Caliper
12-32-200-DA - How to Install the Front Brake Caliper

Setup

(Ref. 12-32-100-DA).

03-12-000-DA)
Parts Table:

1 Nut 6 933523501-3
2 Washer 6 supplied with 933523501-1
3 Bleeder valve 4 supplied with 933523501-1
4 Caliper 1 933523501-1
5 Lining 2 supplied with 933523501-1
7 Tube Assembly 1 supplied with 933523501-1
9 Shim AR supplied with 933523501-1
10 Washer 6 supplied with 933523501-1
11 Capscrew 6 933523501-2
Procedure
(Ref. Fig. 12-32-002)
Notice! The weight of the front brake caliper is 122 kg (270 lb).
Correctly hold the outboard caliper piece (7) and attach an applicable lift device.
Install the outboard caliper piece (7) and outboard brake lining (6) onto the brake
disc.
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 (0.059 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 side.
Install the capscrews (11) and hardened washers (10).

Correctly hold the inboard caliper piece (4) and attach an applicable lift device.
12-32-06 T282B S/N 327

Front Brake Caliper
Put the inboard caliper piece (4) onto the capscrews (11).
Install the inboard brake lining (5).
Lubricate the hex nuts (1) and hardened washers (2) with permatex anti-seize.
Install all the hex nuts (1) and hardened washers (2) onto the capscrews (11).
Tighten the hex nuts (1) to 1005 Nm (740 lbf ft).
Tighten the bleeder screws (3) to 11.3 to 20.34 Nm (100 to 180 lbf in.).
Connect the hydraulic supply (12) and jumper lines (7).
Closeout
Bleed the brakes (Ref. 12-30-300-DA).

Install the tire and rim assembly (Ref. 12-20-200-DA).
T282B S/N 327 12-32-07

Front Brake Caliper
12-32-400-DA - How to Inspect the Brake Lining

Setup

Remove the brake calipers (Ref. 12-32-100-DA).
Procedure
Caution! The brake linings must be replaced in pairs.

If you replace only one brake lining disc damage can occur.
Always replace the two brake linings in the brake housing.
Measure the thickness of the friction lining on the brake lining.

If the thickness is 3 mm (0.118 in.) or less,
Replace the two brake linings.
Inspect the brake lining.
If the lining has cracks or is burned,
If the lining or parts of the lining are broken or loose,
Closeout
12-32-08 T282B S/N 327

Front Brake Caliper
12-32-405-DA - How to Inspect the Caliper Parts

Setup
Disassemble the caliper (Ref. 12-32-600-DA).
Procedure
Inspect the o-ring grooves in the housing for scratches or corrosion.

If there are small scratches or corrosion,
Remove all small scratches and corrosion with a fine emery cloth.
If there are large scratches, large amounts of corrosion, or the housing is
damaged or worn,
Replace the housing.
Inspect the pistons and housing bores for scratches and corrosion.
Remove all scratches and corrosion with a fine emery cloth.
If there are large scratches or corrosion,
Replace the piston and/or the housing.
If the piston shows signs of wear in the area where the seal rubs and you can feel
a defect on the surface,
Replace the piston.
If pieces of the chrome on the piston fell or have cracks,
Replace the piston.
Measure the outer diameter of the pistons.
If the outer diameter measures less than 91.9 mm (3.618 in.),
Replace the piston.
Measure the inner diameter of the housing bores.
If the inner diameter of the bore is larger than 92.2 mm (3.63 in.),
Inspect the caliper ports and bolt holes of the end plates for damage to the
threads.
Use the applicable taps, lubricated with light oil, to inspect the tapped hole and to
clean up minor surface damage.
For fluid ports, use a 4375-20 UNF-2B.
For end plate bolt holes, use a .7500-16 UNF-2B tap.
T282B S/N 327 12-32-09

Front Brake Caliper
Warning! The components of the calipers operate together.

Installation of non-Rockwell parts can cause damage to equipment, defective brakes, and injury
to personnel.
Use only the specified components and do not use components from other calipers.
Replace all components that have damaged threads that cannot be repaired.
Inspect the end plates in the area where they touch the brake lining.
If the end plates are worn or damaged,
Replace the end plates.
Inspect the piston oil seals.
If there is oil on the outside of the caliper housing or on the outside of the seals,
Remove the oil seals.
Caution! The seals and components made from rubber operate with the type of hydraulic oil the
Liebherr haul trucks use.
Incorrect hydraulic oil in the brake system can cause defective brakes.
Always use new seals and make sure the seals are the correct type for mineral oil.
Put a layer of oil on the new seals and the piston.

Install new seals.
Closeout
12-32-10 T282B S/N 327

Front Brake Caliper
12-32-600-DA - How to Disassemble the Front Brake Caliper

Setup
Remove the front brake caliper (Ref. 12-32-100-DA).
Procedure
(Ref. Fig. 12-32-003)
Remove the bolts (2) and end plates (3).

Remove the brake linings (6).
Push the pistons (10) fully into the brake housing (4).
Remove the dust boots (7).
Warning! Compressed air can remove a piston with a dangerous force.

Remove the piston by hand, or use the puller holes that have a thread.
Open the inlet port (5) (11) or bleed valves (1) to prevent a vacuum.
Remove the pistons (10) from the housing bores.
Remove the bleed valves (1), elbow fitting (5) and tee-fitting (11) from the brake
housing.
Remove and discard the o-rings (8) and the backup rings (9).
Closeout
Inspect the caliper parts (Ref. 12-32-405-DA).
T282B S/N 327 12-32-11

Front Brake Caliper
12-32-003 Disassembly/Assembly of the Front Brake Caliper
12-32-12 T282B S/N 327

Front Brake Caliper
12-32-605-DA - How to Assemble the Front Brake Caliper

Setup

Grease Silicone Commercially Available
Oil Hydraulic 5081-A
Adhesive Loctite 271 Commercially Available
Parts Table:

1 Bleeder valve 4
2 Capscrew 8
3 Endplate 2
3A Endplate, (opposite) 2
4 Caliper 1
5 Fitting 1
6 Lining 2
7 Dust boot 6
8 O-ring 6
9 Backup ring 6
10 Piston 6
11 Tee fitting 1
Procedure
(Ref. Fig. 12-32-003)
Danger! The components of the calipers operate together.

to personnel.
Lubricate all pistons, bores, new o-rings, backup rings, and seals with silicone
grease, for example Dow Corning DC-4 or equivalent.
Caution! The seals and components made from rubber are made to operate with the type of
hydraulic oil the Liebherr haul trucks use.
If silicone grease is not available,

Use the same type of fluid that is in the brake system. Do not use silicone grease
T282B S/N 327 12-32-13

Front Brake Caliper
on the dust boot.

Install new o-rings (8) in each of the bore grooves with the large end of the o-ring
toward the pressure side of the caliper (4).
Install new backup rings (9) in each of the bores toward the lining side of the
o-ring groove with the large radius against the o-ring (8).
Push the pistons (10) into the housing bores carefully and do not to damage the
o-rings (8).
Make sure the pistons (10) are straight and fully in the bores.
Caution! Incorrect installation of the dust boot can cause the piston to cut and damage the dust
boot when pressure is applied.
Make sure the dust boots are fully installed into the housing and piston grooves.
Install the dust boots (7) into the housing groove and into the piston groove.
Push the dust boots (7) tightly down around the grooves.
Caution! The brake linings must be replaced in pairs.

If only one brake lining is replaced, disc damage can occur.
Install the brake linings (6) into the brake housing.

Apply Loctite 271 or equivalent to the threads of the end plate bolts (2).
Install the end plates (3) and the bolts (2).
Tighten the bolts (2) to 515 to 625 Nm (380 to 460 lbf ft).
Attention! Some torque values in this procedure are pound-force inch (lbf in.) and some are
pound-force feet (lbf ft).
Read the torque values correctly.
Make sure that the linings (6) move freely inside the end plates (3).
Install the inlet fittings (5) (11) and bleed valves (1) so that the bleed valves (1)
are at the high end of the caliper housing (4) when installed on the haul truck.
Tighten the bleed valves (1) to 11.3 to 20.34 Nm (100 to 180 lbf in.).
Closeout
Caution! Use protective covers if you store the caliper.

Install protective covers over the fittings to prevent contamination inside the housing.
To do a low pressure test of both caliper pieces (4) at 3.5 bar (50 psi) to examine
for leaks, do this procedure:
12-32-14 T282B S/N 327

Front Brake Caliper
Use the same type of fluid that the brake system uses.
Attach one piece of the caliper to a fixture plate with bolts or attach the two
caliper pieces together.
If the caliper pieces are attached together,
Put a 100 mm (3.937 in.) thick spacer between the pistons.
-or-
If one piece of the caliper is attached to a fixture,
Put a 50 mm (1.968 in.) thick spacer between the fixture and the pistons.
T282B S/N 327 12-32-15

Front Brake Caliper
12-32-800-DA - How to Clean the Caliper Parts

Setup
Procedure
Danger! Instructions on how to correctly use materials to clean, hot solution tanks or alkaline
solutions are supplied by the manufacturer of the material.
Personal injury can occur if you do not follow the instructions of the manufacturer.
Follow the instructions supplied by the manufacturer of the material. Do not use gasoline
to clean parts.
Caution! Hot solution tanks or water and alkaline solutions damage the metal parts.
Use only solvent cleaners, for example isopropyl alcohol, kerosene or diesel fuel, to clean
the polished metal parts.
Use a solvent cleaner to clean all metal parts that have polished surfaces. For
example the pistons and piston bores in the housing.
Use solvent cleaners or alkaline solutions to clean metal parts that have rough
surfaces.
Use a wire brush to clean the threads of fasteners and fittings.
Use soap and water to clean parts that are not made of metal.
Use a scraper to remove dirt, contamination and unwanted material from the
linings.
Attention! The brake linings must be clean and free from contamination to operate correctly.
Do not get brake fluid on the brake linings.
If a brake lining has oil or grease contamination,

Replace the brake lining.
Immediately dry all parts with paper, rags, or clean, dry compressed air.
Closeout
12-32-16 T282B S/N 327

Front Brake Disc
12-36 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.
12-36-001 Front Brake Disc
Maintenance Tips
You must burnish the brakes when you install a new brake disc.
T282B S/N 327 12-36-01

Front Brake Disc
12-36-400-DA - How to Inspect the Brake Disc

Setup
Not applicable.
Procedure
Measure the thickness of the brake disc.

If the disc is worn or there are grooves that decrease the thickness of the disc
down to 29 mm (1.142 in.) thick
Replace the brake disc.
Check for distortion with a straight edge.
If the brake disc is warped more than 1.5 mm (0.059 in.)
Inspect the brake disc for heat checks or cracks.
If the disc has heat checks or cracks that are more than 1.5 mm (0.059 in.) deep,
-or-
If the disc has cracks that go completely across the face of the disc,
Closeout
12-36-02 T282B S/N 327

Rear Wheel Assembly
12-40 Rear Wheel Assembly

(Ref. Fig. 12-40-001)
The rear wheel assembly connects to these assemblies:
Rear Brake Assembly (Ref. 12-50-000-DA)
The rear wheel assembly has these assemblies:
Rear Wheel Motor Assembly
Planetary Gear Box

The rear wheel assembly is installed at each end of the axle box and is the rear axle
for the haul truck. Each rear wheel assembly has one wheel motor, one planetary gear
box, and one brake assembly. The rear wheel assemblies transmit the force to move
and help stop the haul truck.
The planetary gear box is the outer part of the rear wheel assembly. The tire and rim
assemblies are attached to the outer spindle of the planetary gear box. The rear wheel
motor assembly is attached to the inner spindle of the planetary gearbox.
Rear Wheel Motor Assembly

The armature of the wheel motor assembly attaches to the planetary gear box. The
wheel motor assembly transmits the propulsion force to the planetary gear box.
In dynamic retarding, the force on the wheel motors is reversed to help stop the haul
truck. See the AC Drive System (Ref. 04-10-000-DA) for more information on dynamic
retarding.
Airflow through the wheels keeps them at a cool temperature. The air enters the axle
box through ducts from a large blower installed on the bottom of the control box. The
cool air flows through the wheel motors and goes out through a large exhaust vent on
the top front of the axle box.
The rear brake assembly is installed on the rear motor assembly inside the axle box.
The rear brakes can slow the wheel motors to stop the haul truck.
Refer to the OEM manual for more information on the operation of the rear wheel
motor assembly.
Planetary Gear Box

The armature of the wheel motor causes the gears in the planetary gear box to turn.
The gears in the planetary gear box turn and cause the outer hub to turn. The tire and
rim assembly is attached to the outer hub of the planetary gear box. The wheel motor
assembly is attached to the inner hub of the planetary gear box and does not move.
The outer hub of the planetary gear box uses bearings to turn around the inner hub.
Refer to the OEM manual for more information on the operation of the planetary gear
box.
The wheel motor is attached to the shaft of the planetary gear box. The distance
between the spacer ring of the coupling and the input shaft of the planetary gear box
must be set during the first installation.
T282B S/N 327 12-40-01

Rear Wheel Assembly
12-40-001 Rear Wheel Assembly
12-40-02 T282B S/N 327

Rear Wheel Assembly
12-40-100-DA - How to Remove the Rear Wheel Assembly

Setup

Drain the oil from the rear wheel assembly (Ref. 12-40-700-DA).
Remove the rear tire and rim assembly (Ref. 12-42-105-DA).
Put the rear of the haul truck on applicable supports.
Make sure that the removal of one rear wheel assembly does not cause the haul
truck to move.
Procedure
(Ref. Fig. 12-40-002)
Disconnect the high voltage cables at the inboard terminals in the axle box.
Disconnect the hydraulic brake lines, speed sensor wires, gear oil cooling hoses,
and temperature sensor wires.
Put protective covers on the hydraulic brake lines, gear oil cooling lines, and
open ports.
Notice! The weight of the rear wheel motor assembly is 16000 kg (35300 lb).
Install the rear wheel assembly lift tool (Liebherr P/N T-128-K Ref.
02-00-000-DA).
Caution! The wheel assembly can move when the capscrews are removed.
Remove the bottom capscrews first and after that remove the top capscrews.
Carefully remove the bottom capscrews (1) and washers (2).

Carefully remove the top capscrews (1) and washers (2), and adjust the lift
device to make sure capscrews turn freely.
Keep the rear wheel assembly level and move the assembly (3) away from the
axle box.
Remove the rear wheel assembly (3).
Closeout
T282B S/N 327 12-40-03

Rear Wheel Assembly
12-40-002 Removal/Installation of the Rear Wheel Assembly
12-40-04 T282B S/N 327

Rear Wheel Assembly
12-40-200-DA - How to Install the Rear Wheel Assembly

Setup

(Ref. 12-40-100-DA).

Adhesive 3M 74 13149-A
03-12-000-DA)
Tubing, heat shrink 15234-Z
Parts Table:

1 Capscrew 60
2 Washer 60
4 Seal 4
Procedure
(Ref. Fig. 12-40-002)
Notice! The weight of the rear wheel motor assembly is 16000 kg (35300 lb).
Install the rear wheel assembly lift tool (Liebherr P/N T-128-K Ref.
02-00-000-DA).
Carefully, put the rear wheel assembly (3) in position against the axle box.
Make sure that the baffle seals (4) are in good condition and replace them, if
necessary.
If the baffle seals must be replaced, do this procedure:
Remove the used baffle seals (4) and use 3M 74 adhesive to install the new
baffle seals (4).
To continue the installation, do this procedure:
Install the capscrews (1) and washers (2) from top to bottom.
Gradually tighten the capscrews (1) to 1850 Nm (1360 lbf ft) in a star pattern.
Make sure that the ends of the high voltage cables are clean and free of oil.
Put heat shrink on the high voltage cable ends.
Connect the high voltage cable ends and make sure that they are secure.
T282B S/N 327 12-40-05

Rear Wheel Assembly
Connect the hydraulic brake lines, speed sensor wires, gear oil cooling hoses,
and temperature sensor wires.
Closeout
Install the rear tire and rim assembly (Ref. 12-42-205-DA).

Fill the oil in the wheel (Ref. 12-40-705-DA).
12-40-06 T282B S/N 327

Rear Wheel Assembly
12-40-400-DA - How to Check the Oil Level of the Rear Wheel

Assembly
Setup

Turn the rear wheel until the oil fill plug is at the 12 o'clock position.
Procedure
(Ref. Fig. 12-40-003)

operation.

If no oil comes out of the port, add oil to the wheel (Ref. 12-40-705-DA).
Install the oil level plug.
Closeout

T282B S/N 327 12-40-07

Rear Wheel Assembly
12-40-003 Rear Wheel Assembly Oil Level Check
12-40-08 T282B S/N 327

Rear Wheel Assembly
12-40-600-DA - How to Disassemble the Rear Wheel

Setup

Remove the rear wheel assembly (Ref. 12-40-100-DA).
Remove the rear brakes (Ref. 12-50-100-DA).
Remove the rear disc brake hub (Ref. 12-52-100-DA).
Procedure
(Ref. Fig. 12-40-004)
Caution! The planetary gearbox cover is not strong enough to hold the rear wheel assembly
vertically.
Put the rear wheel assembly on an applicable assembly device, or on an applicable lift
device horizontally.
Notice! The weight of the planetary gearbox is 11395 kg (25100 lb). The weight of the wheel
motor is 3760 kg (8300 lb).
Install the wheel motor removal tool (Liebherr P/N T-478 Ref. 02-00-000-DA).
Remove the wheel motor (4) from the gearbox (1).
Closeout
T282B S/N 327 12-40-09

Rear Wheel Assembly
12-40-004 Disassembly/Reassembly of the Rear Wheel
12-40-10 T282B S/N 327

Rear Wheel Assembly
12-40-605-DA - How to Assemble the Rear Wheel

Setup

Assemble the coupling to the wheel motor (Ref. 12-40-610-DA).
Assemble the coupling to the gear box (Ref. 12-40-615-DA).

Adhesive Loctite 638
Permatex® anti-seize lubricant 5080-B
Gear oil Mobilgear SHC 320 5087-D
03-12-000-DA)
Parts Table:

1 Gearbox 1
2 Washer 12
3 Capscrew 12
4 Wheel motor 1
Procedure
(Ref. Fig. 12-40-004)
vertically.
Notice! The weight of the planetary gearbox is 11395 kg (25100 lb). The weight of the wheel
motor is 3760 kg (8300 lb).
Apply permatex anti-seize lubricant to the splines of the coupling on the wheel
motor (4) and the gearbox (1).
Apply permatex anti-seize lubricant to the seal face of the coupling on the wheel
motor (4).
Install the coupling of the wheel motor (4) on to the coupling of the gearbox (1).
Turn the shaft of the wheel motor (4) to make a connection with the coupling
spline of the gearbox (1).
T282B S/N 327 12-40-11

Rear Wheel Assembly

Closeout
Install the rear disc brake hub (Ref. 12-52-200-DA).

Install the rear brakes (Ref. 12-50-200-DA).
Install the rear wheel assembly (Ref. 12-40-200-DA).
12-40-12 T282B S/N 327

Rear Wheel Assembly
12-40-610-DA - How to Disassemble the Wheel Motor Coupling

Setup
Procedure
(Ref. Fig. 12-40-005)
(Ref. Fig. 12-40-006)
To disassemble a wheel motor coupling without a centering disc, do this

procedure:
Remove the coupling (5) from the wheel motor shaft.
Remove the snap ring (2), back up ring (3), and spacer (4).
Remove the o-ring (6).
To disassemble a wheel motor coupling with a centering disc, do this procedure:
Remove the coupling (5) from the wheel motor shaft.
Remove the snap ring (2), and centering disc (7).
Remove the o-ring (6).
Closeout
T282B S/N 327 12-40-13

Rear Wheel Assembly
12-40-005 Disassembly/Assembly of the Wheel Motor Coupling without Centering Disc
12-40-006 Disassembly/Assembly of the Wheel Motor Coupling with Centering Disc
12-40-14 T282B S/N 327

Rear Wheel Assembly
12-40-615-DA - How to Assemble the Wheel Motor Coupling

Setup


Parts Table:

1 Capscrew 1
2 Snap ring 1
3 Back-up ring 1
4 Spacer 1
5 Coupling, motor 1
6 O-ring 1
7 Centering disc 1
Procedure
(Ref. Fig. 12-40-005)
(Ref. Fig. 12-40-006)
To assemble a wheel motor coupling without a centering disc, do this

procedure:
Install the spacer (4), back-up ring (3), and snap ring (2) in the coupling (5).
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.
Use an oven to apply heat of approximately 80 to 120 °C (176 to 248 °F) to the
coupling (5).
Apply grease to the o-ring (6) and splines of the wheel motor.
Install the o-ring (6) in the coupling (5).
Install the coupling (5) to the wheel motor shaft.
Apply Loctite 638 to the capscrew (1).
Tighten the capscrew (1) to 2000 Nm (1480 lbf ft).
To assemble a wheel motor coupling with a centering disc, do this procedure:
Install the centering disc (7), and snap ring (2) in the coupling (5).
T282B S/N 327 12-40-15

Rear Wheel Assembly
high temperatures.
Use an oven to apply heat of approximately 80 to 120 °C (176 to 248 °F) to the
coupling (5).
Apply grease to the o-ring (6) and splines of the wheel motor.
Install the o-ring (6) in the coupling (5).
Install the coupling (5) to the wheel motor shaft.
Apply Loctite 638 to the capscrew (1).
Tighten the capscrew (1) to 2000 Nm (1480 lbf ft).
To make sure the coupling is correctly installed, do this procedure:
Measure from the end of the motor shaft to the end of the coupling.
If the measurement is 165 mm (6.496 in.) plus or minus 0.5 mm (0.02 in.),
The coupling is installed correctly.
If the measurement is not 165 mm (6.496 in.) plus or minus 0.5 mm (0.02 in.),
Remove the coupling, install again, and measure one more time.
Closeout
12-40-16 T282B S/N 327

Rear Wheel Assembly
12-40-620-DA - How to Disassemble the Gearbox Coupling

Setup
Procedure
(Ref. Fig. 12-40-007)
vertically.
To remove the gearbox coupling from the shaft, do this procedure:

Remove the snap ring (2).
Use a puller and remove the coupling (1) from the shaft of the gearbox.
Remove the o-ring (7) from the coupling (1).
To disassemble the gearbox coupling, do this procedure:
Remove the screws (8) and sealing washer (6).
Remove the o-ring (5) from the sealing washer (6).
Remove the locking ring (3) and spacer (4) from the coupling (1).
Closeout
T282B S/N 327 12-40-17

Rear Wheel Assembly
12-40-007 Disassembly/Assembly of the Gearbox Coupling
12-40-18 T282B S/N 327

Rear Wheel Assembly
12-40-625-DA - How to Assemble the Gearbox Coupling

Setup

Remove the shipping cover from the gear box shaft, if applicable.
If the gearbox seals are removed, or are not in place, do this procedure:
Assemble the gearbox seals (Ref. 12-40-635-DA).

Parts Table:

7 O-ring 1
8 Capscrew 6
6 Sealing washer 1
5 O-ring 1
1 Coupling, shaft 1
4 Spacer 1
3 Locking ring 1
2 Locking ring 1
Procedure
(Ref. Fig. 12-40-007)
vertically.
To assemble the gearbox coupling, do this procedure:

Apply grease to the o-ring (5).
Install the o-ring (5) on the coupling (1).
Install the sealing washer (6) on the coupling (1).
Apply Loctite 573 to the surface of the sealing washer (6) and install the o-ring
(7).
Apply Loctite 638 to the capscrews (8) and install the capscrews.
T282B S/N 327 12-40-19

Rear Wheel Assembly
Install the spacer (4) and locking ring (3).

To install the gearbox coupling to the shaft, do this procedure:
Apply grease to the splines of the coupling (1).
Install the coupling (1) to the shaft of the gearbox.
Install the snap ring (2).
Closeout
12-40-20 T282B S/N 327

Rear Wheel Assembly
12-40-635-DA - How to Assemble the Gear Box Shaft Seals

Setup


Parts Table:

1 Seal flange 1
2 Retainer ring 1
3 Capscrew 9
4 O-ring 1
5 Seal 2
Procedure
(Ref. Fig. 12-40-004)
Attention! The shaft seals are precision components.

Be careful not to cause damage to the shaft seals.
To assemble the seal flange, do this procedure:

Make sure that the o-ring (4) and shaft seals (5) are in good condition and have
no damage.
Make sure that the seal flange (1) is clean and has no damage.
Make sure that the edges of the seal flange (1) are smooth and chamfered.
Apply Loctite 573 to the outside diameter of the shaft seals (5).
Evenly push the shaft seals (5) into the seal flange (1).
Apply grease to the faces of the seals (5), and do not apply grease between the
seals.
Install the o-ring (4) on the seal flange (1).
To install the seal flange to the gearbox shaft, do this procedure:
Install the seal flange (1) in the gearbox.
Apply Loctite 638 to the capscrews (3).
Install the retainer (2) and capscrews (3).
T282B S/N 327 12-40-21

Rear Wheel Assembly
Closeout
12-40-22 T282B S/N 327

Rear Wheel Assembly
12-40-700-DA - How to Drain the Oil from the Rear Wheel

Assembly
Setup

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.
Procedure
(Ref. Fig. 12-40-008)
Put an applicable container below the oil drain plug at the bottom center position.
The oil capacity for the rear wheel is 280 L (74 U.S. gal).
Remove the oil drain plug at the bottom center.
Remove the oil fill plug at the top center and let the oil drain.
Install the oil fill and oil drain plugs when all the oil drains.
Closeout

T282B S/N 327 12-40-23

Rear Wheel Assembly
12-40-008 Rear Wheel Assembly Oil Drain
12-40-24 T282B S/N 327

Rear Wheel Assembly
12-40-705-DA - How to Fill the Rear Wheel Assembly with Oil

Setup

Turn the rear wheel until the oil fill plug is at the 12 o'clock position.

Oil Mobilgear SHC 320 5087-D
Procedure
(Ref. Fig. 12-40-009)
Remove the oil fill plug.

Slowly pour or use a pump to put the specified lubricant through the oil fill plug.
Give time for trapped air to come out of the rear wheel assembly.
Continue to pour the oil until the oil begins to flow from the oil level plug.
Install the oil fill plug and the oil level plug.
Operate the haul truck for a half an hour and do an oil level check (Ref.
12-40-400-DA).
Closeout
Inspect for leaks from the wheel seals.

T282B S/N 327 12-40-25

Rear Wheel Assembly
12-40-009 Rear Wheel Assembly Oil Fill
12-40-26 T282B S/N 327

Rear Tire and Rim Assembly
12-42 Rear Tire and Rim Assembly

The tires initially installed on the haul truck are 55/80-R63 E3R (41x63 in. rims). For
more information refer to the tire manufacturer maintenance guide or see your local
(Ref. Fig. 12-42-001)
The weight of the tire and rim assembly is 7750 kg (17100 lb), and has a height of
3.912 m (12.8 ft), and a width of 1.4 m (4.6 ft).
The larger tires can have a weight of 7938 kg (17500 lb).
If the air in tire is not released, the assembly can break apart when you remove the nuts with
Make sure that you release the air from the tire before you do maintenance.
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.
12-42-001 Tire and Rim Assembly
T282B S/N 327 12-42-01

Maintenance Tips
If you change the tire size you must change the setting in the electronic control. See
your Liebherr service representative.
12-42-02 T282B S/N 327

12-42-105-DA - How to Remove the Rear Tire and Rim Assembly

Setup

Park the haul truck on a level surface and put chocks on the tires.
Procedure
(Ref. Fig. 12-42-002)
Put the jack in position at the jacking point (Ref. 12-02-000-DA) near the tire that
you remove.
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
Deflate the air from the tire before maintenance.
Remove the valve core and deflate the inboard (8) and outboard (2) tire, as
necessary, to approximately 69 to 103 kPa (10.013 to 14.947 psi).
Notice! It is necessary to keep some pressure in the tire so that the bead seal does not break.
Keep approximately 69 to 103 kPa (10.013 to 14.947 psi) pressure in the tire.
Lift the jack until the tire is clear of the ground.
Move the tire machine into position and hold the outboard tire (2).
Attention! The diffuser valve can be damaged during the removal of the tire and rim assembly.
Remove the outboard tire and rim (2) from the wheel assembly.
Remove the capscrews (5), lockwashers (6), and hose guard (7).
T282B S/N 327 12-42-03

Attention! The valve stem and diffuser valve can be damaged during the removal of the tire
and rim assembly.
Remove the inboard tire and rim (8) from the wheel assembly.
If necessary to remove the rim adapter (4), do this procedure:
Remove the nuts (1) and the rim adapter (4).
Closeout
Inspect the studs (Ref. 12-42-400-DA).

12-42-04 T282B S/N 327

12-42-002 Removal/Installation of the Rear Tire and Rim Assembly
T282B S/N 327 12-42-05

12-42-205-DA - How to Install the Rear Tire and Rim Assembly

Setup

(Ref. 12-42-105-DA).

03-12-000-DA)
Parts Table:

1 Nut 58 53157AC-13
3 Nut 60 53157AC-13
4 Adapter, Rim 1 53157AC-9
5 Capscrew 4 933224401-76
6 Lockwasher 4 933224401-77
7 Guard, hose 1 933224401-75
9 Nut 58 53157AC-13
Procedure
(Ref. Fig. 12-42-002)
Clean the rim and the area on the wheel where you install the rim.
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.
Align the valve stem with the extension hose guard, and the diffuser valve with
the notch in the wheel assembly.
gradually tighten all the nuts (9).
12-42-06 T282B S/N 327


Align the extension hose for the valve stem of the inboard tire in position between
the mounting brackets for the hose guard.
Install the hose guard (7), capscrews (5), and lockwashers (6).
If the rim adapter (4) is removed,
Align the slot of the rim adapter (4) with the extension hose from the inboard tire
and rim (8), and do as follows:
Install the rim adapter (4).
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.
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.
Move the outboard tire and rim (2) into position.
Put the extension hose for the valve stem of the inboard rim through the
clearance hole of the outboard rim.
gradually tighten the nuts (1).
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.
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.
Make sure that the next operation of the haul truck is not longer than one hour
T282B S/N 327 12-42-07

and then tighten all the nuts (1), (3), and (9) to 1850 Nm (1360 lbf ft).
Repeat the previous step three to four times, or until all the nuts keep a torque
value of 1850 Nm (1360 lbf ft).
Closeout
12-42-08 T282B S/N 327

12-42-300-DA - How to Replace the Studs of the Rear Wheel

Setup


Adhesive Loctite, medium duty
Parts Table:
REFERENCE TECHNICAL PART QUANTITY DRAWING-ITEM

1 Stud, rim adapter 58 53157AC-10
2 Stud, rear inboard 58 933224401-96
3 Bolt, rear outboard 60 933224401-97
Procedure
(Ref. Fig. 12-42-003)
To replace the rim adapter studs, do this procedure:

Push the new stud (1) into the rim adapter.
To replace the rear inboard studs, do this procedure:
Push the new stud (2) into the mounting flange on the rear wheel assembly.
To replace the rear inboard bolts, do this procedure:
Loosen and remove the bolts (3), and discard the bolts.
Apply a medium duty Loctite to the bolts (3), and install the bolts.
Tighten the bolts (3) to 922 Nm (680 lbf ft).
Closeout
T282B S/N 327 12-42-09

12-42-003 Replacement of the Studs
12-42-10 T282B S/N 327

12-42-400-DA - How to Inspect the Studs of the Rear Wheel

Setup

Procedure
(Ref. Fig. 12-42-004)
Inspect these items for missing or damaged studs:

the mounting bolts for the outboard tire and rim on rear wheel assembly
the mounting studs for the inboard tire and rim on rear wheel assembly
the rim adapter studs on rear wheel assembly
If there are more than four missing or damaged studs in the bolt circle,
If there are two or more missing or damaged studs adjacent to the other,
If there are less than four serviceable studs between each missing or damaged
stud,
Closeout
T282B S/N 327 12-42-11

12-42-004 Inspection of the Studs
12-42-12 T282B S/N 327

Rear Brakes
12-50 Rear Brakes

The rear brake assembly is installed on this component:
Rear Disc Brake Hub (Ref. 12-52-000-DA)
The rear brake assembly has the components that follow:
Brake Calipers
Brake Discs
12-50-001 Rear Brakes

(Ref. Fig. 12-50-001)
The rear brakes are a two disc assembly. Each of the discs has one service caliper
and one park brake caliper. The calipers are attached to the wheel 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 wheel motor inside the axle box.
When the armature shaft of the wheel motor turns, the discs turn. When you apply the
brakes the calipers close against the discs to help to stop the haul truck.
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
T282B S/N 327 12-50-01

Rear Brakes
The brake lining or brake disc has contamination.

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 °C (400 °F) 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.
Maintenance Tips
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.
12-50-02 T282B S/N 327

Rear Brakes
12-50-100-DA - How to Remove the Rear Brakes

Setup

Bleed the brake system (Ref. 09-52-300-DA).
To remove the brake discs, you must remove the park brakes (Ref.
12-60-100-DA).
Open the access panel on the axle box.
Procedure
(Ref. Fig. 12-50-002)

Bleed the oil from the bleeder valves (17) on the calipers.
Disconnect the hydraulic supply (18) and jumper lines (19) and install protective
covers.
Notice! The weight of the caliper is 42 kg (92.6 lb).

Remove two of the capscrews (7) and washers (6) and install two temporary
alignment studs 350 mm (13.779 in.) long.
Hold the inboard piece of the inboard caliper (5) with an applicable lift device.
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.
Carefully move the inboard caliper piece of the inboard caliper (5) off the
alignment studs.
Notice! The weight of the brake disc is 127 kg (280 lb).

Securely hold the inboard brake disc (8).

Remove the inboard brake disc (8).
Securely hold the outboard caliper piece of the inboard caliper (5).
T282B S/N 327 12-50-03

Rear Brakes
Remove the outboard caliper piece of the inboard caliper (5) and the shims (3).
Remove the capscrews (11) and the disc adapter (4).
Remove two of the capscrews (12) and washers (13) and install two temporary
alignment studs 350 mm (13.779 in.) long.
Hold the inboard piece of the outboard caliper (5) with an applicable lift device.
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.
Carefully move the inboard caliper piece of the outboard caliper (5) off the
alignment studs.
Securely hold the outboard brake disc (8).
Remove the outboard brake disc (8).
Remove the outboard caliper piece of the outboard caliper (5) and the shims (3).
Remove the temporary alignment studs.
If access to the wheel motor is necessary, do this procedure to remove the
remaining parts:
Remove the capscrews (1) and (15) and the adapters (2) and (16).
Closeout
Inspect the brake lining (Ref. 12-50-400-DA).

Inspect the brake disc (Ref. 12-50-405-DA).
To remove the rear disc brake hub, do procedure (Ref. 12-52-100-DA).
12-50-04 T282B S/N 327

Rear Brakes
12-50-002 Removal/Installation of the Rear Brakes
T282B S/N 327 12-50-05

Rear Brakes
12-50-200-DA - How to Install the Rear Brakes

Setup

(Ref. 12-50-100-DA).

03-12-000-DA)
Parts Table:

1 Capscrew 7
2 Adapter 1
3 Shims AR
4 Adapter 1
5 Caliper 2
6 Washer 6
7 Capscrew 6
8 Disc 2
9 Washer 32
10 Capscrew 32
11 Capscrew 12
12 Capscrew 6
13 Washer 6
14 Adapter 1
15 Capscrew 7
16 Adapter 1
Procedure
(Ref. Fig. 12-50-002)
(Ref. Fig. 12-50-003)

Install the adapter (16) and capscrews (15).
Notice! The weight of the brake disc is 127 kg (280 lb).

Install the outboard brake disc (8).
12-50-06 T282B S/N 327

Rear Brakes

Install four of the capscrews (10) and washers (9) at every 90 degrees.
Measure the dimension (X) from the inboard face of the lower adapter (16) to the
inboard face of the disc (8).
Shim thickness is equal to (X) subtract 152 mm (5.984 in.)±15 mm (0.591 in.).
Remove the capscrews (10), washers (9), and the disc (8).
Install the applicable shims (3).
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 (92.6 lb).

Notice! The two calipers are different.

Make sure you install the correct caliper in the correct position and location.
Install the outboard caliper piece of the outboard caliper (5) on the alignment
studs.
Install the outboard brake disc (8).
Install the capscrews (10) and the washers (9).
Install the inboard caliper piece of the outboard caliper (5) on the alignment
studs.
Install the adapter (2) and the capscrews (1).
Install shims (3) to center the adapter (2) over the disc (8) to 0.25 mm (0.01 in.).
Install the park brake adapter (14) and four of the capscrews (12) and washers
(13).
Install the disc adapter (4) and capscrews (11).
Install the inboard brake disc (8).
Install four of the capscrews (10) and washers (9) at every 90 degrees.
Measure the dimension (Y) from the inboard face of the caliper adapter (2) to the
inboard face of the disc (8).
T282B S/N 327 12-50-07

Rear Brakes
Shim thickness is equal to (Y) subtract 152 mm (5.984 in.)±15 mm (0.591 in.).
Remove the capscrews (10), washers (9), and the disc (8).
Install the applicable shims (3).
Install two alignment studs in the location for the capscrews (7) for the inboard
caliper (5).
Install the outboard caliper half of the inboard caliper (5) on the alignment studs.
Install the inboard brake disc (8).
Install the capscrews (10) and the washers (9).
Install the inboard caliper half of the inboard caliper (5).
Install four of the capscrews (7) and washers (6).
Remove the alignment studs and lubricate and install the capscrews (7) and
washers (6) that remain.
Install shims (3) to center the adapter (14) over the disc (8) to 0.25 mm (0.01 in.).
Remove the alignment studs and install all the capsrews (12) and washers (13).

Remove the protective covers and connect the hydraulic supply (18) and jumper
lines (19).
Tighten the bleeder valves (17) to 11.3 to 20.34 Nm (100 to 180 lbf in.).
Closeout
If applicable, install the park brakes (Ref. 12-60-200-DA).

Close the access panel on the axle box.
If you install a new brake disc or brake lining, burnish the brakes (Ref.
12-50-305-DA).
12-50-08 T282B S/N 327

Rear Brakes
12-50-003 Installation of Brake Calipers
T282B S/N 327 12-50-09

Rear Brakes
12-50-300-DA - How to Bleed the Rear Brake

Setup

Make sure that all of the hydraulic connections and fittings are correctly tightened
(Ref. 12-50-200-DA).
Two maintenance personnel are necessary to do the bleed procedure.
Procedure

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.
Put a small rubber tube on the bleed screws to point the fluid away from the
brakes and into an applicable container.
Start the engine.
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.
Loosen the highest bleeder screw on the service brake calipers.
Put a small rubber tube on the bleed valves to point the fluid away from the
brakes.
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.
12-50-10 T282B S/N 327

Rear Brakes

Apply the park brake and at the same time fully apply the service brakes.
This will automatically supply the correct adjustment and setup to the park brake .
Make sure that there are no hydraulic leaks.
Closeout
Correctly discard all the hydraulic fluid collected from the bleed procedure. Follow
the environmental regulations.
Make sure that the brake and steering hydraulic tank is at a serviceable level
(Ref. 07-20-705-AA).
T282B S/N 327 12-50-11

Rear Brakes
12-50-305-DA - How to Burnish the Rear Brake

Setup
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 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.
Procedure
Drive the haul truck 8 to 15 km/h (5 to 9.3 mph) for approximately 135 m (442.9
ft) and at the same time apply the service brakes at 30-50% effort.
Press the override switch on the dump control lever during the time the service
brake is applied.
The brakes get hot and some smoke can show as the temperature increases.
Stop the haul truck and measure the temperature of the disc.
Monitor the front brakes.
If the disc temperature is less than 205 °C (400 °F), do this procedure:
Repeat the procedure.
If the disc temperature is equal to or more than 205 °C (400 °F), do this
procedure:
Let the disc to become cool to 125 °C (255 °F).
Release the service and park brakes and repeat the procedure one time.
Closeout
Inspect for leaks or other unsatisfactory conditions.

12-50-12 T282B S/N 327

Rear Brakes
12-50-400-DA - How to Inspect the Brake Lining

Setup

Remove the brake calipers (Ref. 12-50-100-DA).
Procedure
Caution! If you replace only one brake lining, disc damage can occur.
Measure the thickness of the brake lining.

If the thickness is 3 mm (0.118 in.) or less,
Replace the two brake linings on or before this dimension is reached.
Inspect the brake lining.
If the lining has cracks or signs of burn,
If the lining or portions of the lining fall or break loose from the carrier,
Closeout
T282B S/N 327 12-50-13

Rear Brakes
12-50-405-DA - How to Inspect the Brake Disc

Setup
Remove the brake disc (Ref. 12-50-100-DA).
Procedure
Measure the thickness of the brake disc.

If the disc is worn or has grooves that decrease its thickness down to 22 mm
(0.866 in.) thick, then replace the brake disc.
With a straight edge, check for distortion.
If the brake disc is warped more than 1.5 mm (0.059 in.), then replace the brake
disc.
Inspect the brake disc for heat checks or cracks.
If the disc has heat checks or cracks that are more than 1.5 mm (0.059 in.) deep,
-or-
If the disc has cracks that go completely across the face of the disc,
Closeout
12-50-14 T282B S/N 327

Rear Brakes
12-50-410-DA - How to Inspect the Caliper Parts

Setup
Procedure
Inspect the o-ring grooves in the housing for scratches or corrosion.

Remove all small scratches and corrosion with a fine emery cloth.
If there are large scratches, large amounts of corrosion, or the housing is
damaged or worn,
If the piston shows signs of wear in the seal rubbing area and you can feel an
irregularity on the surface,
Replace the piston.
If the pistons with a layer of chrome show signs of the chrome that falls or
cracks,
Replace the piston.
Inspect the caliper ports and end plate bolt holes for thread damage.
Replace the components that have thread damage that cannot be repaired.
Do a visual inspection of the piston oil seals.
Warning! Liebherr haul trucks use mineral based hydraulic oil.

If there is oil on the outside of the caliper housing or oil leaks past the seals,
Remove the oil seals.
Put a layer of oil on the new seals and the piston.
Install new seals.
Closeout
Reassemble the caliper (Ref. 12-50-605-DA).
T282B S/N 327 12-50-15

Rear Brakes
12-50-600-DA - How to Disassemble the Rear Brake Caliper

Setup
Remove the rear brake caliper (Ref. 12-50-100-DA).
Procedure
(Ref. Fig. 12-50-004)
Notice! The weight of the rear brake caliper is 42 kg (92.6 lb).

Remove the capscrews (19) and endplates (3).

Remove the brake linings (21).
Remove the elbow fittings (1), connectors (2), tee fitting (18), and bleeder screws
(6).
Remove the plugs (5) and (17).
Remove the nuts (14), washers (13), and dust boots (7).
Remove the pistons (10).
Remove and discard the o-rings (9) and backup rings (8).
Remove the plug (15), cap (16), snap ring (20), plug (12), and boot (11).
Closeout
12-50-16 T282B S/N 327

Rear Brakes
12-50-004 Disassembly/Reassembly of the Rear Brake Caliper
T282B S/N 327 12-50-17

Rear Brakes
12-50-605-DA - How to Assemble the Rear Brake Caliper

Setup

Grease Silicone Commercially Available
Oil Hydraulic 5081-A
Adhesive Loctite 271 Commercially Available
Parts Table:

1 Elbow fitting 1 10169416
2 Connector 4 10169416
3 Endplate 2 10169416
3A Endplate (opposite) 2 10169416
4 Caliper 2 10169416
5 Plug 8 10169416
7 Dust boot 4 10169416
8 Backup ring 4 10169416
9 O-Ring 4 10169416
10 Piston 4 10169416
11 Boot 2 10169416
12 Plug 2 10169416
13 Washer 4 10169416
14 Nut 4 10169416
15 Plug 2 10169416
16 Cap 2 10169416
17 Plug 4 10169416
18 Tee fitting 1 10169416
19 Capscrew 12 10169416
20 Snap ring 2 10169416
21 Lining 2 10169416
Procedure
(Ref. Fig. 12-50-004)
Danger! The components of the calipers operate together.

to personnel.
Lubricate all pistons, bores, new o-rings, backup rings, and seals with silicone
grease, for example Dow Corning DC-4 or equivalent.
12-50-18 T282B S/N 327

Rear Brakes
Warning! The seals and components made from rubber are made to operate with the type of
hydraulic oil the Liebherr haul trucks use.
Notice! The weight of the rear brake caliper is 42 kg (92.6 lb).

If silicone grease is not available,

Use the same type of fluid that is in the brake system. Do not use silicone grease
on the dust boot.
Install new o-rings (9) in each of the bore grooves of the caliper (4).
Install new backup rings (8) against the o-rings (9) in each of the bores.
Push the pistons (10) into the housing bores carefully and to not damage the
o-rings (9).
Make sure the pistons (10) are straight and fully in the bores.
Caution! Incorrect installation of the dust boot causes the piston to cut and damage the dust
boot when pressure is applied.
Make sure the dust boots are fully installed into the housing and piston grooves.
Install the dust boots (7) into the housing groove and into the piston groove.
Push the dust boots (7) tightly down around the grooves.
Install the nuts (14) and washers (13).
Attention! Some torque values in this procedure are pound-force inch (lbf in.) and some are
pound-force feet (lbf ft).
Read the torque values correctly.
Tighten the nuts (14) to 13.6 to 17 Nm (120 to 150 lbf in.).

Install the plug (15), cap (16), snap ring (20), plug (12), and boot (11).
Tighten the cap (16) to 340 Nm (250 lbf ft).
Tighten the plug (15) to 27 Nm (240 lbf in.).
Caution! The brake linings are made to be replaced in pairs.

If you replace only one brake lining, disc damage can occur.
Install the brake linings (21) into the brake housing.
T282B S/N 327 12-50-19

Rear Brakes
Apply Loctite 271 to the threads of the end plate bolts (19).
Install the end plates (3) and the bolts (19).
Tighten the bolts (19) to 515 to 625 Nm (380 to 460 lbf ft).
Make sure that the linings (6) move freely inside the end plates (3).
Install the elbow fittings (1), connectors (2), and tee fitting (18), and bleeder
screws (6).
Install the bleeder screws (6) so that the bleeder screws (6) are at the high end of
the caliper housing (4) when the bleeder screws (6) are installed on the haul
truck.
Tighten the bleeder screws (6) to 11.3 to 20.34 Nm (100 to 180 lbf in.).
Install the plugs (5) and (17).
Tighten the plugs (5) and (17) to 11.3 to 20.34 Nm (100 to 180 lbf in.).
Closeout
Caution! If you store the housing put protective covers.

Install protective covers over the fittings to prevent contamination inside the housing.
Do a low pressure test of both caliper halves (4) at 3.5 bar (50 psi) to examine for
leaks.
12-50-20 T282B S/N 327

Rear Disc Brake Hub
12-52 Rear Disc Brake Hub

(Ref. Fig. 12-52-001)
The rear disc brake hub connects to this assembly:
12-52-001 Rear Disc Brake Hub
Operation
The rear disc brake hub is installed on the shaft of the rear wheel motor. The rear disc
brake hub turns when the wheel motor shaft turns. The rear brake discs are attached
to the brake hub and turn when the motor shaft turns.
Maintenance Tips
The rear disc brake hub becomes hot before installation. The temperature of the disc
brake hub decreases and the brake hub tightens to the motor shaft. A special
procedure is necessary to remove the rear disc brake hub (Ref. 12-52-100-DA).
T282B S/N 327 12-52-01

Rear Disc Brake Hub
12-52-100-DA - How to Remove the Rear Disc Brake Hub

Setup

Remove the rear brakes (Ref. 12-50-100-DA).
Procedure
(Ref. Fig. 12-52-002)
(Ref. Fig. 12-52-003)
Remove the capscrew (3) and washer (4).

Remove the capscrews (5), lockwashers (6), and cap plate (2).
Notice! The weight of the hub is 75 kg (165 lb).

Use the disc brake hub puller tool (Liebherr P/N T-504-A Ref. 02-00-000-DA).
Install six Grade 8 rods with a thread, at equally space, in the hub (1).
Make sure that you install the rods with a thread a minimum of 25 mm (0.984 in.)
deep into the hub (1).
Install the mount puller plate onto the rods with a thread.
Install the 3/4-10 inch nuts onto the rods with a thread.
Install a 30 ton hydraulic ram between the wheel motor shaft and the puller plate.
Make sure that the ram base is clear of the hub (1).
Evenly tighten the nuts until the puller plate is against the hydraulic ram.
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 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,

Let the motor shaft and brake hub become cool and then do the procedure again.
Increase the pressure with the ram until the hub (1) breaks free.
Examine the hub (1) and replace it if there is a damage to the hub.
Closeout
Removal all tools, equipment, and unwanted materials from the work area.
12-52-02 T282B S/N 327

Rear Disc Brake Hub
12-52-002 Removal/Installation of the Rear Disc Brake Hub
T282B S/N 327 12-52-03

Rear Disc Brake Hub
12-52-003 Removal/Installation of the Rear Disc Brake Hub
12-52-04 T282B S/N 327

Rear Disc Brake Hub
12-52-200-DA - How to Install the Rear Disc Brake Hub

Setup

(Ref. 12-52-100-DA).

Permatex® anti-seize compound 5080-B
Anti-seize See recommended lubricants (Ref.
03-12-000-DA)
Parts Table:

1 Hub 1
2 Cap Plate 1
3 Capscrew 1
4 Washer 1
5 Capscrew 3
6 Washer 3
Procedure
(Ref. Fig. 12-52-002)
(Ref. Fig. 12-52-003)
Clean and examine the wheel motor shaft.

Apply permatex anti-seize compound to the wheel motor shaft.
high temperatures.
Evenly apply heat to the disc brake hub (1) to 175 °C (345 °F).
Notice! The weight of the hub is 75 kg (165 lb).

Install the hub (1) onto the wheel motor shaft.

Make sure that the hub (1) is flush with the wheel motor shaft.
Install the cap plate (2), lockwashers (6), and capscrews (5).
T282B S/N 327 12-52-05

Rear Disc Brake Hub

Closeout
Install the rear brakes (Ref. 12-50-200-DA).

12-52-06 T282B S/N 327

Park Brake (Carlisle)
12-60 Park Brake (Carlisle)

(Ref. Fig. 12-60-001)
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
12-60-001 Park Brake (Carlisle)

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 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
T282B S/N 327 12-60-01

screws in place.
Packings and backup rings are seated in the grooves in the caliper bores. The
packings 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.
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.
12-60-02 T282B S/N 327

12-60-100-DA - How to Remove the Park Brake

Setup

Procedure
(Ref. Fig. 12-60-002)
(Ref. Fig. 12-60-003)

Disconnect the hydraulic supply lines (4) and install protective covers.
Notice! The weight of the park brake caliper is 48 kg (105.8 lb).

Remove the capscrews (2), washers (1), calipers (3), and shims (5).
Closeout
Inspect the brake disc (Ref. 12-50-405-DA).

T282B S/N 327 12-60-03

12-60-002 Removal/Installation of the Park Brake
12-60-04 T282B S/N 327

12-60-003 Removal/Installation of the Park Brake
T282B S/N 327 12-60-05

12-60-200-DA - How to Install the Park Brake (Carlisle)

Setup

(Ref. 12-60-100-DA).
Parts Table:

1 Washer 12
2 Capscrew 12
3 Caliper 2
5 Shims AR
Procedure
(Ref. Fig. 12-60-002)
(Ref. Fig. 12-60-003)
Connect the hydraulic supply lines (4) to the ports with a thread of the two piston
housings.
Pressurize the hydraulic supply lines (4) to 103 to 207 bar (1490 to 3000 psi) to
retract the pistons.
Keep the hydraulic supply lines (4) pressurized during the installation.
Notice! The weight of the park brake caliper is 48 kg (105.8 lb).

Install the calipers (3), capscrews (2), and washers (1).

Install three shims (4) between the adapter and caliper on the two sides.
Measure the distance between the carrier lining assembly to the brake disc.
Add or remove shims (4) to supply 0.5 to 1.25 mm (0.02 to 0.049 in.) between the
carrier lining assembly and the disc.
Tighten the capscrews (2) to 515 to 530 Nm (380 to 390 lbf ft).
Measure the distance between the carrier lining assembly to the brake disc.
Add or remove shims (5) to supply 0.5 to 1.25 mm (0.02 to 0.049 in.) between the
carrier lining assembly and the disc.
Closeout

12-60-06 T282B S/N 327

12-60-300-DA - Mechanical Release of the Park Brake

Setup

Procedure
(Ref. Fig. 12-60-004)
(Ref. Fig. 12-60-005)
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.
Gradually tighten all of the capscrews (1) one turn at a time.
Closeout
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.
Stop the engine and apply the hand and park brakes.
T282B S/N 327 12-60-07

12-60-004 Mechanical Release of the Park Brake
12-60-08 T282B S/N 327

12-60-005 Mechanical Release of the Park Brake
T282B S/N 327 12-60-09

12-60-400-DA - Inspection of the Caliper Parts

Setup
Procedure
Inspect the carrier lining assembly for worn or damaged parts.

If the piston shows signs of wear in the seal rubbing area and you can feel a
defect on the surface,
Replace the piston.
If the pistons with a layer of chrome show signs of the chrome that falls or
cracks,
Replace the piston.
Inspect all bleeder screws and fitting for damage to the threads.
Replace all components that have thread damage that cannot be repaired.
Closeout
Assemble again the caliper (Ref. 12-60-605-DA).
12-60-10 T282B S/N 327

12-60-600-DA - How to Disassemble the Park Brake Caliper

Setup
Remove the park brake caliper from the haul truck (Ref. 12-60-100-DA).
Procedure
(Ref. Fig. 12-60-006)
Loosen all of the capscrews (1), one turn at a time, to release the load off the
springs.
Notice! There is an epoxy adhesive layer on the screws to lock the screws to the pistons.
It can be necessary to use more than usual torque value to loosen the screws. If
necessary, use heat, 175 °C (345 °F) maximum, to loosen the screws.
Remove the capscrews (1), washers (2), and piston cap (3).
Remove the capscrews (8) and the carrier lining (7).
Remove the springs (4) and (5).
Remove and discard the packings (10) and (13).
Remove the backup rings (9) and (14), and the bleeder (11).
Closeout
T282B S/N 327 12-60-11

12-60-006 Disassembly/Reassembly of the Park Brake Caliper
12-60-12 T282B S/N 327

12-60-605-DA - How to Assemble the Park Brake Caliper

Setup

Epoxy adhesive Scotch Weld, structural adhesive Commercially available
2158 B/A
Solvent Commercially available
Procedure
(Ref. Fig. 12-60-006)
Lubricate the packings (10) and (13), and the backup rings (9) and (14) with
mineral oil.
Install the packing (13) in the grooves of the piston housing (12).
Install the backup ring (14) in the grooves of the piston housing (12) with the
rounded side against the packing (13).
Install the packing (10) in the grooves of the piston housing (12).
Install the backup ring (9) in the grooves of the piston housing (12) with the
rounded side against the packing (10).
Clean the screws (8) with solvent to remove all used adhesive.
Apply an epoxy adhesive layer to the threads of the screws (8) so that the epoxy
covers four to five threads.
Put the carrier lining (7) in position on the piston (6).
Install the screws (8).
Carefully put the piston (6) in the piston housing (12), and do not damage the
packings (10) and (13), and the backup rings (9) and (14).
Install the springs (5) and (4) on the ends with a thread of the screws (8).
Put the piston cap (3), washers (2), and capscrews (8) in position on the piston.
Tighten the capscrews (8) gradually.
Closeout
Put protective covers on all open ports.
T282B S/N 327 12-60-13

12-60-14 T282B S/N 327

13 Frame and Structures
Frame.............................................................................................................. 13-10-01
Frame Specification and MaintenanceTables..................................... 13-10-04
Hoist Carriage................................................................................................ 13-12-01
Superstructure............................................................................................... 13-20-01
How to Remove the Hood and Grill.....................................................13-20-04
How to Remove the Superstructure Crossmember............................ 13-20-08
How to Remove the Diagonal Ladder and Handrails.......................... 13-20-10
How to Remove the Battery Box......................................................... 13-20-16
How to Install the Hood and Grill........................................................ 13-20-18
How to Install the Superstructure Crossmember................................ 13-20-20
How to Install the Diagonal Ladder and Handrails.............................. 13-20-21
How to Install the Battery Box............................................................. 13-20-23
Superstructure Specification and MaintenanceTables........................13-20-24
Dump Body.....................................................................................................13-30-01
How to Remove the Dump Body.........................................................13-30-02
How to Install and Align the Dump Body.............................................13-30-04
How to Inspect the Dump Body.......................................................... 13-30-06
How to Install and Align the Dump Body Guides................................ 13-30-07
How to Lift the Dump Body for Maintenance.......................................13-30-10
How to Lower the Dump Body after Maintenance...............................13-30-11
How to Lower the Dump Body Manually............................................. 13-30-12
Dump Body Specification and MaintenanceTables.............................13-30-13
Dump Body Pivot Pin.................................................................................... 13-32-01
How to Remove the Dump Body Pivot Pin and Bearing..................... 13-32-02
How to Install and Align the Dump Body Pivot Pin and Bearing......... 13-32-04
Dump Body Pivot Pin Specification and MaintenanceTables............. 13-32-06
Dump Body Pads........................................................................................... 13-34-01
How to Remove the Dump Body Pads................................................13-34-02
How to Install and Align the Dump Body Pads....................................13-34-05
Dump Body Pads Specification and MaintenanceTables................... 13-34-08
Rock Knocker.................................................................................................13-36-01
How to Remove the Rock Knocker..................................................... 13-36-02
How to Install the Rock Knocker......................................................... 13-36-04
Rock Knocker Specification and MaintenanceTables......................... 13-36-05
Axle Box......................................................................................................... 13-40-01
How to Remove the Axle Box Access Door........................................ 13-40-02
How to Install the Axle Box Access Door............................................ 13-40-04
How to Check the Axle Box, Drag Links and Control Arm Bushing.... 13-40-05
Axle Box Specification and MaintenanceTables................................. 13-40-07
Rear Control Arm...........................................................................................13-50-01
How to Remove the Rear Control Arm................................................13-50-02
How to Install the Rear Control Arm....................................................13-50-05
Rear Control Arm Specification and MaintenanceTables................... 13-50-09
Drag Link........................................................................................................ 13-60-01
How to Remove the Drag Link............................................................ 13-60-02

How to Install the Drag Link..................................................................................... 13-60-05
Drag Link Specification and MaintenanceTables..................................................... 13-60-07

13 Frame and Structures
(Ref. Fig. 13-00-001)
The frame and structures chapter has these sections:
Superstructure (Ref. 13-20-000-DA)
Dump Body (Ref. 13-30-000-DA)
Dump Body Pivot Pin (Ref. 13-32-000-DA)
Dump Body Pads (Ref. 13-34-000-DA)
Rock Knocker (Ref. 13-40-000-DA)
Rear Control Arm (Ref. 13-50-000-DA)
Drag Link (Ref. 13-60-000-DA)
T282B S/N 327 13-00-01

Frame and Structures Maintenance Manual
13-00-001 Frame and Structures
13-00-02 T282B S/N 327

Maintenance Manual Frame and Structures
13-00-002 Frame and Structures
Overview
The dump body is installed above the frame and uses the frame as support. The dump
body transmits the weight of the load to the frame.
T282B S/N 327 13-00-03

The frame transmits the weight of the dump body to the wheels through the
suspensions and the axle box. The axle box is not directly attached to the frame.
The frame is the primary support for the haul truck. Many components are installed on
the frame and connect to other components or systems.
The superstructure is the primary support for many components.
13-00-04 T282B S/N 327

Frame
13-10 Frame
(Ref. Fig. 13-10-001)
The frame is assembled from a nickel-copper alloy ASTM A-710. High-stress areas on
the frame have stiffeners to make the structure stronger.
The frame has the components that follow:
Hoist Carriage (Ref. 13-12-000-DA)
T282B S/N 327 13-10-01

Frame
13-10-001 Frame

The frame is the primary support for the haul truck and the components that follow:
Power Module Mounts
13-10-02 T282B S/N 327

Frame
Superstructure Mounts
Front Suspension Upper Mounts
Front Control Arms Pivot with Bushing
Fuel and Hydraulic Tank Mounts
Dump Body Pivot Bushings
Rear Suspension Upper Mount Bushing
Rear Axle Control Arm Mounts
Drag Link Mounts
Maintenance Tips
The A-710 steel on the frame has very good weld properties (Ref. 14-00-000-DA).
T282B S/N 327 13-10-03

Frame
13-10-900-DA - Frame Specification and MaintenanceTables

Setup
Notice! There a different types of frames on the different trucks.

Make sure that you know the correct part number of your frame.
Procedure
Table A is for the specifications of the frame.
Table B is for the checks and inspections.
Part Number Hours Inspect
Closeout
13-10-04 T282B S/N 327

Hoist Carriage
13-12 Hoist Carriage

The hoist carriage is attached to the frame with pins, tear drop, bicycle links, panhead
bar, and bushings.
The lower dump cylinder pivot pin connects to these components:
Dump Body Cylinders (Ref. 08-50-000-DA)
13-12-001 Hoist Carriage
Operation
(Ref. Fig. 13-12-001)
The bores for the drag links are installed on the hoist carriage. All drag link forces from
the rear axle are transmitted to the side frame rails through the hoist carriage.
The lower dump cylinder pivot pins are welded to the hoist carriage. There is one lower
dump cylinder pivot pin on both sides of the haul truck.
T282B S/N 327 13-12-01

Hoist Carriage
13-12-02 T282B S/N 327

Superstructure
13-20 Superstructure
The superstructure is a platform installed on the top of the frame at the front of the haul
truck.
T282B S/N 327 13-20-01

Superstructure
13-20-001 Superstructure

The superstructure is the support for many components and personnel. The
components that are attached to the superstructure are:
13-20-02 T282B S/N 327

Superstructure
Operator cab
Control cabinet
Grid box
Battery box
Ladders
Handrails
Engine air cleaners
Hood and grill
T282B S/N 327 13-20-03

Superstructure
13-20-100-DA - How to Remove the Hood and Grill

Setup

01-20-000-DA).
Remove the ladders and handrails from the hood and grill (Ref. 13-20-110-DA).
Procedure
(Ref. Fig. 13-20-002)
(Ref. Fig. 13-20-003)
(Ref. Fig. 13-20-004)
Remove the capscrews (15) and (15A), washers (16), and backup bars (17), (18),
(19), (21), (22), and baffle (20).
Notice! The weight of the hood and grill without fluids is 1095 kg (2400 lb).
Attach an applicable lift device to the hood and grill.

Remove the capscrews (13), lockwashers (12), washers (11), and hood (5).
Remove the capscrews (1), lockwashers (2), washers (3), and grill (4).
Closeout
13-20-04 T282B S/N 327

Superstructure
13-20-002 Removal/Installation of the Hood and Grill
T282B S/N 327 13-20-05

Superstructure
13-20-06 T282B S/N 327

Superstructure
T282B S/N 327 13-20-07

Superstructure
13-20-105-DA - How to Remove the Superstructure

Crossmember
Setup
(Ref. Fig. 13-20-005)

01-20-000-DA).
Remove the hood (Ref. 13-20-100-DA).
Remove the battery covers and battery box (Ref. 13-20-115-DA).
Procedure
Notice! The crossmember (4) is very heavy.


Remove the locknuts (3), washers (2), capscrews (1), and the crossmember (4).
Closeout
13-20-08 T282B S/N 327

Superstructure
13-20-005 Removal/Installation of the Crossmember
T282B S/N 327 13-20-09

Superstructure
13-20-110-DA - How to Remove the Diagonal Ladder and

Handrails
Setup

01-20-000-DA).
Procedure
(Ref. Fig. 13-20-006)
(Ref. Fig. 13-20-007)
(Ref. Fig. 13-20-008)
(Ref. Fig. 13-20-009)
Notice! The weight of the handrail is 67 kg (148 lb).

Attach an applicable lift device or support to the handrail (28).

Remove the capscrews (25), lockwashers (26), washers (27), and handrail (28).
Notice! The weight of the handrail is 45 kg (99.2 lb).


Remove the capscrews (8), lockwashers (9), washers (10), and handrail (7).
Notice! The weight of the ladder is 242 kg (535 lb).

Attach an applicable lift device to the ladder (1).

Remove the capscrews (2), locknuts (6), washers (3), bushings (4), and wear
strips (5).
Remove the capscrews (16), washers (14), locknuts (13), shims (15), and ladder
(1).
Remove the capscrews (21) and (22), locknuts (24), lockwashers (20), washers
(23), shims (18), and support (19).
Attach an applicable support or lift device to the platform (17).
Remove the capscrews (12), lockwashers (11), and platform (17).
Closeout
13-20-10 T282B S/N 327

Superstructure
T282B S/N 327 13-20-11

Superstructure
13-20-006 Removal/Installation of the Diagonal Ladder and Handrails
13-20-12 T282B S/N 327

Superstructure
T282B S/N 327 13-20-13

Superstructure
13-20-14 T282B S/N 327

Superstructure
T282B S/N 327 13-20-15

Superstructure
13-20-115-DA - How to Remove the Battery Box

Setup

01-20-000-DA).
Remove the batteries (Ref. 06-10-100-DA).
Procedure
(Ref. Fig. 13-20-010)
Disconnect the hoses (6) and install protective covers.

Remove the capscrews (4), lockwashers (3), and washers (2) and (1).
Remove the battery boxes (5).
Closeout
13-20-16 T282B S/N 327

Superstructure
13-20-010 Removal/Installation of the Battery Box
T282B S/N 327 13-20-17

Superstructure
13-20-200-DA - How to Install the Hood and Grill

Setup

01-20-000-DA).
Parts Table:

3 Washer 10 51008AA-17
4 Grill 1 51008AA-12
5 Hood 1 51008AA-13
6 Washer 10 51008AA-8
10 Washer 8 51008AA-8
11 Washer 5 51008AA-7
15A Capscrew 13 51020BX-8
16 Washer 33 51020BX-41
17 Bar, backup 2 51020BX-72
18 Bar, backup 2 51020BX-120
19 Bar, backup 2 51020BX-74
20 Baffle 1 51020BX-82
21 Bar, backup 1 10467957-17
22 Bar, backup 1 10467957-18
Procedure
(Ref. Fig. 13-20-002)
(Ref. Fig. 13-20-003)
(Ref. Fig. 13-20-004)
Notice! The weight of the hood and grill without fluids is 1095 kg (2400 lb).
Attach an applicable lift device to the grill (4).

Put the grill (4) in position on the bumper.
13-20-18 T282B S/N 327

Superstructure
Install the capscrews (1), lockwashers (2), and washers (3).

Install the hood (5), capscrews (13), lockwashers (12), and washers (11).
Install the baffle (20), and capscrews (15) and (15A), washers (16), and backup
bars (17), (18), (19), (21), and (22).
Closeout
Install the ladders and handrails to the hood and grill (Ref. 13-20-210-DA).
T282B S/N 327 13-20-19

Superstructure
13-20-205-DA - How to Install the Superstructure Crossmember

Setup

01-20-000-DA).
Parts Table:

2 Washer 16 51006AX-9
3 Locknut 8 51006AX-1
4 Crossmember 1 51006AX
5 Washer 8 51006AX-8
6 Lockwasher 8 51006AX-10
Procedure
(Ref. Fig. 13-20-005)
Notice! The crossmember (4) is very heavy.

Install the crossmember (4), locknuts (3), washers (2), and capscrews (1).
Closeout
Install the battery covers and battery box (Ref. 13-20-215-DA).

Install the hood (Ref. 13-20-200-DA).
13-20-20 T282B S/N 327

Superstructure
13-20-210-DA - How to Install the Diagonal Ladder and

Handrails
Setup

01-20-000-DA).
Parts Table:

1 Ladder, diagonal 1 51007BC-6
2 Capscrew 4 51007BC-50
3 Washer 8 51007BC-8
4 Bushing 4 51007BC-41
5 Wear strip 2 51007BC-42
6 Locknut 4 51007BC-1
7 Handrail 1 51007BC-32
9 Lockwasher 8 51007BC-9
10 Washer 8 51007BC-4
14 Washer 10 51007BC-49
15 Shim 1 51007BC-40
17 Platform 1 51007BC-25
18 Shim 2 51007BC-39
19 Support 1 51007BC-28
23 Washer 8 51007BC-49
27 Washer 12 51007BC-4
28 Handrail 1 51007BC-31
Procedure
(Ref. Fig. 13-20-006)
Attach an applicable support or lift device to the platform (17).
T282B S/N 327 13-20-21

Superstructure
Install the capscrews (12), lockwashers (11), and platform (17).

Install the capscrews (21) and (22), locknuts (24), lockwashers (20), washers
(23), shims (18), and support (19).
Notice! The weight of the ladder is 242 kg (535 lb).

Attach an applicable lift device to the ladder (1).

Install the capscrews (16), washers (14), necessary shims (15), locknuts (13),
and ladder (1).
Install the capscrews (2), locknuts (6), washers (3), bushings (4), and wear strips
(5).
Notice! The weight of the handrail is 45 kg (99.2 lb).


Install the capscrews (8), lockwashers (9), washers (10), and handrail (7).
Notice! The weight of the handrail is 67 kg (148 lb).


Install the capscrews (25), lockwashers (26), washers (27), and handrail (28).
Closeout
13-20-22 T282B S/N 327

Superstructure
13-20-215-DA - How to Install the Battery Box

Setup

01-20-000-DA).
Parts Table:

1 Washer 12 53236-X-14
2 Washer 12 53236-X-5
3 Lockwasher 12 53236-X-6
4 Capscrew 12 53236-X-4
5 Battery box 3 53236-X-12
Procedure
(Ref. Fig. 13-20-010)
Install the battery boxes (5).

Install the capscrews (4), lockwashers (3), and washers (2) and (1).
Closeout
Install the batteries (Ref. 06-10-200-DA).

T282B S/N 327 13-20-23

Superstructure
13-20-900-DA - Superstructure Specification and

MaintenanceTables
Setup
Notice! There a different types of superstructures on the different trucks.

Make sure that you know the correct part number of your superstructure.
Procedure
Table A is for the specifications of the superstructure.
Closeout
13-20-24 T282B S/N 327

Dump Body
13-30 Dump Body

(Ref. Fig. 13-30-001)
The dump body is made from alloy steel. The dump body has a flat floor plate and a
front vertical plate. The front plate is installed at a 90-degree angle to the floor plate to
prevent damage during load operations.
The dump body interfaces with the component that follows:
The dump body has the components that follow:
Dump Body Pivot Pin (Ref. 13-32-000-DA)
Dump Body Pads (Ref. 13-34-000-DA)
Rock Knockers (Ref. 13-36-000-DA)
13-30-001 Dump Body

The dump body is attached to the frame with the dump body pivot pin. 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 is
against the dump body pads on the frame.
Maintenance Tips
The A-656 alloy steel of the dump body has very good weld properties (Ref.
14-00-000-DA).
T282B S/N 327 13-30-01

Dump Body
13-30-100-DA - How to Remove the Dump Body

Setup

01-20-000-DA).
If necessary to remove the dump body exhaust, do this procedure:
Remove the dump body exhaust (Ref. 05-40-100-DA).
Procedure
(Ref. Fig. 13-30-002)
Notice! The weight of the dump body can be more than 42000 kg (92600 lb). Dirt or unwanted
material add a large increase to the total weight.
Use an applicable lift device that can hold this weight. See your Liebherr service
representative for the weight of your dump body.
Lower the dump body and make sure that it is against the dump body pads on
the frame.
Make sure that all hydraulic pressure is released.
Disconnect all wires and grease lines from the dump body (1).
Install protective caps on the grease lines.
Remove the dump cylinder upper pins (Ref. 08-50-100-DA).
Attach the overhead hoist to the lift points on the dump body (1).
Tighten the tension on the cables of the overhead hoist.
Make sure that the dump body stays against the dump body pads on the frame.
Remove the dump body pivot pins (Ref. 13-32-100-DA).
Carefully, lift the dump body away from the haul truck.
Closeout
13-30-02 T282B S/N 327

Dump Body
13-30-002 Removal/Installation of the Dump Body
T282B S/N 327 13-30-03

Dump Body
13-30-200-DA - How to Install and Align the Dump Body

Setup

01-20-000-DA).
(Ref. 13-30-100-DA).
Procedure
(Ref. Fig. 13-30-002)
Remove the dump body pads (Ref. 13-34-100-DA).

Align the rear pivot pin ports and install the dump body pivot pins.
Slowly lower the dump body while you align the dump cylinders.
Use the tool (Liebherr P/N 10025660 Ref. 02-00-000-DA) and an applicable
bottle jack to extend the dump cylinder enough to align the holes.
Notice! The function of the Liebherr tool P/N 10025660 and bottle jack is to extend the dump
cylinder.
Do not use these tools as a support for the dump body or for any other function.
Install the dump cylinder upper pins (Ref. 08-50-200-DA).

To continue the alignment of the dump body, do this procedure:
Slowly lower the dump body (1).
Monitor the toes of the dump body main beams.
Caution! Both cylinders must stop to retract at the same time.

If they do not stop at the same time , this can cause the alignment of the dump body
guides, the pads, and the pivot pins to be incorrect.
See your Liebherr representative before you continue with the procedure.
Notice! Monitor the toes of the dump body main beams to make sure that the cylinders stop at
the same time. It is easier and more accurate to monitor the toes than the cylinders.
If the toes do not stop at the same time, the cylinders do not stop at the same time.
See your Liebherr representative before you continue with the procedure.
13-30-04 T282B S/N 327

Dump Body
Make sure that the toes of the dump body main beams stop at the same time.
Align the toes of the dump body main beams with the main frame rails.
If the toes are not exactly on top of the main frame rails, do this procedure:
Make sure that the overhang is equal on all sides.
Make sure that the overhang is square.
Notice! The dump body guides and the pivot pin shim stacks can be removed.
If you cannot align the toes of the dump body main beams with the main frame rails, do
this step:
Remove the dump body guides and the pivot pin shim stacks.
Make sure that the overhang is within 6.35 mm (0.25 in.).

To continue with the alignment of the dump body, do this procedure:
Align the pivot pins (Ref. 13-32-200-DA).
Align the dump body guides (Ref. 13-30-500-DA).
Install the dump body pads (Ref. 13-34-200-DA).
Closeout
If the dump body exhaust is removed, do this procedure:

Install the dump body exhaust (Ref. 05-40-200-DA).
Remove the protective caps and connect all wires and grease lines to the dump
body (1).
T282B S/N 327 13-30-05

Dump Body
13-30-400-DA - How to Inspect the Dump Body

Setup

01-20-000-DA).
Procedure
Inspect the dump body pivot bushings and pins for side to side movement.
To inspect the condition of the dump body, do these steps:
Inspect the dump body for deformation, or damaged parts.
Inspect for cracks in critical areas.
Inspect the floor and side plate thickness.
Inspect the dump body pads for wear.
Make sure that the pads are equal in relation to the other pads, and supply a
smooth and level surface for the dump body.
Inspect the rock knockers and fasteners.
Inspect the dump body alignment guides and adjust as necessary.
Make sure that the dump body pivot pins are in place with the keepers, and
correctly lubricated.
Inspect the heated dump body to the exhaust connection, if applicable.
Closeout
13-30-06 T282B S/N 327

Dump Body
13-30-500-DA - How to Install and Align the Dump Body Guides

Setup

Use a safety harness you do when maintenance above ground (Ref.
01-20-000-DA).
Make sure that the installation of the dump body is completed (Ref.
13-30-200-DA).
Make sure that the installation of the dump body pivot pin and bearing is
completed (Ref. 13-32-200-DA).
Parts Table:

1 Spacer AR TI-2133BG-13
Procedure
(Ref. Fig. 13-30-003)
Measure the dimensions (X) on both sides of the haul truck.

The measurement (X) is between the frame wear plates (6) and the dump body guides (7).
All measurements must be accurate to 1.5 mm (0.0625 in.).
Make sure that each of the dimensions (X) is equal to 3.6 to 12.7 mm (0.142 to
0.5 in.)
If the dimensions (X) are not equal to 3.6 to 12.7 mm (0.142 to 0.5 in.), do this
procedure:
Calculate the total thickness of the spacers necessary to reduce the dimensions
(X) to 3.6 to 12.7 mm (0.142 to 0.5 in.).
Weld as many of the spacers (1), (2), (3), (4), or (5) as necessary.
Follow the symbol that is shown.
Notice! The thickness of the spacers can be different.

Make sure that you weld the thickest spacers adjacent to the frame wear plates (6) and
T282B S/N 327 13-30-07

Dump Body
the thinnest spacers adjacent to the dump body guide (7).
Do a check that all the spacers are welded correctly.

Make sure that the spacers are level with the top and the sides of the dump body
pads.
Closeout
13-30-08 T282B S/N 327

Dump Body
13-30-003 Dump Body Shimming Procedure
T282B S/N 327 13-30-09

Dump Body
13-30-900-DA - How to Lift the Dump Body for Maintenance

Setup

Make sure that the haul truck has enough clearance above to lift the dump body.
Procedure
Start the engine.

Put the dump control lever in the UP position and fully lift the dump body.
Warning! The dump system is pressurized when the dump body is in the UP position with or
without the engine in operation.
Make sure the two safety cables or bars are installed on the anchors.
Install the safety bar or cable to the anchors.

Stop the engine.
Closeout
13-30-10 T282B S/N 327

Dump Body
13-30-905-DA - How to Lower the Dump Body after Maintenance

Setup
Procedure
Warning! The dump system is pressurized when the dump body is in the UP position with or
without the engine in operation.
Make sure that all personnel are at safe distance from the dump body.
Move or lift the dump body to remove tension in the cable or safety bar.
Remove the safety bar or cable from the anchors.
Start the engine.
Put the dump control lever in the DOWN position and fully lower the dump body.
Stop the engine.
Closeout
T282B S/N 327 13-30-11

Dump Body
13-30-910-DA - How to Lower the Dump Body Manually

Setup
Procedure
Warning! The dump system is pressurized when the dump body is extended with or without the
engine in operation.
Make sure that all personnel are at safe distance from the dump body.
Gradually, open the manual bypass valve on the dump valve.

The dump body lowers.
Close the manual bypass valve when the dump body is fully lowered.
Closeout
13-30-12 T282B S/N 327

Dump Body
13-30-960-DA - Dump Body Specification and

MaintenanceTables
Setup
Notice! There a different types of dump bodies on the different trucks.

Make sure that you know the correct part number of your dump body.
Procedure
Table A is for the specification of the dump body.
Closeout
T282B S/N 327 13-30-13

Dump Body
13-30-14 T282B S/N 327

Dump Body Pivot Pin
13-32 Dump Body Pivot Pin

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
function of the dump body pivot pins is to supply a pivot point for the dump body. The
dump body lifts or lowers and turns around the dump body pivot pin.
There are bearing sleeves installed in the bore of the frame for the dump body pivot
pin. The dump body pivot pin turns against the bearing sleeves and not the frame.
These bearing sleeves are items that are worn and they can be replaced.
T282B S/N 327 13-32-01

Dump Body Pivot Pin
13-32-100-DA - How to Remove the Dump Body Pivot Pin and

Bearing
Setup

01-20-000-DA).
If necessary, disconnect the top of the dump cylinder (Ref. 08-50-100-DA).
Procedure
(Ref. Fig. 13-32-001)
material adds a large increase to the total weight.
Attach an applicable lift device to the dump body.

Remove the lubrication hoses (7) and install protective caps on the hoses (7) and
open ports.
Notice! The weight of the pivot pin (1) is 88 kg (194 lb).

Lift the rear of the dump body until all the weight is removed from the pivot pins
(1).
Lift the dump body until the support legs are away of the bearing area.
Put safety supports below the dump body to hold the full weight of the rear of the
dump body.
Lower the dump body until it is against the safety supports.
Remove the capscrew (4) and locknut (5).
Carefully, remove the pin (1), and shims (2).
Remove the bearing sleeves (6) with a hydraulic puller.
Remove the spacer (3).
Examine the pin (1) and bearing sleeves (6).
Replace the pin (1) and bearing sleeves (6) if worn or damaged.
Closeout
13-32-02 T282B S/N 327

Dump Body Pivot Pin
13-32-001 Removal/Installation of the Dump Body Pivot Pin and Bearing
T282B S/N 327 13-32-03

Dump Body Pivot Pin
13-32-200-DA - How to Install and Align the Dump Body Pivot

Pin and Bearing
Setup

01-20-000-DA).
(Ref. 13-32-100-DA).

Parts Table:

1 Pivot pin 2 51005BV-19
2 Shim AR 51005BV-23
3 Spacer 2 51005BV-17
4 Capscrew 2 51005BV-5
5 Locknut 2 51005BV-1
6 Bearing sleeve 4 51005BV-16
Procedure
(Ref. Fig. 13-32-001)
material adds a large increase to the total weight.
Clean the bore ports on the frame.

Make sure that the bore ports for the pin (1) are clean and smooth.
Make sure that the new bearing sleeves (6) are clean and smooth.
Measure the dimension (X) of the outside diameter of the new bearing sleeve (6).
Measure the dimension (Y) of the inside diameter of the bore ports.
Make sure that (X) minus (Y) is equal to 0.025 to 0.127 mm (0.001 to 0.005 in.).
Danger! Very cold liquids can cause injury.

13-32-04 T282B S/N 327

Dump Body Pivot Pin
Freeze the bearing sleeves (6).

Install the bearing sleeves (6) and spacer (3).
Move the safety supports as necessary and lower the dump body until you align
the pin holes.
Make sure the two safety supports are between the top frame rails and the dump
body beam runners.
Notice! The weight of the pivot pin (1) is 88 kg (194 lb).

Install the pivot pin (1).

Install the capscrew (4) and locknut (5).
Remove the safety supports and lower the dump body.
To do the alignment of the pivot pins, do this procedure:
Make sure that the first step of the dump body alignment is completed (Ref.
13-30-200-DA).
Measure the dimensions (A) between the frame and the dump body on both
sides of the truck.
Measure the dimensions (B) between the frame and the dump body on both
sides of the truck.
If (A) or (B) is greater than 1.5 mm (0.059 in.), do this procedure:
Install the applicable shims (2) to reduce the measurement to 1.5 mm (0.0625
in.).
Make sure that (A) plus (B) is within 1.5 to 3 mm (0.0625 to 0.25 in.).
You can remove the pivot pins to get within the specified limits.
Make sure that the dimensions (A) and (B) are within the specified limits.
Make sure that the hangover of the toes is the same as specified in (Ref.
11-20-200-DA).
Replace the pivot pin capscrew (4).
Closeout
If necessary, connect the top of the dump cylinder (Ref. 08-50-200-DA).

T282B S/N 327 13-32-05

Dump Body Pivot Pin
13-32-900-DA - Dump Body Pivot Pin Specification and

MaintenanceTables
Setup
Notice! There a different types of pivot pins on the different trucks.

Make sure that you know the correct part number of your pivot pin.
Procedure
Table A is for the specifications of the pivot pin.
Closeout
13-32-06 T282B S/N 327

Dump Body Pads
13-34 Dump Body Pads

(Ref. Fig. 13-34-001)
There are five dump body pads for each side of the dump body.
13-34-001 Dump Body Pads
Operation
The dump body pads are installed on the frame. The dump body lowers against the
dump body pads. The pads supply a level surface and absorb the vibrations for the
dump body.
T282B S/N 327 13-34-01

Dump Body Pads
13-34-100-DA - How to Remove the Dump Body Pads

Setup

01-20-000-DA).
Lift the dump body for maintenance (Ref. 13-30-900-DA).
Procedure
(Ref. Fig. 13-34-002)
(Ref. Fig. 13-34-003)

Remove the pads (3), (3A), (6), (7), and (8), and shims (4) and (9).
Attention! Pads that are not equal cause stress in the dump body and the frame.
If you replace a pad, replace the pad on the opposite side of the frame.
If the pads have cracks or they have damages,

Discard the pads.
Closeout
13-34-02 T282B S/N 327

Dump Body Pads
13-34-002 Removal/Installation of the Dump Body Pads
T282B S/N 327 13-34-03

Dump Body Pads
13-34-003 Removal/Installation of the Dump Body Pads
13-34-04 T282B S/N 327

Dump Body Pads
13-34-200-DA - How to Install and Align the Dump Body Pads

Setup

01-20-000-DA).
Make sure that the installation of the dump body is completed (Ref.
13-20-200-DA).
Make sure the installation of the dump body pivot pin and bearing is completed
(Ref. 13-32-200-DA).
Make sure the installation the dump body guides is completed (Ref.
13-30-500-DA).
(Ref. 13-34-100-DA).
Parts Table:

1 Washer 32 53382-A-9
2 Capscrew 16 53382-A-5
3 Pad 8 53382-A-24
3A Pad 2 53382-A-11
4 Shims AR 53382-A-37 to 42
5 Locknut 16 53382-A-2
6 Pad 8 53382-A-24
7 Pad 8 53382-A-24
8 Pad 8 53382-A-24
9 Shims AR TI-2133BG-2 to 4
10 Shims AR TI-2133BG-6 to 8
Procedure
(Ref. Fig. 13-34-002)
(Ref. Fig. 13-34-003)
Attention! Pads that are not equal cause stress in the dump body and the frame. The pads
must supply a smooth and level surface for the dump body.
If you replace a pad, replace the pad on the opposite side of the frame.
Measure all dump body pads.
Notice! The pads are usually 44.45 mm (1.75 in.) thick. Pads that are 50.8 mm (2 in.) can exist.
You can use the 50.8 mm (2 in.) pads if the thickness (T) of the shims necessary below this pad
is more than 6.35 mm (0.25 in.).
If you use a 50.8 mm (2 in.) pad,
T282B S/N 327 13-34-05

Dump Body Pads
Make sure that you remove 6.35 mm (0.25 in.) of the necessary shims to supply a smooth
and level surface with the adjacent 44.45 mm (1.75 in.) pads.
Make sure that the thickness of each pad is 44.5 mm (1.752 in.).
Measure the dimension (D) on the driver side.
Calculate the thickness (T) of the shims necessary below the pad (8), with the
formula:
T is equal to D minus 15.9 mm (0.626 in.).
If (T) is a negative number,
Do not install shims below the pad (8).
Measure the dimension (F) on the driver side.
Calculate the thickness (T) of the shims necessary below the pad (6), with the
formula:
T is equal to F minus 30.2 mm (1.189 in.).
If (F) is a negative number,
Do not install shims below the pad (6).
Measure the dimensions (D) and (F) on the passenger side and calculate the
thickness (T).
Notice! The thickness (T) can be different for the driver and passenger side of the haul truck.
Make sure that you calculate the thickness (T) correctly and install the correct shims on
the correct side of the truck.
Record all the measurements.

All measurements must be accurate to 1.5 mm (0.059 in.).
Notice! If a shim stack is thicker than 25.4 mm (1 in.), something with the frame, the dump
body, or the hoist cylinder is out of tolerance.
Make sure that you correct the incorrect condition before you do the full procedure one
more time.
Put a straight edge across the pads (6) and (8) on the driver side.
The edge must be aligned with the main frame rail.
Measure the dimensions (M3), (M7), and (M3A) between the bottom of the
straight edge and the top of the main frame rail for the pads (3), (7), and (3A).
Calculate the thickness (T) of the shims necessary below each of the pads (3),
(7), and (3A) with the formula:
T is equal to M3, M7, and M3A minus 44.5 mm (1.752 in.).
Calculate the thickness of the shims necessary for the passenger side.
13-34-06 T282B S/N 327

Dump Body Pads
Lift the dump body to install the pads (Ref. 13-30-900-DA).

Install the pads (6) and (8) and the applicable shims (9) on the two sides of the
truck.
Follow the calculations and install the pads (3), (7), and (3A) and the applicable
shims (9), (4), and (10).
Closeout

T282B S/N 327 13-34-07

Dump Body Pads
13-34-900-DA - Dump Body Pads Specification and

MaintenanceTables
Setup
Notice! There a different types of dump body pads on the different trucks.
Make sure that you know the correct part number of your dump body pad.
Procedure
Table A is for the specifications of the dump body pad.
Closeout
13-34-08 T282B S/N 327

Rock Knocker
13-36 Rock Knocker

(Ref. Fig. 13-36-001)
There are two rock knockers installed on the dump body.
13-36-001 Rock Knocker
Operation
The rock knocker is a steel bar that is attached to the dump body above the rear
wheels. The function of the rock knocker is to remove rocks that fall between the two
rear tires.
T282B S/N 327 13-36-01

Rock Knocker
13-36-100-DA - How to Remove the Rock Knocker

Setup

01-20-000-DA).
Procedure
(Ref. Fig. 13-36-002)
Notice! The weight of the rock knocker is 83 kg (183 lb).

Attach an applicable lift device to the rock knocker (5).

Remove the pin (1), pin detent (3), cotter pin (4), washer (2), and rock knocker
(5).
Closeout
13-36-02 T282B S/N 327

Rock Knocker
13-36-002 Removal/Installation of the Rock Knocker
T282B S/N 327 13-36-03

Rock Knocker
13-36-200-DA - How to Install the Rock Knocker

Setup

01-20-000-DA).
Parts Table:

1 Pin 1 53382-A-33
2 Washer 1 53382-A-10
3 Pin detent 1 53382-A-18
4 Cotter pin 1 53382-A-1
5 Rock knocker 1 53382-A-23
Procedure
(Ref. Fig. 13-36-002)
Notice! The weight of the rock knocker is 83 kg (183 lb).

Attach an applicable lift device to the rock knocker (5).

Put the rock knocker (5) in position.
Install the pin (1), pin detent (3), cotter pin (4), and washer (2).
Closeout
13-36-04 T282B S/N 327

Rock Knocker
13-36-900-DA - Rock Knocker Specification and

MaintenanceTables
Setup
Notice! There a different types of rock knockers on the different trucks.

Make sure that you know the correct part number of your rock knocker.
Procedure
Table A is for the specifications of the rear rock knocker.
Closeout
T282B S/N 327 13-36-05

Rock Knocker
13-36-06 T282B S/N 327

Axle Box
13-40 Axle Box

(Ref. Fig. 13-40-001)
The axle box connects to these components:
Control Arm (Ref. 13-50-000-DA)
Drag Links (Ref. 13-60-000-DA)
Rear Suspension (Ref. 11-20-000-DA)
Rear Wheel Assembly (Ref. 12-40-000-DA)
13-40-001 Axle Box

The axle box provides some functions for the haul truck. The axle box is found in the
aft of the haul truck. The axle box is attached to the rear control arm, the drag links,
and the rear wheel assembly. The planetary gear box and wheel motor assemblies are
attached to the axle box. There are air duct holes on the axle box for the air to
decrease the temperature of the motors. The AC drive cooling system (Ref.
05-88-000-DA) sends the air to the axle box. There is an entry door with a seal on the
axle box. Most of the rear service and park brake components are found in the axle
box. The housing is pressurized during operation.
The main function of the axle box, control arm, drag links and suspensions is to make
the loads stable and to decrease the stresses to the main frame. If the haul truck has a
heavy load, the drag links and control arm with their positions to the frame and the
suspensions, absorb the vibrations before they reach the frame.
T282B S/N 327 13-40-01

Axle Box
13-40-100-DA - How to Remove the Axle Box Access Door

Setup
Procedure
(Ref. Fig. 13-40-002)
Notice! The weight of the access door is 41 kg (90.4 lb).

Hold the access door (3) and remove the capscrews (1) and locknuts (2).
Remove the access door (3).
Closeout
13-40-02 T282B S/N 327

Axle Box
13-40-002 Removal/Installation of the Axle Box Access Door
T282B S/N 327 13-40-03

Axle Box
13-40-200-DA - How to Install the Axle Box Access Door

Setup

Parts Table:

2 Locknut 2 51019-Z-2
3 Access Door 1 51019-Z-33
Procedure
(Ref. Fig. 13-40-002)
Notice! The weight of the access door is 41 kg (90.4 lb).

Hold the access door (3) in position and install the capscrews (1) and locknuts
(2).
Closeout
13-40-04 T282B S/N 327

Axle Box
13-40-400-DA - How to Check the Axle Box, Drag Links and

Control Arm Bushing
Setup
Procedure
(Ref. Fig. 13-40-003)

Park the haul truck on a smooth, flat surface.
Make sure that the front and rear wheels are blocked.
Install the dial indicator in the position shown in the figure.
Put the dial indicator in the center of its operational range.
Release all the brakes.
Put the truck in forward and slowly move the truck until there is tension on the
bushing.
Read the indicator and record the indication.
Put the truck in reverse and slowly move the truck until there is tension on the
bushing.
Read the indicator and record the indication.
Calculate the difference between the two indications.
If the difference is more than 3 mm (0.118 in.),
Replace the bushing.
Closeout
T282B S/N 327 13-40-05

Axle Box
13-40-003 Axle Box, Drag Links and Control Arm Bushing Check
13-40-06 T282B S/N 327

Axle Box
13-40-900-DA - Axle Box Specification and MaintenanceTables

Setup
Notice! There a different types of axle boxes on the different trucks.

Make sure that you know the correct part number of your axle box.
Procedure
Table A is for the specifications of the axle box.
Closeout
T282B S/N 327 13-40-07

Axle Box
13-40-08 T282B S/N 327

Rear Control Arm
13-50 Rear Control Arm

(Ref. Fig. 13-50-001)
The rear control arm connects to these assemblies:
13-50-001 Rear Control Arm
Operation
The rear control arm attaches to the frame and to the top of axle box. The control arm
is in a position to absorb the vibrations before they reach the frame. The rear control
arm ensures support for the axle box.
T282B S/N 327 13-50-01

Rear Control Arm
13-50-100-DA - How to Remove the Rear Control Arm

Setup
Procedure
(Ref. Fig. 13-50-002)
Disconnect the lubrication hoses (22) and install protective covers.
Notice! The weight of the control arm is 936 kg (2050 lb).

Attach a sling to the control arm (21) and to an applicable lift device.
Remove the safety lockwire from the capscrews (18).
Remove the capscrews (18), washers (19), retaining cap (20), and ring retainer
(14).
Warning! The control arm can move suddenly when you remove the pin.
Make sure that all personnel are not near the control arm when you remove the pin.
Notice! The weight of the pin (15) is 66 kg (146 lb).

Remove the pin (15).

Loosen the capscrews (16).
Notice! The weight of the upper boss is 94 kg (207 lb).

If the upper boss prevents the removal of the control arm,

Remove the capscrews (7) and (8), washers (6) and (25), retainer (5) and shims
(9).
Remove the capscrews (1), washers (2), and bushing retainer (3).
13-50-02 T282B S/N 327

Rear Control Arm
Warning! The control arm can move suddenly when you remove the pins.
Make sure that all personnel are not near the control arm when you remove the pin.

Pull the pins (10).

Remove the shims (11).
Remove the control arm (21).
Examine the bushings (12) and (13) for damage.
Notice! The weight of the bushing is 29 kg (63.9 lb).

If the bushings (12) and (13) are damaged,

Remove the bushings (12) and (13).
Closeout
T282B S/N 327 13-50-03

Rear Control Arm
13-50-002 Removal/Installation of the Control Arm
13-50-04 T282B S/N 327

Rear Control Arm
13-50-200-DA - How to Install the Rear Control Arm

Setup

Make sure that the truck is in the same condition as the removal procedure (Ref.
13-50-100-DA).
Make sure that the rear suspension (Ref. 11-20-200-DA) and the drag links (Ref.
13-60-200-DA) are installed.

Machine Oil Commercially available
Parts Table:
REF. TECHNICAL LABEL QUANTITY DRAWING-ITEM

2 Washer 8 51019-Z-15
3 Bushing Retainer 2 51019-Z-30
4 Pin Retainer 2 51019-Z-40
6 Washer 16 51019-Z-16
8 Capscrew 16 51019-Z-8
9 Shim AR 51019-Z
10 Pin 2 51019-Z-29
11 Shim AR 51019-Z
12 Bushing 2 51019-Z-51
13 Bushing 1 51019-Z-51
14 Ring Retainer 1 51019-Z-17
15 Pin 1 51019-Z-24
16 Capscrew 9 51019-Z-9
17 Washer 9 51019-Z-52
18 Capscrew 3 51019-Z-10
19 Washer 3 51019-Z-16
21 Control Arm 1 51019-Z-31
23 Capscrew 8 51019-Z-8
24 Washer 8 51019-Z-16
25 Washer 16 51019-Z-15
Procedure
(Ref. Fig. 13-50-002)
T282B S/N 327 13-50-05

Rear Control Arm
Notice! The weight of the bushing is 29 kg (63.9 lb).

If the bushings (12) and (13) are removed,

Install the bushings (12) and (13).
Notice! The weight of the control arm is 936 kg (2050 lb).

Attach a sling to the control arm (21) and to an applicable lift device.
Move the control arm (21) into position.
Notice! A pair of fit-up pins can be used in place of the pins (10) to install the control arm (21).
The pins must have minimal clearance for easier installation and removal, and must be
clearly marked "For Side Clearance Measurement Only." The standard pin diameter is
159.982 to 159.944 mm (6.298 to 6.297 in.).
Align the pin holes and install the fit-up pins through the frame bushings and the
control arm bushings (12).
Hit the pins until their inboard ends are flush with the inboard surface of the
bushings (12).
Move the control arm (21) fully to the left (or fully to the right).
Use a set of feeler gauges and measure the dimension (X) of the distance
between the frame and the ball bushing (12).
If the measurement (X) is greater than 1.6 mm (0.063 in.), shims are necessary.

Replace the fit-up pins, one at a time, with the pins (10).
If necessary, lubricate the capscrews (23) with machine oil.
Install the necessary shims (11), pin retainer (4), washers (24), and capscrews
(23).
If more than one shim is necessary,
Install one shim (11) on one end of the control arm and another shim (11) on the
other end of the control arm (21).
Tighten the capscrews (23) until the retainers (4) are flat against the pins (10),
but do not use a torque wrench.
Install the retainers (5), washers (6) and (25), and capscrews (7) and (8).
13-50-06 T282B S/N 327

Rear Control Arm
Tighten the capscrews (7) and (8), but do not use a torque wrench.
Evenly tighten the capscrews (7) to 205 Nm (150 lbf ft).
Hit the inboard end of the pins (10) and tighten again the capscrews (7) to 205
Nm (150 lbf ft).
Make sure the pins (10) are fully installed.
Move the control arm (21) fully to the right.
On the left side of the control arm (21), remove the retainer (5), capscrews (7)
and (8), and washers (6) and (25), with the pin (10) in place.
Measure the dimension (Y) from the outboard face of the frame boss to the end
of the pin (10).
(Y) plus 0.127 mm (0.005 in.) is equal to the quantity of shim necessary for the
left side.
Install the necessary shims (9) on the left side of the control arm (21).
If necessary, lubricate the capscrews (7) and (8) with machine oil.
Install the retainer (5), washers (6) and (25), and capscrews (7) and (8).
Move the control arm (21) fully to the left.
On the right side of the control arm (21), remove the retainer (5), capscrews (7)
and (8), and washers (6), but do not move the pin (10).
Measure the dimension (Y) from the outboard face of the frame boss to the end
of the pin (10).
(Y) plus 0.127 mm (0.005 in.) is equal to the quantity of shim necessary for the
right side.
Install the necessary shims (9) on the right side of the control arm (21).
Install the retainer (5), washers (6) and (25), and capscrews (7) and (8).
Install the bushing retainers (3), washers (2), and capscrews (1).
Notice! The weight of the upper boss is 94 kg (207 lb).

If the upper boss is removed,
T282B S/N 327 13-50-07

Rear Control Arm
Loosely, install the capscrews (16) and washers (17).

Align the control arm (21) over the axle box.

Apply grease to the pin (15) and install the pin.

Install the retaining cap (20), ring retainer (14), washers (19), and capscrews
(18).
Attach the capscrews (18) with lockwire.
If necessary, lubricate the capscrews (16).
Install and tighten the capscrews (16) to 435 Nm (320 lbf ft).
Attach the capscrews (16) with lockwire.
Remove the protective covers and connect the lubrication hoses (22).
Closeout
13-50-08 T282B S/N 327

Rear Control Arm
13-50-900-DA - Rear Control Arm Specification and

MaintenanceTables
Setup
Notice! There a different types of rear control arms on the different trucks.
Make sure that you know the correct part number of your rear control arm.
Procedure
Table A is for the specifications of the rear control arm.
Closeout
T282B S/N 327 13-50-09

Rear Control Arm
13-50-10 T282B S/N 327

Drag Link
13-60 Drag Link

(Ref. Fig. 13-60-001)
The drag links connect to these assemblies:
13-60-001 Drag Link
Operation
There are two drag links on the haul truck. The drag links attach to the frame and to
the bottom of the axle box. The drag links absorb the vibrations before they reach to
the frame. The drag links ensure support for the axle box.
T282B S/N 327 13-60-01

Drag Link
13-60-100-DA - How to Remove the Drag Link

Setup
Procedure
(Ref. Fig. 13-60-002)
Disconnect the lubrication hoses (18) and install protective covers.
Notice! The weight of the drag link is 345 kg (760 lb).

Attach an applicable lift device to the end of the drag link (8) that you remove.
Put a hydraulic jack directly below the pin that you remove.
To remove the end of the drag link from the axle box, do this procedure:
Remove the clamps (5).
Remove the capscrews (16), washers (17), and cover (6).
Remove and discard the safety lockwire from the capscrews (3).
Warning! The drag link can move suddenly when you remove the pin (4.
Make sure that all personnel are not near the drag link when you remove the pin.

Hit on the pin or use a puller to remove the pin (4).

To remove the end of the drag link from the frame, do this procedure:
Warning! The drag link can move suddenly when you remove the pin (14).
Make sure that all personnel are not near the drag link when you remove the pin.

13-60-02 T282B S/N 327

Drag Link
Tap on the pin or use a puller to remove the pin (14).

After you remove the drag link (8), do this procedure:
Examine all bushings (9) and (15), rings (7) and (10), frame bores and pin
surfaces (4) and (14) for damage and wear.
Closeout
T282B S/N 327 13-60-03

Drag Link
13-60-002 Removal/Installation of the Drag Link
13-60-04 T282B S/N 327

Drag Link
13-60-200-DA - How to Install the Drag Link

Setup

(Ref. 13-60-100-DA).

Machine Oil Commercially available
Lockwire 13565-A
Parts Table:

1 Retainer 1 51019-Z-25
2 Washer 3 51019-Z-16
3 Capscrew 3 51019-Z-10
4 Pin 1 51019-Z-24
5 Clamp 2 51019-Z-43
6 Cover 1 51019-Z-47
7 Ring, retainer 2 51019-Z-17
8 Drag Link 1 51019-Z-27
9 Bushing 1 51019-Z-51
10 Ring, retainer 2 51019-Z-17
11 Capscrew 3 51019-Z-10
12 Washer 3 51019-Z-16
13 Retainer 1 51019-Z-25
14 Pin 1 51019-Z-24
15 Bushing 1 51019-Z-51
16 Capscrew 15 51019-Z-46
17 Washer 15 51019-Z-49
Procedure
(Ref. Fig. 13-60-002)
Notice! The weight of the drag link is 345 kg (760 lb).

To install the drag link to the axle box, do this procedure:

Align the drag link bores with the axle box bores.
T282B S/N 327 13-60-05

Drag Link

Securely put the pin (4) on a hydraulic jack, or similar device, and align the pin (4)
with the bottom of the bore and bushing (15).
Slowly lift the lift device and push the pin (4) up until the head of the pin (4) is flat
against the bottom face of the lower boss.
Install the retainer (1), the washers (2), and capscrews (3).
To install the drag link to the frame, do this procedure:
Align the drag link bores with the frame bores.

Securely put the pin (14) on a hydraulic jack, and align the pin (4) with the
outboard side of the bore and bushing (9).
Slowly push the pin (14) in until the head of the pin (14) is flat against the face of
the outboard boss.
Install the retainer (13), the washers (12), and capscrews (11).
After you install the two ends of the drag link, do this procedure:
Tighten the capscrews (3) and (11) to 925 Nm (680 lbf ft).
Secure the capscrews (3) and (11) with lockwire.
Install the cover (6) without tension to let the drag link move.
Install the washers (17) and capscrews (16).
Remove the protective covers and connect the lubrication hoses (18).
Closeout
13-60-06 T282B S/N 327

Drag Link
13-60-900-DA - Drag Link Specification and MaintenanceTables

Setup
Notice! There a different types of drag links on the different trucks.

Know the correct part number of your drag link.
Procedure
Table A is for the specifications of the drag links.
Closeout
T282B S/N 327 13-60-07

Drag Link
13-60-08 T282B S/N 327

14 Welding Procedures
General Practices and Specifications..........................................................14-02-01
Ni-Cr-Mo Steel Castings................................................................................14-10-01
Repair Procedure for Ni-Cr-Mo Steel Castings................................... 14-10-02
Ni-Cr-Mo Steel Plate...................................................................................... 14-20-01
Repair Procedure for Ni-Cr-Mo Steel Plate.........................................14-20-02


14 Welding Procedures
The welding procedures have the sections that follow:
Ni-Cr-Mo Steel Castings(Ref. 14-10-000-DA)
Ni-Cr-Mo- Steel Plate (Ref. 14-20-000-DA)
The welding procedures have this subsection:
General Practices and Specifications (Ref. 14-02-000-DA)
Overview
Caution! The welding current can flow through the control wires, power cables, hydraulic
cylinders, suspension cylinders, pivot points, and steering system components of the haul truck.
Connect the welder ground cable directly to the work piece before you start to weld.
T282B S/N 327 14-00-01

Welding Procedures Maintenance Manual
14-00-02 T282B S/N 327

Maintenance Manual Welding Procedures
14-02 General Practices and Specifications

The general practices and specifications subsection have this information:
Typical material properties
Welding procedures and specifications at the Liebherr factory
Weak weld joints
Electrodes
Operation
Typical Material Properties
The frame of the haul truck is made of nickel-copper alloy steel referred to as ASTM
A-710. The dump body is made from A656 Grade 80 material. The physical properties
of the filler metal must be almost the same as the properties of the base metal.
Typical A-710 material properties are as follows:
Yield strength - 552000 kPa (80102.665 psi)
Tensile strength - 621000 kPa (90115.499 psi)
% elongation (5.33 cm (2.098 in.)) - 25%
% reduction of area - 69%
Impact properties are as follows:
CVN at 22 °C (72 °F) - 141 Nm (105 lbf ft)
CVN at -40 °C (-40 °F) - 27 Nm (240 lbf in.)
Welding Procedures and Specifications at the Liebherr Factory

The welding procedures and specifications that the Liebherr factory uses are:
Specifications
Material specification - ASTM A710
Welding process - FCAW filet weld
Manual or machine - manual
Position of welding - IG (flat)
Filler metal specification - AWS A5.29
Filler metal class - AWS class E81T1-Ni1
Flux or shielding gas - 75% Argon, 25% CO2
Single or multiple pass - multiple
Welding current - 275 amps
Polarity - reversed
Root treatment - back gouge to sound metal
Preheat and interpass temperature - preheat 65 °C (149 °F) minimum
Post heat treatment - as required
T282B S/N 327 14-02-01

Weld Procedure
All passes are as follows:
Electrode size - 1.5 mm (0.059 in.)
Welding amps - 275 amps
Power volts - 27
Travel speed - 245 mm (9.646 in.) per minute
Optional electrode - AWS E8018 C-3 or equivalent for maintenance welding
You must fill all craters to a minimum of 85 percent of the full cross section of the welds. Refer to
the schematic diagram for the applicable quantity to fill.
The undercut must not exceed these parameters:
MATERIAL THICKNESS MAXIMUM UNDERCUT

1/4 inch or less 10% of material thickness
1/4 inch to 2 inches 1/32 inch
2 inches and over 1/16 inch
The weld overlap must not be more than 1/16 inch beyond the fusion line of the weld.
The sum of the diameters of visual or surface porosity, piping porosity included, must not be more
than 3/8 inch in one four inch length of weld. There must not be a void more than 3/32 inch in
diameter.
Welds must have no cracks.
Weak Weld Joints

The capacity of metal to absorb gases increases if its temperature increases. The
capacity of metal to absorb gases decreases if its temperature decreases. If metal is
welded and the temperature increases, gases from the flux layer or the atmosphere
are absorbed by the metal. As the hot or molten steel becomes cool, the gas that is
absorbed is pushed out of the metal solution and causes gas pockets. These gas
pockets are pressurized which can cause cracks under the bead of the weld. This
"under-bead" crack causes the most defective welds.
Welded joints with visible or invisible cracks or fissures are not strong joints. The
welded joint breaks in a short time.
Caution! Alloy steel absorbs hydrogen gas very easy.

Use only electrodes with a low-hydrogen external layer for manual arc welding (8018C3 or
equivalent).
Alloy steel absorbs hydrogen gas very easy. In welding operations, the source of
hydrogen gas is the external layer on the electrodes.
For manual or arc welding, use only electrodes with a low-hydrogen layer (8018C3 or
equivalent). For other welding methods, use a low-hydrogen procedure, such as inert
gas shielded arc, or submerged arc welding.
Moisture on the electrodes can cause a weak weld joint.
Electrodes
14-02-02 T282B S/N 327

Electrodes that have an external layer that is low-hydrogen absorb moisture when they
are exposed to the air. Moist electrodes collect a large quantity of hydrogen during the
weld procedure. Electrodes that are moist cause under-bead weld cracks even though
they are low-hydrogen electrodes. You must use the correct electrodes and the
electrodes must be dry.
Repair
It is not always possible for a maintenance welder to weld in a flat position. A "stick"
electrode AWS E8018 C-3 is recommended.
Before you weld a crack of a defective weld, find the size of the crack with one of the
procedures that follow:
a magnetic particle inspection,
a dye penetrant inspection,
or other equally positive procedure.
Do the steps that follow to repair the crack:
Increase the temperature of the repair area to 150 °C (300 °F) for a distance of approximately six
inches in all directions from the repair area.
Remove the crack and metal around the crack to approximately two inches more on both ends of
the crack.
Remove the sharp edges with a grinder and weld again.
Buttering Technique
In (Ref. Fig. 14-02-001), there is a piece of metal that is defective because of a fracture
that extends fully through the base metal. Cracks do not frequently occur at a
convenient 90 degree angle. Sometimes a large piece will fall out when the part is
beveled, as shown in the illustration.
The best system is to use a double "V" or double "U" joint. This is not possible if there
is no access from the two sides and the weld must be made fully from one side.
To weld with the buttering technique, do this procedure:
"Butter" or pad the empty spots to fill them first.
Make the root opening as small as possible before the root bead.
Cover the two sides.
Let the weld padding bead overlap the face of the plate for a small area.
The function of the buttering technique is to greatly decrease the quantity of cross
section of the weld bead applied at one time.
T282B S/N 327 14-02-03

14-02-001 Buttering Technique
Maintenance Tips
To keep low-hydrogen electrodes dry, do this procedure:
Open the quantity of electrodes that you can use in a two hour interval.
Put open electrodes in an oven or other hot and dry area that is 120 to 150 °C (248 to 300 °F).
Dry the electrodes that were exposed to the air for some time in an oven before use.
The electrode manufacturer can recommend the time and temperature to put the
electrodes in the oven. These values change with different types of electrodes.
Make sure that you dry the electrodes that come from containers that are not air tight
before use.
If possible grind and blend weld with the parent metal.
Do not try to use a wide weave bead to fill up the large gap (Ref. Fig. 14-02-001) in this
type of joint.
14-02-04 T282B S/N 327

Ni-Cr-Mo Steel Castings
14-10 Ni-Cr-Mo Steel Castings

The Ni-Cr-Mo steel castings has this procedure:
Repair Procedure for Ni-Cr-Mo Steel Castings (Ref. 14-10-600-DA)
Operation
The function of the repair procedure is to cover minor repairs of casting where you
cannot treat the part with heat after repairs. It also gives information how to prepare a
damaged bore for machining.
The repair procedure for Ni-Cr-Mo steel castings uses the SMAW or FCAW process.
T282B S/N 327 14-10-01

14-10-600-DA - Repair Procedure for Ni-Cr-Mo Steel Castings

Setup
Make sure that you refer to ASTM A-487-4Q, ANSI/AWS D1.1 Structural Welding
Code.
Make sure that the base metal agrees with ASTM A-487 or equivalent.
Make sure that the SMAW filler metal agrees with AWS A5.5/E8018-C3.
Make sure that the FCAW filler metal agrees with AWS A5.29/E81T1NiL.
Make sure that the shielding gas composition is 75% Argon and 25% CO2.
Make sure that the flow rate is 30-40 CFH (850-1130 LPH) (use with E81T1NiL).
Procedure
Remove all metal, as necessary, with one of the procedures that follow:
air carbon arc gouging
chipping
grinding
If you remove metal with air carbon arc gouging, do this procedure:
Use a preheat temperature of 204 °C (400 °F) minimum for a distance equal to the thickness of
the part, but not less than approximately three inches in all directions from the repair area.
Grind the surface to remove all the carbon layer before you start to weld.
Fully remove all defects.
Make sure that the joint geometry agrees with AWS D1.1 Section 2.
-or-
Make sure that the joint geometry is approved by engineering department.
Make sure that the surface is clean and free of all unwanted material, and agrees
with AWS D1.1 Section 3.
Inspect all the surfaces for defects and make sure it is prepared correctly.
Make sure that the preheat temperature and the temperature between the passes
is from 150 to 260 °C (300 to 500 °F).
Make sure that you increase the temperature of the castings to 204 °C (400 °F)
before you start to weld.
Make sure that the minimum temperature before you apply heat is 10 °C (50 °F).
Increase the temperature of the local area equal to the thickness of the casting,
but not less than approximately six inches in all directions from the repair area.
Make sure that you weld in the flat position if possible.
Make sure that the current is DCEP for the two procedure types (SMAW and
FCAW).
14-10-02 T282B S/N 327

Make sure that the necessary current for the electrode size agrees with qualified
weld procedures per AWS D1.1.
Make sure that the width of the weld pass is not more than three times the core
diameter of the electrode you use for the flat position.
Correctly fill all the craters before you stop the arc.
Clean each weld pass with applicable procedures before you make a weld pass
again.
Closeout
Do the heat treatment after you weld as necessary.

Do an applicable inspection (V.T., U.T., R.T., or M.P.I) to make sure of the weld
quality.
T282B S/N 327 14-10-03

14-10-04 T282B S/N 327

Ni-Cr-Mo Steel Plate
14-20 Ni-Cr-Mo Steel Plate

The Ni-Cr-Mo steel plate has this procedure:
Repair Procedure for Ni-Cr-Mo Steel Plate (Ref. 14-20-600-DA)
Operation
The function of the repair procedure is to cover minor repairs of steel plate.
The repair procedure for Ni-Cr-Mo steel plate uses the SMAW or FCAW process.
T282B S/N 327 14-20-01

14-20-600-DA - Repair Procedure for Ni-Cr-Mo Steel Plate

Setup
Make sure that you refer to ASTM A829, SAE/AISI 8620, ANSI/AWS D1.1
Structural Welding Code.
Make sure that the base metal agrees with ASTM A829, SAE/AISI 8620 or
equivalent.
Make sure that the SMAW filler metal agrees with AWS A5.5/E8018-C3.
Make sure that the FCAW filler metal agrees with AWS A5.29/E81T1NiL.
Make sure that the shielding gas compositions is 75% Argon and 25% CO2.
Make sure that the flow rate is 30-40 CFH (850-1130 LPH).
Procedure
Remove all metal, as necessary, with one of the procedures that follow:
air carbon arc gouging
machining
If you remove metal with air carbon arc gouging, do this procedure:
Increase the temperature to 204 °C (400 °F) minimum for a distance equal to the
thickness of the part, but not less than approximately three inches in all directions
from the repair area.
Make sure that the you prepare the weld with a geometry of 60 degrees minimum
that includes the side wall angle, and 3/8 inch minimum root radius.
Make sure that the surface is clean and free of all material that can damage the
weld .
Examine the surfaces of the prepared weld area with one of the two procedures
that follow:
Magnetic particle (wet)
Magnetic particle (dry)
Make sure that the initial temperature and the temperature between the passes is
from 150 to 260 °C (300 to 500 °F).
Make sure that the minimum temperature before you apply heat is 10 °C (50 °F).
Increase the temperature of the local area equal to the thickness of the material,
but not less than approximately three inches in all directions from the repair area.
Make sure that you weld in the flat position if possible.
Make sure that the current is DCEP for the two procedure types (SMAW and
FCAW).
Make sure that the width of SMAW weld pass is not more than three times the
core diameter of the electrode you use for the flat position.
Make sure that the width of FCAW weld pass is not more than 5/8 inch, and that
14-20-02 T282B S/N 327

you use a multiple-pass split-layer procedure.

Clean each weld pass with applicable procedures before you make a weld pass
again.
Closeout
Do the post-weld heat treatment as necessary.

Do applicable inspection (V.T., U.T., R.T., M.T., or P.T.) to make sure of the weld
quality.
T282B S/N 327 14-20-03

14-20-04 T282B S/N 327

Index
Accumulators 09-00-01, 09-41-01, 09-41-01,
09-52-01
Brake and Steering 09-41-01
Servicing 09-41-07, 09-41-09, 09-41-11,
09-41-13, 09-52-08, 09-52-10,
09-52-12
Adjustment 09-40-06
Battery 05-80-01, 06-00-01, 06-10-01
Disconnect Switch 06-12-01
Replacement 06-10-02, 06-10-04
Brake and Steering
Servicing 07-20-13, 07-20-15, 07-20-15
Brakes
Foot Pedals 04-40-01
Front 12-36-01
Burnishing 12-30-04
Replacement 12-32-03, 12-32-06
Rear
Bleeding 12-50-10
Burnishing 12-50-12
Replacement 12-50-03, 12-50-07
Breather Replacement 07-20-22, 07-20-24
Check 09-40-03, 09-40-03, 09-40-03
Cleaning
Caliper Parts 12-32-16
Dump System
Servicing 07-20-12, 07-20-18, 07-20-18
Reference
Engine Overspeed 04-12-09, 04-12-09
Ground Fault 04-12-04, 04-12-12
Steering Encoder Failure 04-12-11
Truck Overspeed 04-12-09
Filters 03-20-07
Replacement 09-20-03, 09-20-03, 09-20-05,
09-20-05
Dump System 08-60-07, 08-60-08
Replacement 08-60-03, 08-60-05
Engine Air Cleaner 05-60-06
Indicator Panel 04-12-15
Brake Active Indicator 04-12-14, 04-12-15
Jacking Points 12-00-01
Lubrication
Auto Lube System 10-10-01
Servicing 10-10-11
Lubrication, Fluids, and 03-20-01
Filters
Oil and Lubricant 03-12-01
Specifications
Operations
Lifting the Dump Body 13-30-10
Lowering the Dump Body 13-30-11
Operator Cab Systems 04-30-01
Main Dash Panel
Accessory Panel
Automatic 04-12-20
Temperature Control Panel
Engine System 04-12-22
Data Port
Siemens Drive 04-12-22
System Data Port
Display Panel
Dump Body UP 04-12-07
Indicator
Left and Right 04-12-06, 04-12-06
Turn Signal Indicator
Service Brake ON 04-12-07
Indicator
Left Dash Panel
Left Dash Panel
Switches
Headlight 04-12-03
Switch
Right Dash Panel 04-12-13
Right Dash Panel 04-12-18
Switches
Hand Brake Switch 04-12-18, 04-12-18
Steering Column and
Controls
Horn Button 04-30-02
Tilt and Telescopic 04-30-01, 04-30-01
Lever
Park Brake
Replacement 12-60-03, 12-60-06, 12-60-06,
12-60-06
Payload Weigh System
Fault Codes 10-52-01
Payload Meter 10-52-01
Preventive Maintenance 03-30-01
Pumps
Replacement 09-10-05, 09-10-07
Dump System
Replacement 08-10-03
Pump Drive
Replacement 07-10-03, 07-10-05, 07-10-07,
07-10-09
Servicing 07-10-10, 07-10-10, 07-10-11
Safety
Safety Symbols 01-12-01, 01-12-01
Signs and Labels 01-10-01, 01-16-01
SBS Computer 10-80-01
Compact Flash Disc 10-80-02
Replacement
PC7 BIOS Settings 10-80-14
Schematics
Electrical 06-01-01
Suspension 11-00-01
Charging/Discharging 11-10-15, 11-10-18, 11-10-22,
11-20-15, 11-20-17, 11-20-21
Inspections and Checks 11-10-21, 11-10-23, 11-20-20
Replacement
Front Suspension 11-10-07, 11-20-07
Rear Suspension 11-20-03, 11-20-05
Graphic Index
01-16-001 Safety Signs and Labels................................................................01-16-02
01-16-002 Safety Harness Anchor Tie-Off Points.......................................... 01-16-06
01-18-001 Safety Harness Anchor Tie-Off Points.......................................... 01-18-01
01-30-001 O-ring Dimensions.........................................................................01-30-06
02-00-001 Control Arm Pin Puller...................................................................02-00-02
02-00-002 Axle Box Stand..............................................................................02-00-03
02-00-003 Front Wheel Lifting Bracket........................................................... 02-00-04
02-00-004 Nitrogen Charging and Gauging Kit.............................................. 02-00-06
02-00-005 Front Suspension Pin Puller..........................................................02-00-07
02-00-006 Chain and Spreader Beam............................................................02-00-08
02-00-007 Rear Wheel Assembly Lifting Beam..............................................02-00-09
02-00-008 Rear Suspension Removal Tool....................................................02-00-10
02-00-009 Dump Cylinder Shipping Brackets.................................................02-00-11
02-00-010 Measuring Tool..............................................................................02-00-12
02-00-011 Lifting Fixture.................................................................................02-00-13
02-00-012 Shipping Skid................................................................................ 02-00-14
02-00-013 Disc Brake Hub Puller................................................................... 02-00-15
02-00-014 Dump Cylinder Tool.......................................................................02-00-16
02-00-015 Front Wheel Bearing Installation................................................... 02-00-17
02-00-016 Electrical Repair Kit....................................................................... 02-00-18
03-14-001 Chassis Assembly with Power Module..........................................03-14-02
03-14-002 Chassis Assembly......................................................................... 03-14-03
03-14-003 Superstructure Assembly.............................................................. 03-14-04
03-14-004 Front Wheel Assembly.................................................................. 03-14-05
03-14-005 Lower Control Arm........................................................................ 03-14-06
03-14-006 Upper Control Arm........................................................................ 03-14-07
03-14-007 Front Suspension.......................................................................... 03-14-08
03-14-008 Rear Suspension...........................................................................03-14-09
03-14-009 Rim................................................................................................ 03-14-10
03-14-010 Tire and Rim..................................................................................03-14-11
03-14-011 Wheel Motor.................................................................................. 03-14-12
03-14-012 Planetary Gear Box....................................................................... 03-14-13
03-14-013 Planetary Gear Box Assembly...................................................... 03-14-14
03-14-014 Fuel Tank Assembly......................................................................03-14-15
03-14-015 Fuel and Hydraulic Tank Assembly...............................................03-14-16
03-14-016 Dump Cylinder...............................................................................03-14-17
03-14-017 Power Module Assembly...............................................................03-14-18
03-14-018 Alternator.......................................................................................03-14-19
03-14-019 Air Cleaner.................................................................................... 03-14-20
03-14-020 Cab with Air Conditioning.............................................................. 03-14-21
03-20-001 Central Service Assembly............................................................. 03-20-02
03-20-002 Central Oil Sample Points............................................................. 03-20-02
04-00-001 Cab Controls and Instrumentation.................................................04-00-02
04-00-002 Cab Controls and Instrumentation.................................................04-00-03
04-10-001 Main Dash Panel........................................................................... 04-10-01
04-10-002 Retard/Grade Speed Label........................................................... 04-10-02
04-12-001 Controls and Indicators................................................................. 04-12-01
04-12-002 Left Dash Panel.............................................................................04-12-02
04-12-003 Display Panel................................................................................ 04-12-05
04-12-004 Main Dispaly Screen..................................................................... 04-12-06
04-12-005 Bar Gauge Screen.........................................................................04-12-08
04-12-006 Fault and Alarm Window............................................................... 04-12-09
04-12-007 Right Dash Panel.......................................................................... 04-12-13
04-12-008 Indicator Panel.............................................................................. 04-12-14
04-12-009 Keypad.......................................................................................... 04-12-17
04-12-010 Right Dash Panel Switches........................................................... 04-12-18
04-12-011 Accessory Panel............................................................................04-12-20
04-20-001 Floor Mounted Center Console..................................................... 04-20-01
04-20-002 Dump Control Lever Adjustment................................................... 04-20-06
04-30-001 Steering Column............................................................................04-30-01
04-40-001 Foot Pedal Controls.......................................................................04-40-01
04-40-002 How to remove/How to install the Brake Pedal............................. 04-40-04
04-40-003 How to remove/How to install the Brake Pedal............................. 04-40-05
04-40-004 How to Remove/How to Install the Retarding Pedal..................... 04-40-07
04-40-005 How to Remove/How to Install the Retarding Pedal..................... 04-40-08
04-40-006 How to Remove/How to Install the Accelerator Pedal................... 04-40-10
04-40-007 How to Remove/How to Install the Accelerator Pedal................... 04-40-11
04-50-001 Seats............................................................................................. 04-50-01
04-60-001 Replacement of the Glass............................................................. 04-60-03
04-60-002 Dimensions of the Glass, front...................................................... 04-60-04
04-60-003 Dimensions of the Glass, front side...............................................04-60-05
04-60-004 Dimensions of the Glass, rear side............................................... 04-60-06
04-60-005 Dimensions of the Glass, rear....................................................... 04-60-07
04-70-001 Access Panels...............................................................................04-70-02
04-70-002 Access Panels...............................................................................04-70-03
05-02-001 Power Module Assembly...............................................................05-02-01
05-02-002 Removal/Installation of the Power Module Assembly................... 05-02-06
05-10-001 Removal/Installation of the Engine................................................05-10-04
05-10-002 Removal/Installation of the Engine................................................05-10-05
05-20-001 Removal/Installation of the Traction Alternator............................. 05-20-03
05-20-002 Removal/Installation of the Traction Alternator............................. 05-20-04
05-20-003 Alternator Measurements.............................................................. 05-20-08
05-20-004 Engine Flywheel Run-Out Check.................................................. 05-20-10
05-20-005 Engine Endplay Measurements.................................................... 05-20-13
05-30-001 Radiator.........................................................................................05-30-01
05-30-002 Tank Gasket.................................................................................. 05-30-02
05-30-003 Removal/Installation of the Radiator............................................. 05-30-05
05-30-007 Replacement of the Tubes............................................................ 05-30-14
05-40-001 Removal/Installation of the Exhaust System................................. 05-40-04
05-40-007 Replacement of the Exhaust Blankets.......................................... 05-40-14
05-60-001 Removal/Installation of the Engine Air Cleaner Ducts...................05-60-03
05-60-002 Air Cleaner Restriction Check....................................................... 05-60-07
05-60-003 Air Cleaner Servicing Procedure................................................... 05-60-10
05-62-001 Filter Restriction Indicators............................................................05-62-01
05-70-001 Removal/Installation of the Engine Heater.................................... 05-70-03
05-70-002 Removal/Installation of the Engine Heater.................................... 05-70-04
05-88-001 AC Drive Cooling System..............................................................05-88-01
05-88-002 Removal/Installation of the AC Cooling System Motor..................05-88-04
05-88-003 Removal/Installation of the Alternator Cooling Duct...................... 05-88-06
05-88-004 Removal/Installation of the Axle Box Cooling Duct....................... 05-88-08
06-01-001 Electrical Schematics.................................................................... 06-01-03
06-10-001 Removal/Installation of the 24 VDC Battery Bank.........................06-10-03
06-12-001 Battery Disconnect Switch Box..................................................... 06-12-01
06-30-001 Grid Box........................................................................................ 06-30-01
06-30-002 Inspection of the Grid Box............................................................. 06-30-04
07-10-001 Pump Drive....................................................................................07-10-01
07-10-002 Pump Drive....................................................................................07-10-02
07-10-003 Removal/Installation of the Pump Drive........................................ 07-10-04
07-10-004 Removal/Installation of the U-Joint Assembly............................... 07-10-06
07-20-001 Hydraulic Tank.............................................................................. 07-20-01
07-20-002 Dump System Hydraulic Tank.......................................................07-20-02
07-20-003 Dump System Hydraulic Tank.......................................................07-20-03
07-20-004 Brake and Steering Hydraulic Tank...............................................07-20-04
07-20-005 Brake and Steering Hydraulic Tank...............................................07-20-05
07-20-006 Removal/Installation of the Fuel and Hydraulic Tank.................... 07-20-08
07-20-007 Removal/Installation of the Fuel and Hydraulic Tank.................... 07-20-09
07-20-008 Brake and Steering Hydraulic Drain.............................................. 07-20-14
07-20-009 Brake and Steering Hydraulic Replenishment...............................07-20-16
07-20-010 Brake and Steering Hydraulic Replenishment...............................07-20-17
07-20-011 Dump System Strainers Servicing.................................................07-20-21
07-20-012 Dump System Tank Breather Replacement.................................. 07-20-23
07-20-013 Brake and Steering Breather Replacement...................................07-20-25
07-30-001 Central Service Assembly............................................................. 07-30-02
08-02-001 Dump System Components.......................................................... 08-02-02
08-02-002 Dump System Inspection.............................................................. 08-02-06
08-02-003 Dump System Pressure Check..................................................... 08-02-09
08-02-004 Dump System Schematic.............................................................. 08-02-11
08-10-001 Dump Pumps.................................................................................08-10-02
08-10-002 Removal/Installation of the Dump Pumps..................................... 08-10-04
08-20-001 Dump Valve...................................................................................08-20-02
08-20-002 Removal/Installation of the Dump Valve....................................... 08-20-04
08-30-001 Pilot Control Valve Assembly........................................................ 08-30-01
08-30-002 Pilot Control Valve System............................................................08-30-02
08-30-003 Removal/Installation of the Pilot Control Valve............................. 08-30-04
08-30-004 Removal/Installation of the Manifold Valve................................... 08-30-06
08-40-001 Dump Body Control Lever............................................................. 08-40-01
08-40-002 Dump Body Control Lever Adjustment.......................................... 08-40-05
08-50-001 Dump Body Cylinders....................................................................08-50-01
08-50-002 How to Remove/Install the Dump Body Cylinders.........................08-50-05
08-60-001 Dump System Pressure Filters......................................................08-60-01
08-60-002 Dump System Pressure Filters......................................................08-60-02
08-60-003 How to remove/How to install the Pressure Filters........................08-60-04
08-60-004 Dump System Pressure Filter Servicing........................................08-60-09
09-00-001 Brake and Steering System...........................................................09-00-02
09-02-001 Brake and Steering System Pressure Setup.................................09-02-04
09-02-002 Brake and Steering System Pressure Setup.................................09-02-05
09-02-003 Brake and Steering System Pressure Test................................... 09-02-08
09-02-006 Brake and Steering System Schematic.........................................09-02-11
09-10-001 Brake and Steering Pump............................................................. 09-10-02
09-10-002 Brake and Steering Pump............................................................. 09-10-03
09-10-003 Removal/Installation of the Brake and Steering Pump..................09-10-06
09-20-001 Brake and Steering Pressure Filter............................................... 09-20-01
09-20-002 Brake and Steering Pressure Filter............................................... 09-20-02
09-20-003 Removal/Installation of the Pressure Filter....................................09-20-04
09-20-004 Brake and Steering Pressure Filter Servicing............................... 09-20-08
09-30-001 Brake and Steering Manifold......................................................... 09-30-02
09-30-002 Brake and Steering Manifold......................................................... 09-30-03
09-30-003 Removal/Installation of the Brake and Steering Manifold..............09-30-05
09-40-001 Steering System............................................................................ 09-40-02
09-40-002 Toe-In Check.................................................................................09-40-04
09-40-003 Toe-In Adjustment......................................................................... 09-40-07
09-41-001 Steering Accumulator.................................................................... 09-41-02
09-41-002 Removal/Installation of the Steering Accumulator.........................09-41-04
09-41-003 Steering Accumulator System Bleed.............................................09-41-08
09-41-004 Steering Accumulator Precharge Check....................................... 09-41-10
09-41-005 Steering Accumulator Precharge Drain.........................................09-41-12
09-41-006 Steering Accumulator Precharge Replenishment......................... 09-41-15
09-42-001 Flow Amplifier Valve......................................................................09-42-01
09-42-002 Removal/Installation of the Flow Amplifier Valve.......................... 09-42-03
09-42-003 Removal/Installation of the Flow Amplifier Valve.......................... 09-42-04
09-43-001 Steering Control Valve.................................................................. 09-43-01
09-43-002 Removal/Installation of the Steering Control Valve....................... 09-43-03
09-44-001 Steering Cylinders......................................................................... 09-44-01
09-44-002 Removal/Installation of the Steering Cylinders..............................09-44-03
09-45-001 Tie Rods........................................................................................ 09-45-01
09-45-002 Removal/Installation of the Tie Rods.............................................09-45-03
09-46-001 Idler Arm Assembly....................................................................... 09-46-01
09-46-002 Removal/Installation of the Idler Arm Assembly............................ 09-46-04
09-46-003 Idler Arm Pin and Bearing Inspection............................................09-46-09
09-47-001 Steering Arm................................................................................. 09-47-01
09-47-002 Removal/Installation of the Steering Arm...................................... 09-47-03
09-48-001 Steering Stop Pads....................................................................... 09-48-01
09-48-002 Removal/Installation of the Steering Stop Pads............................ 09-48-03
09-50-001 Brake System................................................................................ 09-50-02
09-50-002 Brake System Components...........................................................09-50-04
09-52-001 Brake Accumulators...................................................................... 09-52-02
09-52-002 Removal/Installation of the Brake Accumulators........................... 09-52-04
09-52-003 Brake Accumulator System Bleed.................................................09-52-07
09-52-004 Brake Accumulator Precharge Check........................................... 09-52-09
09-52-005 Brake Accumulator Precharge Drain.............................................09-52-11
09-52-006 Brake Accumulator Precharge Replenishment............................. 09-52-14
09-54-001 Hand Brake Valve and Manifold....................................................09-54-01
09-54-002 Removal/Installation of the Hand Brake Valve and Manifold........ 09-54-03
09-60-001 Buddy Steering and Braking Components.................................... 09-60-02
09-60-002 Connection and Operation............................................................ 09-60-05
10-10-001 Auto Lube Components.................................................................10-10-03
10-10-002 Auto Lube System......................................................................... 10-10-05
10-10-003 Auto Lube Injector Adjustment...................................................... 10-10-09
10-10-004 Auto Lube Injector Adjustment...................................................... 10-10-10
10-20-001 Gear Oil Cooling Components...................................................... 10-20-02
10-20-004 Removal/Installation of the Gear Oil Cooling Pump...................... 10-20-06
10-20-005 Gear Oil Filter Servicing................................................................ 10-20-09
10-20-006 Gear Oil Breather Replacement.................................................... 10-20-11
10-50-001 Liebherr Payload Weigh System Schematic................................. 10-50-03
10-50-002 Liebherr Payload Weigh System Installation.................................10-50-05
10-50-010 Software Load in the Ecoplus........................................................10-50-19
10-52-001 LPWS Display Meter Set-Up......................................................... 10-52-04
10-52-002 LPWS Display Meter Set-Up......................................................... 10-52-04
10-52-003 Payload Data Collection Procedure.............................................. 10-52-05
10-80-001 SBS Computer Setup with XP Embedded-Step 1.........................10-80-05
10-80-002 SBS Computer Setup with XP Embedded-Alternate Method........ 10-80-07
11-00-001 Suspensions..................................................................................11-00-02
11-10-003 Removal/Installation of the Front Suspension...............................11-10-04
11-10-004 Front Suspension Oil Drain........................................................... 11-10-09
11-10-005 Front Suspension Oil Fill Procedure..............................................11-10-13
11-10-006 Front Suspension Oil Fill Procedure..............................................11-10-14
11-10-007 Front Suspension Gas Discharge Procedure................................11-10-17
11-10-008 Front Suspension Gas Charge Procedure.................................... 11-10-20
11-10-009 Front Suspension Pressure Check................................................11-10-24
11-10-010 Suspension Test Procedure.......................................................... 11-10-27
11-20-001 Rear Suspension...........................................................................11-20-01
11-20-002 Rear Suspension...........................................................................11-20-02
11-20-003 Removal/Installation of the Rear Suspension............................... 11-20-04
11-20-004 Rear Suspension Oil Drain............................................................11-20-09
11-20-005 Rear Suspension Oil Fill Procedure.............................................. 11-20-14
11-20-006 Rear Suspension Gas Discharge Procedure................................ 11-20-16
11-20-007 Rear Suspension Gas Charge Procedure.....................................11-20-19
11-20-008 Rear Suspension Pressure Check................................................ 11-20-23
11-30-001 Upper and Lower Control Arms.....................................................11-30-01
11-30-002 Removal/Installation of the Control Arms...................................... 11-30-04
12-00-001 Wheel Assemblies.........................................................................12-00-02
12-02-001 Jacking Points............................................................................... 12-02-01
12-10-001 Front Wheel Assembly.................................................................. 12-10-01
12-10-002 Removal/Installation of the Front Wheel (Complete).....................12-10-06
12-10-003 Possible formation of pit-shaped corrosion................................... 12-10-11
12-10-004 Possible formation of pittings........................................................ 12-10-11
12-10-005 Front Wheel Bearings Oil Level Check......................................... 12-10-13
12-10-006 Removal/Installation of the Front Wheel....................................... 12-10-16
12-10-007 Removal/Installation of the Front Wheel....................................... 12-10-17
12-10-008 Front Wheel Bearings Oil Drain.....................................................12-10-24
12-10-009 Front Wheel Bearings Oil Fill.........................................................12-10-26
12-12-001 Upper and Lower King Pins and Spindle.......................................12-12-01
12-12-002 Removal/Installation of the Kingpins............................................. 12-12-03
12-12-003 King Pin Bushing Wear Check...................................................... 12-12-09
12-12-004 Inspection of the Spindle............................................................... 12-12-11
12-12-005 Inspection of the Hub.................................................................... 12-12-13
12-20-001 Tire and Rim Assembly................................................................. 12-20-01
12-20-002 Removal/Installation of the Front Tire and Rim Assembly............ 12-20-05
12-20-003 Replacement of the Studs............................................................. 12-20-09
12-20-004 Inspection of the Studs..................................................................12-20-10
12-30-001 Front Brakes..................................................................................12-30-02
12-30-002 Front Brake Burnish Procedure.....................................................12-30-05
12-32-001 Front Brake Caliper....................................................................... 12-32-01
12-32-002 Removal/Installation of the Front Brake Caliper............................ 12-32-05
12-32-003 Disassembly/Assembly of the Front Brake Caliper....................... 12-32-12
12-36-001 Front Brake Disc............................................................................12-36-01
12-40-001 Rear Wheel Assembly...................................................................12-40-02
12-40-002 Removal/Installation of the Rear Wheel Assembly....................... 12-40-04
12-40-003 Rear Wheel Assembly Oil Level Check.........................................12-40-08
12-40-004 Disassembly/Reassembly of the Rear Wheel............................... 12-40-10
12-40-005 Disassembly/Assembly of the Wheel Motor Coupling without Centering
Disc...................................................................................................................12-40-14
12-40-006 Disassembly/Assembly of the Wheel Motor Coupling with Centering
Disc...................................................................................................................12-40-14
12-40-007 Disassembly/Assembly of the Gearbox Coupling......................... 12-40-18
12-40-008 Rear Wheel Assembly Oil Drain.................................................... 12-40-24
12-40-009 Rear Wheel Assembly Oil Fill........................................................ 12-40-26
12-42-001 Tire and Rim Assembly................................................................. 12-42-01
12-42-002 Removal/Installation of the Rear Tire and Rim Assembly............. 12-42-05
12-42-003 Replacement of the Studs............................................................. 12-42-10
12-42-004 Inspection of the Studs..................................................................12-42-12
12-50-001 Rear Brakes.................................................................................. 12-50-01
12-50-002 Removal/Installation of the Rear Brakes....................................... 12-50-05
12-50-003 Installation of Brake Calipers.........................................................12-50-09
12-50-004 Disassembly/Reassembly of the Rear Brake Caliper....................12-50-17
12-52-001 Rear Disc Brake Hub.....................................................................12-52-01
12-52-002 Removal/Installation of the Rear Disc Brake Hub......................... 12-52-03
12-52-003 Removal/Installation of the Rear Disc Brake Hub......................... 12-52-04
12-60-001 Park Brake (Carlisle)..................................................................... 12-60-01
12-60-002 Removal/Installation of the Park Brake......................................... 12-60-04
12-60-003 Removal/Installation of the Park Brake......................................... 12-60-05
12-60-004 Mechanical Release of the Park Brake......................................... 12-60-08
12-60-005 Mechanical Release of the Park Brake......................................... 12-60-09
12-60-006 Disassembly/Reassembly of the Park Brake Caliper.................... 12-60-11
13-00-001 Frame and Structures....................................................................13-00-02
13-00-002 Frame and Structures....................................................................13-00-03
13-10-001 Frame............................................................................................ 13-10-02
13-12-001 Hoist Carriage............................................................................... 13-12-01
13-20-001 Superstructure...............................................................................13-20-02
13-20-002 Removal/Installation of the Hood and Grill.................................... 13-20-05
13-20-005 Removal/Installation of the Crossmember.................................... 13-20-09
13-20-006 Removal/Installation of the Diagonal Ladder and Handrails......... 13-20-12
13-20-010 Removal/Installation of the Battery Box........................................ 13-20-17
13-30-001 Dump Body....................................................................................13-30-01
13-30-002 Removal/Installation of the Dump Body........................................ 13-30-03
13-30-003 Dump Body Shimming Procedure................................................. 13-30-09
13-32-001 Removal/Installation of the Dump Body Pivot Pin and Bearing.....13-32-03
13-34-001 Dump Body Pads.......................................................................... 13-34-01
13-34-002 Removal/Installation of the Dump Body Pads............................... 13-34-03
13-34-003 Removal/Installation of the Dump Body Pads............................... 13-34-04
13-36-001 Rock Knocker................................................................................ 13-36-01
13-36-002 Removal/Installation of the Rock Knocker.....................................13-36-03
13-40-001 Axle Box........................................................................................ 13-40-01
13-40-002 Removal/Installation of the Axle Box Access Door....................... 13-40-03
13-40-003 Axle Box, Drag Links and Control Arm Bushing Check.................13-40-06
13-50-001 Rear Control Arm.......................................................................... 13-50-01
13-50-002 Removal/Installation of the Control Arm........................................13-50-04
13-60-001 Drag Link....................................................................................... 13-60-01
13-60-002 Removal/Installation of the Drag Link............................................13-60-04
14-02-001 Buttering Technique...................................................................... 14-02-04

Manual de Manutenção (10339442 327 MM VALE Rev002 Mar 15 09)

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Manual de Manutenção (10339442 327 MM VALE Rev002 Mar 15 09)

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Maintenance Manual 01 Introduction

Serial Numbers: 05 Power Module

07 Hydraulic Power and Distribution

09 Brake and Steering System

4100 Chestnut Avenue, 14 Welding Procedures

T282B S/N 327  01-00-01

[Page left intentionally blank]

01-00-02  T282B S/N 327

Health Hazard Information

Haul Truck Safety Precautions

Work Area Safety

T282B S/N 327  01-10-01

[Page left intentionally blank]

01-10-02  T282B S/N 327

01-12 Health and Safety Information

Warning! This symbol indicates possible hazards to persons.

Caution! This symbol indicates possible damage to equipment.

Attention! This information gives instructions to make procedures easier.

First Aid Kit

T282B S/N 327  01-12-01

components or parts that move.

01-12-02  T282B S/N 327

T282B S/N 327  01-12-03

[Page left intentionally blank]

01-12-04  T282B S/N 327

01-16 Haul Truck Safety Precautions

Safety Signs and Labels

T282B S/N 327  01-16-01

01-16-001 Safety Signs and Labels

01-16-02  T282B S/N 327

DO NOT OPERATE WITHOUT GUARDS

T282B S/N 327  01-16-03

Unless you are approved, keep from these areas.

Safety Sign and Label Maintenance

How to Clean a Component Before Maintenance or Inspection

Stop the engine and let the temperature completely decrease.

01-16-04  T282B S/N 327

T282B S/N 327  01-16-05

01-16-002 Safety Harness Anchor Tie-Off Points

Jack and Lift Devices

Warning! Keep from under a haul truck held by a jack, or a lift.

01-16-06  T282B S/N 327

Do not inflate the tires above the recommended pressure.

T282B S/N 327  01-16-07

Dump Body Safety

01-16-08  T282B S/N 327

01-18 Safety Harness Anchor Tie-Off Points

01-18-001 Safety Harness Anchor Tie-Off Points

T282B S/N 327  01-18-01

[Page left intentionally blank]

01-18-02  T282B S/N 327

01-20 General Maintenance Practices

Fire and Explosion Hazards

T282B S/N 327  01-20-01

Prepare the Work Area

01-20-02  T282B S/N 327

01-22 How to Use this Publication

Removal and Installation Procedures

T282B S/N 327  01-22-01

The installation procedures can include a parts table.

01-22-02  T282B S/N 327

01-30 Useful Information

T282B S/N 327  01-30-01

T282B S/N 327 01-00-01

01-00-02 T282B S/N 327

T282B S/N 327 01-10-01

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T282B S/N 327 01-12-01

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T282B S/N 327 01-16-01

01-16-02 T282B S/N 327

T282B S/N 327 01-16-03

01-16-04 T282B S/N 327

T282B S/N 327 01-16-05

01-16-06 T282B S/N 327

T282B S/N 327 01-16-07

01-16-08 T282B S/N 327

T282B S/N 327 01-18-01

01-18-02 T282B S/N 327

T282B S/N 327 01-20-01

01-20-02 T282B S/N 327

T282B S/N 327 01-22-01

01-22-02 T282B S/N 327

T282B S/N 327 01-30-01

01-30-02 T282B S/N 327

T282B S/N 327 01-30-03

01-30-04 T282B S/N 327

T282B S/N 327 01-30-05

01-30-06 T282B S/N 327

T282B S/N 327 01-30-07

01-30-08 T282B S/N 327

T282B S/N 327 02-00-01

02-00-02 T282B S/N 327

T282B S/N 327 02-00-03

02-00-04 T282B S/N 327

T282B S/N 327 02-00-05

02-00-06 T282B S/N 327

T282B S/N 327 02-00-07

02-00-08 T282B S/N 327

T282B S/N 327 02-00-09

02-00-10 T282B S/N 327

T282B S/N 327 02-00-11

02-00-12 T282B S/N 327

T282B S/N 327 02-00-13

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T282B S/N 327 02-00-15

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T282B S/N 327 02-00-17

02-00-18 T282B S/N 327

T282B S/N 327 03-00-01

03-00-02 T282B S/N 327