Cortez Training Manual

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Liebherr Mining Equipment Co.

_______________________________________________________
Product Support Division
T-282 Systems Overview

and Operation Manual
For Training Purposes Only
All materials set forth in this manual are for the purpose of technical training only. The
information is pertinent to all models of Liebherr Mine Haul Trucks, but is specifically
directed towards the T-282 and T-282B models. The information herein is subject to
change as design applications and components change on the trucks themselves.
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T-282 Systems Overview and Operation Manual
Table of Contents
Section: Pages:
Hydraulic System Overview 3 – 29
Husco Split Spool System 30 – 49
Danfoss Flow Amplifier 50 – 55
Autolube System 56 – 66
Contamination and Wear Limits 67 – 74
Preventative Maintenance 75 – 120

500 Hour 75 – 84
1000 Hour 85 – 93
1500 Hour 94 – 102
2500 Hour 103 – 111
5000 Hour 112 – 120
Michelin Tires 121 – 129
Dash Computer Programming 130 – 136
Payload Weigh System 137 – 157
Super Jack 158 - 167

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_______________________________________________________
T-282B Hydraulic Systems

Overview
Training Material
Liebherr Mining Equip. Co Technical Training Department

4100 Chestnut Ave. Telephone = 757-928-2503
Newport News, VA.
23607
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Husco
T-282 and T-282B
Split Spool System
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The term split spool describes the spool section of the main valve. The spool section
encloses two spools and its components. Each spool is equivalent to one-half the spool in
a conventional valve. The spool operates in synchronization with or in opposition to its
mate. Each section is basically two 2-position / 3-way diverting valves. This feature
allows control and circuit flexibility.
The hydraulic schematic section depicted above will be utilized to describe specific
components and functions of the Husco Split Spool Valve.
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The hydraulic schematic section depicted above will be utilized to describe specific
components and functions of the Split Spool Pilot Valve and the Pilot Control Valve.
The Inlet Section of the Main Dump Control Valve consists of a Flow Control Valve,
Main Relief Valve, Low Pressure Relief Valve, Load Check Valve, and an Anti-Void
Poppet. Take note of this particular diagram depicting the Husco 6500 Series, which has
two inlet sections to accommodate the T-282s dual pump system.
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Hydraulic flow for the split spool system can range from 90 GPM to 500 GPM. The 500
GPM is possible by using the 6500s paralleled inlet section.
Some of the working features of the Main Dump Control Valve are as follows:
• Complete pressure control is provided by a main relief valve.

• The large capacity flow control in the inlet section of the split spool, allows a low
neutral pressure drop.
• A great degree of mounting flexibility is possible, which allows the pilot valve to
be located as to simplify controls and minimize line connections.
The Pilot Spool Valve is spring centered to the neutral position. The center passage is
open and pilot flow from the main valve is unobstructed. As depicted here, the Pilot
Spool Valve is actuated by a Pilot Control Valve.
When the Pilot Control Valve directs flow to either end of the Split Spool, this will
overcome the spring bias, and the flow control poppet opens and the pump flow is
directed to the outlet.
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Main Dump Valve Component Descriptions and Operations:
1. INLET = the port connection(s) for the system pump lines.

2. OUTLET = the port connection for the line(s) that directs return flow to the
reservoir.
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3. HIGH PRESSURE CORE = the passage which is common to the inlet section and
the spool section of the main valve and directs pump flow to the spool sections.
4. DRAIN PASSAGE = the passage which allows portions of the surface area
between main valve sections to bleed-off directly to the outlet.
5. FLOW CONTROL = the inlet section component between the inlet and outlet ports.
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5. MAIN RELIEF VALVE = the element located inside of the flow control poppet.
It is a pilot operated (compound) relief valve, and has the capacity to limit the
working pressure at full pump flow.
6. LOW PRESSURE RELIEF VALVE = the assembly located between the low
pressure core and the outlet, and provides a controlled back pressure in the low
pressure core when oil is returning from an actuator.
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7. LOAD CHECK POPPET = the check valve that allows free flow from the inlet to
the high pressure core and prevents flow from the high pressure core to the inlet.
8. ANTI-VOID POPPET = the check valve that allows free flow from the low
pressure core and prevents flow from the high pressure core from entering the low
pressure core.
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9. PILOT SUPPLY ORIFICE = the orifice that is located between the inlet and the
spring side of the flow control valve. It is in conjunction with the flow control
spring, which regulates the amount of pilot flow to the pilot valve.
10. PILOT SUPPLY PORT = the port connection for directing flow from the pilot
supply orifice to the pilot valve inlet. (See drawings above and below for
reference)
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11. FLOW CONTROL or DAMPENING POPPET = this is an orifice / check valve

arrangement located between the pilot supply orifice and the spring side of the
flow control. This arrangement regulates the filling or exhausting of the volume
of oil behind the flow control. The orifice slows the movement of the flow
control and prevents sudden changes in the direction of the pump flow, and
thereby reduces shocks or surges.
12. WORK PORT or WORKING PORT = the port connection on the main valve
spool section for a working line to be connected to one side of an actuator.
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13. LONG HOLE = this term relates to the cross drilled hole in the spool section,
which covers and provides a passage for flow from the low pressure core to its
corresponding main spool.
14. MAIN SPOOL = There are one main spool for each work port and they are spring
biased at both ends. This is to block the work port from the high and low pressure
cores when there is no flow through the spool cross-holes. When there is flow
from the pilot valve to the main valve work port (through the cross-holes) a
positive differential pressure at the top of the spool will overcome the bottom
spring bias and the spool will overcome the top spring bias and the spool will shift
to connect the work port to the low pressure core.
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15. RESTRICTOR POPPETS = these check valves are located in the main spools and
are identified as DAMPENING POPPETS in the above diagram. They permit
free flow from the work port to the pilot port and restrict flow from the pilot port
to the work port. They are also used to control spool response and / or spool
movement during void conditions.
16. PILOT VALVE INLET SECTION = the port connection for receiving pilot flow
from the main valve pilot supply port.
17. PILOT VALVE OUTLET = connection for return to tank.
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18. CENTER PASSAGE = the passage that directs pilot flow from the inlet to the
outlet of the pilot valve when the spool is centered or in the float position.
19. BRIDGE CORE = this passage directs flow from the center passage to a control
port when the pilot valve spool is shifted.
20. PILOT SPOOL = the element in the system which is controlled directly by the
operator of the unit. The pilot spool transforms the small pilot flow from the main
valve into control signals which cause the main valve to direct the large working
flow.
21. LOAD CHECK = the valve that allows free flow from the center passage to the
bridge core and prevents flow from the bridge core to the center passage.
22. SOLENOID VALVES = located on the pilot control valve, which when activated
by an operators selector will shift the flow of pilot pressure to the Split Spool
Pilot Valve.
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Dump Sucton Lines
Total output from dump pumps

= 300 GPM
Q = Flow Rate = VA
= 300 GPM
Q (per cylinder) = 150 GPM (2 pumps)
V = velocity
A = x-sectional area
inside dia = 4.00 in

A= 12.57 in2
V = Q/A = 3.83 ft/s

This is velocity thru lines when truck is at full throttle
Dump Cylinders Area Ratios
Extend Volume = 72 GAL

Retract Volume = 26 GAL
Without Counter Balance Valve

Extend Time = Extend Volume/Pump Flow = 28.8 seconds
Retract Time = Retract Volume/Pump Flow = 10.4 seconds
Flow Rate Coming out of Cylinder When Retracted = Extend Volume/Retract Time
= 415.4 GPM
If we consider taking one section out of gear pump

Remaining Section Disp = 26.34 CIR
Gear Ratio = .875:1 increase = 1.143
RPM = 1900
Flow Rate = Displacement*Gear Ratio*RPM = 247.6 GPM
Retract time with One section removed = Retract Volume/Flow Rate = 12.6 seconds
Flow Rate Coming out of Cylinder When Retracted = Extend Volume/Retract Time
= 343 GPM
With Counter Balance Valve

Counter Balance Valve Max Flow Rate = 120 GPM
Retract Time With Counter Balance Valve = Retract Volume/Valve Flow Rate = 13 seconds
Flow Rate Coming out of Cylinder When Retracted W/Counter Balance Valve = 332.3 GPM
Pump output satisfies valve max flow rate

Percentage pump exceeds valve max flow rate by = 3.2%
Flow out of each cylinder is reduced GPM (over value without counterbalance
by 72.6 valve)
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Dump System Return Lines
Q (per cylinder) = 412 GPM (RETRACT CYLINDER AT FULL THROTTLE)

V = velocity
A = x-sectional area of line
inside dia = 2.00 in

A= 3.14 in2
V = Q/A = 42.08 ft/s

This is velocity thru lines when truck is at full throttle
inside dia = 3.00 in AT TANK EACH RETURN LINE FLOW COMBINES AND GOES INTO 3" PIPE
A= 7.07 in2
V = Q/A = 37.40 ft/s
ENGINE RPM
1900
PUMP DRIVE SPEED INCREASE

1.143
PUMP RPM
2171.4
Dump System
Pump Displacements
Section 1 9.86 CIR
Section 2 6.93 CIR
Flow Rate per

pump
157.8 GPM
Inlet Pressure @ above listed flow rate

95 psi
Pump efficiency
0.9
Hydraulic HP
19.4
Brake and Steering System

Pump
Displacement
8 CIR
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Flow Rate @ full stroke of pump

75.2 GPM
System Pressure
3200 psi
Pump Efficiency
0.92
Hydraulic HP w/pump @ full stroke

152.6
Hydraulic HP w/pump compensated (off stroke)

7.6
ENGINE RPM
700
PUMP DRIVE SPEED INCREASE

1.143
PUMP RPM
800.0
Dump System
Pump Displacements
Section 1 9.86 CIR
Section 2 6.93 CIR
Flow Rate per

pump
58.1 GPM
Inlet Pressure @ above listed flow rate

95 psi
Pump efficiency
0.9
Hydraulic HP
7.2
Brake and Steering System
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Pump
Displacement
8 CIR
Flow Rate @ full stroke of pump

27.7 GPM
System Pressure
3200 psi
Pump Efficiency
0.92
Hydraulic HP w/pump @ full stroke

56.2
Numbers below are calculated based on 13017-W dump cylinder
Stage 1
Bore = 15.5
Rod OD = 14
Stroke = 56.5
Extend Area = 188.7 in2
Retract Area = 34.8 in2
Extend Volume = 10661.1 in3 or 46.2 gallons
Retract Volume = 1963.6 in3 or 8.5 gallons
Stage 2
Bore = 11.5
Rod OD = 7.5
Stroke = 56.5
Stage 1/Stage 2 extend area ratio = 1.817
Total extend/cyl 16529.7 in3 or 71.6 gallons

Total retract/cyl 5336.1 in3 or 23.1 gallons
numbers above are assuming cylinder is in use, has been ran

several times. Numbers were calculated by myself on 5/7/03
and also verified by Great Bend on 5/7/03. Numbers do not
take into account internal tubes, etc.
Difference between extend and retract for both cylinders
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once truck has been running long enough to fill up cylinders is

96.91 gallons
Time to extend cylinder
Time to Extend Stage 1 19.5 seconds

Time to Retract Stage 2 6.2 seconds
Total Extend Time 30.2 seconds
Total Retract Time 9.8 seconds
Total Cycle Time 40.0 seconds
Times reported from Don Harris at Chuqui follows (13017-W). He times the trucks at every PM.
Up 27
Down 18
Numbers below are calculated based on 13017-X dump cylinder
Stage 1
Bore = 15.5
Rod OD = 14
Force stage 1
Stroke = 56 extend
Extend Area = 188.7 in2 566075.7
Stage 2
Primary Bore = 12.5 Transfer tube OD = 5.5
Seconday Bore = 9
Rod OD = 11.5
Stroke = 56
169 IS CORRECT according to Hans, but this number lines up with TI-272
Extend Area = 162.6 in2 calc's
Stage 1/Stage 2 extend area ratio = 1.16


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144.32 gallons

Times reported from Don Harris at Chuqui follows. He times the trucks at every PM.
Up 27
Down 18
Numbers below are calculated based on 2TD-400 x 2850 Hub dump cylinder
Stage 1
Bore = 15.748
Rod OD = 14.76
Stroke = 56.7
RATIO W RATIO X
Stage 2 13017-W
Bore = 13 11.5 0.65 0.923077
Rod OD = 12 7.5
Stroke = 56.9

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139.71 gallons

Times reported from Don Harris at Chuqui follows. He times the trucks at every PM.
Up 27
Down 18
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_______________________________________________________
Danfoss Flow Amplifier
Training Material

Newport News, VA.
23607
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Danfoss Flow Amplifier and Steering Unit

Load Sensing Steering Units have an extra connection for Load Sensing {LS}. This will
allow a Load Pressure Signal to be directed from the Steering Unit to a Danfoss Priority
Valve.
The Load Sensing Signal controls the oil flow from the priority valve to the Steering
Unit.
The LS connection is open to the tank when the Steering Unit is in the neutral position.
Currently, Liebherr uses the OSPBX LS model Steering Unit, which can only be used
with the Danfoss Flow Amplifiers OSQA or the OSQB.
NOTE: OSPBX LS Steering Units must not be connected directly to the steering
cylinder.
Under normal operating conditions where the Steering Pump supplies an adequate oil
flow and pressure, the torque necessary on the steering wheel will not exceed 45 Lbf-in.
If the oil flow from the steering system fails, the steering unit will automatically function
in manual steering mode. {Accumulator Pressure}
Specifically, Liebherr T-282 trucks use the Steering Unit model OSPBX 630 LS. This
unit is rated at 16.6 GPM flow, 3200 PSI pump pressure, and 220 PSI return tank
pressure. The cubic inch displacement of this unit is 38.4 cu/in. The Liebherr part
number for this pump is 13042-H.
If so desired, the OSPBX 630 LS Steering Unit can be replaced with the model OSPL 800
LS. This model produces 48.8 cu/in displacement. Its max flow rate is 21.0 GPM with
3200 PSI pump pressure and 220 PSI return tank pressure. The Liebherr Part number is
13042-K.
The Liebherr Steering System combines the Steering Unit OSPBX LS with the Flow
Amplifier OSQB. The T-282 part number for the Flow Amplifier is 13490-B and the part
number for the Flow Amplifier used in the T-252 and T-262 trucks is 13490-A.
The Flow Amplifiers OSQA {13490-A}and OSQB {13490-B}contain a Directional

Valve, and Amplification Stage, a Priority Valve, a Pilot Pressure Relief Valve, Shock
Valves, and Suction Valves.
The OSQB model will also contain a Back Pressure Valve.
Either Flow Amplifiers will amplify the flow of oil from the Steering Unit ports L or R
by a factor of 4, 5, or 8. This is dependant on the steering wheel speed and resistance.
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If the oil flow from the Supply Pump fails, then the Flow Amplifier cuts off the
amplification and manual steering occurs.
Flow Amplifier Valves

Shock Valves
Suction Valves
Directional Valve
Amplification Stage
Pilot Pressure Relief Valve
Priority Valve
Back Pressure Valve
Check Valve
Example
Priority Valves: This valve is used in Load Sensing Systems where the same pump
supplies oil to the Steering System and the working hydraulics. The Steering System has
first priority.
Pilot Pressure Relief Valve: This valve protects the Steering Unit against excessive
pressure. The Pilot Pressure Relief Valve works with the Priority Valve to limit the
maximum steering pressure at ports HP and HT. The Pilot Pressure Relief Valve on the
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OSQA is set at 37 GPM and the OSQB is set at 63 GPM. The pressure settings for the T-
252 and T-262 are 2540 and the setting for the T-282 is 2973 (plus or minus) 70 PSI.
Back Pressure Valve: This valve is used to increase the capacity of the Suction Valve.
Shock Valves: These valves protect the Flow Amplifier from external forces applied to
the Steering Cylinders. They limit the maximum pressure drop from CL to HT and from
CR to HT. The Shock Valves for the T-252 and T-262 are set at 2.6 GPM and 3480, and
the setting for the T-282 is 3626 (plus or minus) 150 PSI.
Suction Valve: This valve ensures oil suction on the side of the Steering Cylinder
Pistons, where in unfavorable conditions, cavitation might occur. This valve is also more
commonly referred to as the ANTI-CAVITATION valve. The capacity of the Suction
Valve is increased in the OSQB by the built-in Back Pressure Valve.
Operation of the Steering Unit / Amplifier Valve Example:

1.) Operator turns the Steering Wheel to the left.
2.) Pilot pressure from the Steering Control Valve passes through port LS on the
Amplifier Valve – shifting the Priority Valve to allow System Pressure to pass through
port HP on the Amplifier Valve to port P on the Steering Unit.
3.) At the same time, flow from the main system travels to the Amplification Stage in
the Amplifier Valve.
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5.) There are two valves in the Flow Amplifiers Amplification Stage, whch can be
referred to as Flow Control Valves. Pilot pressure tapped off of flow from the DCV is
used to shift the first flow control valve and allow system flow to pass through the 1st
flow control valve and into the 2nd flow control valve.
6.) Pilot pressure tapped off of the 1st flow control valve is used to shift the 2nd
flow control valve. Flow is then allowed to travel back to the 1st flow control
valve, where system flow and directional flow join together.
7.) Flow exits the 1st flow control valve and passes through the DCV and travels
to the CL port on the Flow Amplifier.
8.) Flow leaves the Amplifier at port CL and enters into the base side of the Left
Steering Cylinder and the rod side of the Right Steering Cylinder.
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9.) Return fluid flow from the Steering Cylinders enters into port CR of the Amplifier
Valve. This flow continues to pass through the DCV and on to a junction in the
Amplifier Valve where fluid return flow from the Steering units T port meet.
10.) This fluid flow then passes through the Suction Valve and exits the Amplifier
Valve at port HT and continues on back to the main reservoir.
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_______________________________________________________
Autolube System
Training Material

Newport News, VA.
23607
Page 57 of 167
Autolube System Overview
The T-282B is equipped with either a hydraulically or air operated Auto Lubrication
System. This system consists of a centrally located lubricant reservoir and pump unit,
connected to a network of hoses, manifolds and adjustable injectors that automatically
supply lubricant to all critical pivot points on the machine. The following drawings and
figures show the basic functions and overall layout as it has been applied to the T-282B
Mine Haul Truck.
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Stage 1 injector operation: When the injector is in its normal, or rest position, the
discharge chamber is filled with lubricant from the previous cycle. Under pressure of the
incoming lubricant, the slide valve will open the passage leading to the piston.
Stage 2 injector operation: When the slide valve uncovers the passage, lubricant is
admitted to the top of the piston, forcing the piston down. The piston forces lubricant
from the discharge chamber through the outlet port to the bearing.
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Stage 3 injector operation: As the piston completes its stroke, it pushes the slide valve
past the passage, cutting off further admission of lubricant to the passage. Piston and
slide valve remain in this position until lubricant pressure in the supply line is vented
(relieved) at the pump.
Stage 4 injector operation: After pressure is relieved, the compressed spring moves the
slide valve to the closed position. This opens the port from the measuring chamber and
permits the lubricant to be transferred from the top of the piston to the discharge
chamber.
Notice that the injector action shown above requires the lubricant pressure to be built up,
and then to be relieved (vented). It is the increasing and decreasing of the pressure that
transfers the measured amount of lubricant from the inlet to the outlet and it is only in
between these cycles that the lubricant is in the measuring chamber. The lubricant output
quantity of the injector is controlled by the position of the adjusting screw, which
controls the amount of travel of the injector piston. With the adjusting screw hand
tightened into the injector, the lubricant output is increased to the maximum. Turning the
adjusting screw in will decrease the lubricant output. When the injector has been
adjusted for the desired volume output, the locknut is tightened against the face of the
injector.
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Basic Auto Lube System Components
Item: Part Number: Description: Item: Part Number: Description:

1 13223-A-1 PUMP ASSY. 9 13223-A-9 NUT
2 13223-A-2 PUMP ASSY. (NOT SHOWN) 10 13223-A-10 VENT PIPE
3 13223-A-3 ADAPTER 11 13223-A-11 OUTLET CHECK
4 13223-A-4 NUT 12 13223-A-12 VENT FITTING
5 13223-A-5 GASKET 13 13223-A-13 VENT ASSY.
6 13223-A-6 GASKET 14 13223-A-14 BRACKET ASSY.
7 13223-A-7 GASKET 15 13223-A-15 BUSHING
8 13223-A-8 SCREW 16 13223-A-16 WASHER
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Basic Auto Lube System Overview
• The pump and the controller systems are in a rest state until a preset time interval
occurs.
• When the controller times out, a 24 VDC signal will energize SV1, and force it
open.
• As SV1 opens, the resulting hydraulic fluid pressure closes the vent valve and
flows through the pressure reducing valve.
• The pressure reducing valve lowers the hydraulic fluid pressure to the operating
range of the hydraulic pump.
• After the system pressure has been reduced, it passes on to SV2 which controls
the direction of the hydraulic cylinder, which operates the grease pump.
• The 24 VDC signal is also sent to the cycle timer located at SV2. The cycle timer
will send a pulsing signal, 1 second on and 1 second off, to SV2. The SV2 directs
the hydraulic fluid to the pump at 30 cycles / minute.
• With the vent valve closed, the pump continues to cycle until maximum pressure
is achieved and the injectors have metered grease to the bearings.
• When the maximum pressure is reached, the pressure switch closes.
• The closed pressure switch signals the controller to stop the pumping cycle.
• At this moment, the controller terminates the signals to SV1 and SV2.
• When SV2 is de-energized, the pump stops cycling.
• When SV1 is de-energized, the hydraulic fluid stops flowing to the pressure
reducing valve and the vent valve.
• When the vent valve is de-energized, it opens and allows the grease pressure to
drop to zero, so the injectors can recharge for their next output cycle.
• The system is now at rest and ready for another lube cycle and the sequence will
repeat itself.
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Important Notes:
• If the cylinder pressure exceeds 620 PSI, excessive cylinder wear and pre-mature
failure is eminent.
• Input oil pressure to the pump and output lubrication pressure to the grease
injectors is relegated by a “suggested” ratio. The “theoretical” ratio of the pump
is 16 to 1. The Liebherr applications and internal frictions encountered will
produce a slightly lower output ratio. As a safety margin, consider the pump
output ration to be 10 to 1!
• When adjusting the pressure regulator, set the pressure between 300 to 600 PSI.
For best results, and longer component life, choose the setting 400 to 500 PSI.
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Autolube System Specific Information
Specifications:
SV1 and SV2 Power Requirements = 6
Zero to 3000 PSI Amps @ 24VDC
Gauge Recommended.
Theoretical Ration = 16 to 1
Input Flow @ 30 Cycles per Minute =

1.0 GPM
Maximum Hydraulic Temperature =

210 Degrees F.
Output Pressure = 7500 PSI Maximum

SV1
SV2 Output Flow = 11 cubic inches per min.
Operational Temperature Range =

-40 degrees F. to +135 degrees F.
Filtration Requirements = 10 Micron
Pressure Regulator Adjustment Screw.
As previously noted, the recommended

pressure setting is between 300 and 600
PSI. 300 PSI is determined to be optimal
for Liebherr Equipment.
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The Autolube Pump Manifold

has the “pressure” port and the
“return” line port marked on the
left side of the manifold block.
They are marked “T” for tank
(return) and “P” for pressure.
Pressure
Tank (Return)
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Vent Valve Vent Stem
The Vent Valve is used to vent excessive grease pressure to the atmosphere. If the
condition of excessive grease is coming out of the vent stem, check the following:
A.) Pressure Reducing / Regulator valve is set too high.

B.) Blockage in output grease line.
C.) Vent bleeder screw loose. (Located on end of the stem)
C2
C2 C1
Grease Output
Block and C1
connecting line.
Output lines from the manifold are marked “C1” and “C2”. Routing of the hoses from
the manifold to the pump is important for pump controlling action. Note: Grease flow is
produced in both “up” and “down” strokes of the pump’s piston.
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Grease Injector Maintenance:
If connections for hoses are not

kept tight, the output injector
pressure drops to the connecting
component. More importantly:
If one connection is loose, the
manifold pressure drops and
reduces lubrication effort to all
connecting components.
Dust covers are used on the

manual purge zerks. These zerks
do not have a check ball on the
inside. A loose cap will allow the
same conditions as above.
When adjusting the injector

output, a minimum “spring”
pressure adjustment will give you
the maximum grease output.
Lock Nut
Adjustment Screw
10
Page 67 of 167

_______________________________________________________
Contamination and Wear

Limits
Training Material

Newport News, VA.
23607
Page 68 of 167Mjfcifss!Njojoh!Frvjqnfou!Dp/
Oil contamination and wear limits guideline:
For hydraulic oil samples, the accumulative particle count for various particle size ratings is an important
measure concerning the cleanliness and/or contamination of the hydraulic system.
As a general overview or outline, filter change intervals can be effectively monitored by using the following
simple guidelines:
Change your filters when you see the contamination

If your particle rating is: level of:
15 microns 500 particles per milliliter
The following six notations need to be included in your analysis of a typical oil sample report that gives
only the contaminant PPM.
{1} Including wear metals and additives.

{2} Certain oleated {plant based chemical} oil additives will cause high copper concentrations,
which may be normal. Due to chemical reactions between certain oil additives and their cooler
cores, certain engines can show copper concentrations up to 300 PPM. Liebherr engines are
not affected.
{3} Including silica {dirt}. Oil companies, some times, use silicone based defoaming additives.
These additives can cause a particle count of up to 25 PPM even for new oils.
{4} Aluminum concentrations depend also on silicon contamination. High aluminum concentration
during the initial operation of the machine is not alarming as long as the silicone level remains
normal.
{5} No rating available unless high silicon contamination is present.
{6} FAT-type final drives and some swing gears on Litronic machines feature oil submerged disc
brakes. Excessive wear on these disc brakes can result in high iron, copper {brass} and tin
{brass} concentrations.
Contamination Chart:
Contaminations are in PPM.
For Engines:
Abrev: Normal: Abnormal: Severe:
Aluminum {4} Al 0 < 25 26 < 40 > 41
Chromium Cr 0 < 20 21 < 40 > 41
Copper {2} Cu 0 < 25 26 < 50 > 51
Iron Fe 0 < 145 146 < 275 > 276
Lead Pb 0 < 40 41 <100 > 101
Nickel Ni 0 < 20 21 < 50 > 51
Tin Sn 0 < 20 21 < 50 > 51
Silicon {3} Si 0 < 25 26 < 65 > 66
Water H2O 0 < .05% .05% < 0.1% > .1%
1
For Splitterboxes, Swing Gears, and Final Drives:

Aluminum {4} Al 0 < 60 > 61 > 61
Chromium Cr 0 < 20 21 < 40 > 41
Copper {2} {6} Cu 0 < 50 50 < 150 > 151
Iron {6} Fe 0 < 500 501 < 1500 > 1501
Lead Pb 0 < 50 > 51 > 51
Nickel Ni 0 < 20 > 21 > 21
Tin Sn 0 < 20 > 21 > 21
Silicon {3} Si 0 < 50 51 < 150 > 151
Water H2O 0 < .05% .05% < 0.1% > .1%
For Hydraulic Systems:

Aluminum {4} Al 0 < 20 21 < 50 > 51
Chromium Cr 0 < 20 21 < 50 > 51
Copper {2} Cu 0 < 25 26 < 65 > 66
Iron Fe 0 < 20 21 < 50 > 51
Lead Pb 0 < 20 21 < 50 > 51
Nickel Ni 0 < 20 21 < 50 > 51
Tin Sn 0 < 20 21 < 50 > 51
Silicon {3} Si 0 < 25 26 < 65 > 66
Water H2O 0 < .05% .05% < 0.1% > .1%
For Front Wheels Assemblies

Aluminum {4} Al 0 < 20 21 < 50 > 51
Chromium Cr 0 < 20 21 < 50 > 51
Copper {2} Cu 0 < 25 26 < 65 > 66
Iron Fe 0 < 500 501 < 700 > 701
Lead Pb 0 < 20 21 < 50 > 51
Nickel Ni 0 < 20 21 < 50 > 51
Tin Sn 0 < 20 21 < 50 > 51
Silicon {3} Si 0 < 25 26 < 65 > 66
Water H2O 0 < .05% .05% < 1% > 1%
ISO Scales for Contaminants:
2
In the 1990's a method of measuring particle sizes was developed utilizing a two dimensional method, which
led to the development of a set of scale numbers used to identify the size of the particle. And there was a
scale of numbers used to identify the quantity of particles found in a millileter of oil.
These ISO codes were commonly made up of 2 scale numbers representing the number of particles from
5 micron to 15 micron. The scale numbers are defined such that each successive scale is generally a
doubling of the previous scale. The particle count can be expressed as the number of particles per ml or
per 100 ml, but the ISO range numbers and the ISO codes do not change.
The first ISO Scale numbers was referred to as the ISO 4406 scale. In 1999, this scale was further improved
to use 3 dimensional measuring methods. The scale was then named the ISO 4406:1999. It allowed for the
use of three scale numbers representing the number of particles greater than or equal to 4 micron, 6 micron,
and 14 micron in size.
It is important to note here that the net effect of this change kept the ISO rating unchanged. If a fluid was
determined to have an ISO rating of 18/15/13 under the ISO 4406 scale, then it would have the same number
applied to the ISO 4406:1999 scale.
ISO 4406 Scale:
Number of Particles per 100 ml of Fluid:
More Than: Up to and Including: Scale Number:

8,000,000 16,000,000 24
4,000,000 8,000,000 23
2,000,000 4,000,000 22
1,000,000 2,000,000 21
500,000 1,000,000 20
250,000 500,000 19
130,000 250,000 18
64,000 130,000 17
32,000 64,000 16
16,000 32,000 15
8,000 16,000 14
4,000 8,000 13
2,000 4,000 12
1,000 2,000 11
500 1,000 10
250 500 9
130 250 8
64 130 7
32 64 6
16 32 5
8 16 4
4 8 3
2 4 2
1 2 1
It is important to remember that when using the ISO 4406 scale, the third number used in this system was
optional. It represented the quantity of particles in the 2 micron range found in 100 ml of fluid.
3
For example: If you had an ISO number of 19/15/11, then the first digits would represent the amount of par-
ticles that you had equal to or under the 2 micron size. The second digits would represent the
number of particles that you had in the 5 micron size, and the third digits would represent the
number of particles that you had in the 15 micron size.
Therefore, using the above scale, you would read {19} as between 250,000 to 500,000 particles
above or below the 2 micron size. The number {15} would represent that you had between
16,000 to 32,000 particles in the 5 micron size. The number {11} would indicate that you had
1,000 to 2,000 particles in the 15 micron size.
ISO 4406:1999 Scale:

Number of Particles per 1 ml of Fluid:
More Than: Up to and Including: Scale Number:

1,300,000 2,500,000 28
640,000 1,300,000 27
320,000 640,000 26
160,000 320,000 25
80,000 160,000 24
40,000 80,000 23
20,000 40,000 22
10,000 20,000 21
5,000 10,000 20
2,500 5,000 19
1,300 2,500 18
640 1,300 17
320 640 16
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
2.5 5 9
1.3 2.5 8
0.64 1.3 7
0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0 0.01 0
4
It is important to remember here, that when using the ISO 4406:1999 scale that the third digits are not
optional. The three sets of digits now indicate the size and number of particles in the 4 micron size, the 6
micron size, and the 14 micron size.
Also, it is equally important to remember that this scale utilizes a fluid volume of 1 ml and not 100 ml as in the
ISO 4406 scale.
Therefore, the example ISO number of 19/15/11 would indicate the following:
{19} = 2,500 to 5,000 particles in the 4 micron range.
{15} = 160 to 320 particles in the 6 micron range.
{11} = 10 to 20 particles in the 14 micron range.
The cleanliness level of a hydraulic system is the starting point for determining the cleanliness level required
for efficient and acceptable operation.
The first step in determining this is to determine if your hydraulic system is a low, medium, or high pressure
system. Use the following scale to make this determination:
0 to 500 PSI {35 Bar} = Low Pressure System

500 to 1500 PSI {35 to 100 Bar} = Medium Pressure System
Any system pressures above 1500 PSI or 100 Bar is considered a High Pressure System.
The second step in determining your cleanliness requirements would be to determine what major
components are integrated into your system. For example, gear pumps, vane pumps, or piston pumps, your
cleanliness requirements would vary.
Therefore, use the following two charts to determine your system cleanliness requirements:
Cleanliness Level Based on Pressure:
System Type: Recommended Cleanliness Levels {ISO 4406}
Low Pressure / Manual Control: 20/18/15 or better

Low to Medium Pressure with
Electro-Hydraulic Controls: 19/17/14 or better
High Pressure - Servo Controlled: 16/14/11 or better
Cleanliness Level for Fluid Power Components
System Component: Recommended Cleanliness Level {ISO 4406:1999}
Gear Pump 19/17/14

Piston Pump / Motor 18/16/13
Vane Pump 19/17/14
Directional Control Valve 19/17/14
Servo Valve 16/14/11
5
Beta Ratings:
The beta ratio gives the best indication of the performance of the filter. The Beta ratio is derived
by a multi-pass filtration test per ISO 4572.
The filtration ratio or beta is calculated by dividing the number of particles entering the filter by
the number of particles leaving the filter. This is the ratio of upstream particles to downstream
particles at a stated particle size.
Number of particles upstream (entering) > Xµm

βχ = Number of particles downstream (exiting) > Xµm
The larger the beta ratio, the better and more efficient the filter.
There are in fact three types of filter ratings used. They are the Nominal Rating, the Absolute
Filtration Rating, and the Beta Ratio.
The Nominal Filtration Rating is an arbitrary micrometer value indicated by the filter
manuracturer. Do to the lack of reproducibility, this rating should only be used for reference.
The Absolute Filtration Rating indicates the diameter of the largest hard spherical particle that
will pass through a filter under specified test conditions. This is only an indication of the
largest opening in the filter element. It does not indicate the largest particle that will pass
through the element, as particles of greater length than diameter may pass through.
The Beta Ratio can be directly related to filter efficiency. The following table shows this
relationship for particles greater than Xµm, with 1,000,000 upstream particles:
βx Efficiency Downstream Particle Count

1 0 1,000,000
2 50.00% 500,000
20 95.00% 50,000
50 98.00% 20,000
75 98.70% 13,000
100 99.00% 10,000
200 99.50% 5,000
750 99.87% 1,333
1,000 99.90% 1,000
5,000 99.98% 200
10,000 99.99% 100
6
Suction Screens:
Suction Screens are rated by U. S. Sieve numbers. The following chart is an indicator of the
screen mesh sizes:
U.S. Sieve No. µm Inches

50 297 0.0117
60 238 0.0009
70 210 0.0083
100 149 0.0059
140 105 0.0041
200 74 0.0029
270 53 0.0021
325 44 0.0017
As an aid for visual concept, the following chart gives the sizes of familiar objects:
Substance µm Inches
Grain of Table Salt 100 0.004
Human Hair Diameter 70 0.0027
Lower Limit of Visibility 40 0.00158
White Blood Cells 25 0.001
Talcum Powder 10 0.0004
Red Blood Cells 8 0.0003
Bacteria 2 0.00008
"Silt" <5 <0.0002
7
Page 75 of 167
Mjfcifss!Njojoh!Frvjqnfou!Dp/!!
_______________________________________________________
T-282 Preventative
Maintenance
English Version
Training Material
Newport News, VA.
23607
Page 76 of 167 500 Hour PM
Supervisor: ________________
Date: _____________________
Hour Meter: _______________
Truck Number: _____________
Fluids, Filters, and Lubrication:

Item Description OK Need Attn. Tech. Init. Comments
1 (Take an engine oil sample.)
2 (Change the engine oil.)
3 (Change the engine oil filters.)
(Inspect and change the air filters if
4 necessary.)
5 (Clean the air filter dust collectors.)
6 (Check the coolant concentration/condition.)
7 (Verify the steering and brake hyd tank level.)

(Take an oil sample of the Steering/Brake
8 Tank.)
(Verify the oil level of the hyd dump system
9 tank.)
(Take an oil sample of the hyd dump system
10 tank.)
11 (Fill the autolube tank.)
12 (Check the complete autolube system.)
(Check all areas for proper amounts of
13 grease.)
14 (Suspension bearings and pins.)
15 (Right upper and lower front.)
16 (Left upper and lower front.)
17 (Rear upper and lower left.)
18 . (Rear upper and lower right.)
19 (Pins and bearing of hoist cilinders).
( Check front control arms for proper amount of
20 grease)
21 (Upper and lower left.)
1
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

22 (Upper and lower right.)
(Check rear control arms for proper amount of
23 grease ).
( Drag Link,pins,front and rear bearing.for
24 proper amount of grease )
25 .( Grease the driveline U-joints)
Radiator
(Check the upper and lower radiator mounting
26 bolts.)
27 (Check the stabalizer bolts.)
28 (Check the radiator upper tank for leaks.)
29 (Check the radiator tubes and hoses for leaks.)

.(Inspect the radiator for blockages, and clean
30 as necessary.)
31 (Check the radiator fan bolts.)
32 .(Check the fan drive belt.)
Engine
(Check the engine mounting bolts for
33 tightness.)
(Test the engine emergency shut-down
34 system.)
35 (Check Engine Oil Press.)
(Note low idle pressure.)
(Note high idle pressure.)
(Note max. oil press.)
2
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

36 (Record the low RPM.)
37 (Record the high RPM)
38 (Record the WOT RPM.)
39 (Check the alternator / engine mounting bolts.)
40 ( Check the engine for oil and coolant leaks.)

41 (Check the exhaust system.)
(Check the turbochargers for leaks and
42 vibration damage.)
(Check the air intake tubes, the rubber boots,

43 and connections for proper tightness.)
44
Wheels, Suspensions, and Brakes
45 (Check the front suspension pins.)
(Right upper and lower.)
(Left upper and lower.)
46 (Check the control arm bushings.)
47 (Check the king pin bushings.)
48 (Check the suspension bushings, rear.)
(Left upper and lower front.)
3
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

49 (Check the suspension system pressures.
(Right front ) 1050 PSI = Specs. Actual =
(Left, front.) 1050 PSI = Specs. Actual =
(Right rear.) 550 PSI = Specs. Actual =
(Left rear.) 550 PSI = Specs. Actual =
50 (Check the rear chasis pivot pins.)
(Check the drag link pins for proper
51 lubrication.)
(Right.)
(Left.)
(Check the axle box and wheel motor
52 connections for cleanliness.)
.(Check the steering cylinders for leaks and
53 proper lubrication.)
54 (Check the steering pin bushings.)
55 (Check the steering pin links.)
56 (Check the steering system pressure.) 2800 PSI=Specs. Actual =
(Check the steering system accumulator
57 pressure.) 1800 PSI=Spec. Acutal =
Check the steering accumulator for leaks and
58 damage.)
Check and record the brake accumulator 1800 PSI=Spec. Rear Actual =
59 charge pressure.) Front Actual =
(Check and record the brake system Front Spec. = 2800 PSI Actual =
60 pressures.) Rear Spec. = 1500 PSI Actual =
(Check the brake accumulators for leaks or
61 damage.)
(Check brake system hoses for leaks and
62 damage.)
4
Supervisor: ________________
Date: _____________________
Hour Meter: _______________
63 (Check the operation of the service brakes.)

64 (Check the park brake operation.)
65 (Check the handbrake operation.)
(Check the front and rear brake caliper
66 assemblies.)
67 (Check the final drive oil level.)
68 (Check the front wheel hub oil level.)
Fuel and Hydraulic
69 Check fuel hoses for leaks and damage.)
(Check the hyd. Tank and the fuel tank for
70 proper mounting.)
71 (Check the hyd. Hoses for damage and leaks.)

Operator's Cab
72 (Check the cabin doors, latches, and mirrors.)

(Check the operation of the A/C and the
73 windshield wipers.)
(Check the drivers horn and the backup
74 alarm.)
75 (Check the shift selector.)
76 (Check the cab mounting bolts.
77 (Check the cabin lights and the platform lights.)

78 (Check the instument panel.)
79 (Check the retarder pedal.)
5
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

80 (Check the seats and safety belts.)
81 Check the access ladders and hand rails.)
Chassis and Dump Body
82 (Check the dump body pivot pins.)
83 (Check the dump body pads.)
84 (Check the overall dump body condition.)
85 (Check the condition of the rock ejectors.)
86 (Check the chassis for cracks.)
(Check underneath the superstructure for
87 proper bolt security and note any damage.)
88 (Check the front wheel hub caps.)
89 (Inspect the axle box door and seal.)
Electrical System
90 (Visually check the main alternator.)
(Check the grid box for obstructions and
91 damage.)
92 (Check the battery box and connections.)
93 (Check the 24volt alternator drive belt.)
(Check all electrical connections for corrosion
94 and tightness.)
95 (Check all running lights.)
6
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

96 (Check emergency lights.)
97 (Check Siemens cable conditions.)
98 (Check axle box cables.)
(Check the condition of the axle box air duct
99 hoses.)
Hydraulic System Checks
(Check the dump body cylinders for damage or
100 leaks.)
101 (Check upper and lower cylinder pins.)
102 (Check hyd pump mounting.)
(Check the general condition of the control
103 valve and hoses. Include the Husco valve.)
(Check all hyd hoses for chaffing and
104 damage.)
(Check and record the hydraulic system
105 pressure.) 3000 PSI = Specs. Actual =
Brakes
106
107
108
109
7
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

. (Check the rear brake discs for fisures and
110 heat marks and distortion.)
111 (Bleed the brake system if necessary.)
112 (Check the parking brake pads.)
113 . (Take an oil sample of the front wheel hub oil.)

System Services
(Change the dump system hyd filters.) 13055-
114 H-1
(Change the steering and brake filters.) 13055-
115 G-1
116 (Change the breather filters in the hyd system.)

117 (Take an oil sample of the hyd system.)
(Take an oil sample of the steering and brake
118 system.)
(Check the oil level in the hyd tank and the
119 steering and brake tank.)
120 (Grease the driveline crosses.)
121
122
8
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

(Replace the fluid cooling filters for the
123 wheelmotors.) 13055-S-1 (2)
124
125
126
127
128
129
130
131
132
133
9
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

4 necessary.)

8 Tank.)
9 tank.)
10 tank.)
13 grease.)
20 grease)
10
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

23 grease ).
25
Radiator
26 bolts.)

30 as necessary.)
Engine
33 tightness.)
34 system.)
11
Supervisor: ________________
Date: _____________________
Hour Meter: _______________



44
12
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

51 lubrication.)
(Right.)
(Left.)
58 damage.)
61 damage.)
62 damage.)
13
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

66 assemblies.)
Fuel and Hydraulic

Operator's Cab

74 alarm.)

14
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

Electrical System
91 damage.)
94 and tightness.)
15
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

99 hoses.)
100 leaks.)
104 damage.)
Brakes
(Check the rear brake pad thickness.
106 Minimum = 1/8" or 3mm.)
(Measure the rear brake discs. Minimum =
107 7/8" or 22mm.)
(Check the thickness of the front brake pads.
(Measure the thickness of the front brake
109 discs. Minimum = 7/8" or 22mm.)
16
Supervisor: ________________
Date: _____________________
Hour Meter: _______________


System Services
114 H-1
115 G-1

118 system.)
121 (Grease the cabin door hinges with molicote.)

122 (Check and adjust the toe-in if necessary.)
17
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

123 wheelmotors.) 13055-S-1 (2)
124 Clean Seimens Inverter Box.
125
(Check the level of the refrigerant in the wheel
126 motors. Replace if necessary.)
127
128
129
130
131
132
133
18
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

4 necessary.)

8 Tank.)
9 tank.)
10 tank.)
13 grease.)
20 grease)
19
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

23 grease ).
Radiator
26 bolts.)

30 as necessary.)
Engine
33 tightness.)
34 system.)
20
Supervisor: ________________
Date: _____________________
Hour Meter: _______________



44 (Test the air intake system.)
21
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

51 lubrication.)
(Right.)
(Left.)
58 damage.)
61 damage.)
62 damage.)
22
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

66 assemblies.)
Fuel and Hydraulic

Operator's Cab

74 alarm.)

23
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

Electrical System
91 damage.)
94 and tightness.)
24
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

99 hoses.)
100 leaks.)
104 damage.)
Brakes
106
107
108
109
25
Supervisor: ________________
Date: _____________________
Hour Meter: _______________


System Services
114 H-1
115 G-1

118 system.)
121
122
26
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

123 wheelmotors.) 13055-S-1 (2)
124 (Clean the hydraulic tank strainers.)
125 (Clean the steering and brake tank strainers.)

127
128
129
130
131
132
133
27
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

4 necessary.)

8 Tank.)
9 tank.)
10 tank.)
13 grease.)
20 grease)
28
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

23 grease ).
Radiator
26 bolts.)

30 as necessary.)
Engine
33 tightness.)
34 system.)
29
Supervisor: ________________
Date: _____________________
Hour Meter: _______________



30
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

51 lubrication.)
(Right.)
(Left.)
58 damage.)
61 damage.)
62 damage.)
31
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

66 assemblies.)
Fuel and Hydraulic

Operator's Cab

74 alarm.)

32
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

Electrical System
91 damage.)
94 and tightness.)
33
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

99 hoses.)
100 leaks.)
104 damage.)
Brakes
107 7/8" or 22mm.)
34
Supervisor: ________________
Date: _____________________
Hour Meter: _______________


System Services
114 H-1
115 G-1

118 system.)

35
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

123 wheelmotors.) 13055-S-1 (2)
124
125
126
127
128
129
130
131
132
133
36
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

4 necessary.)

8 Tank.)
9 tank.)
10 tank.)
13 grease.)
20 grease)
37
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

23 grease ).
Radiator
26 bolts.)

30 as necessary.)
Engine
33 tightness.)
34 system.)
38
Supervisor: ________________
Date: _____________________
Hour Meter: _______________



39
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

51 lubrication.)
(Right.)
(Left.)
58 damage.)
61 damage.)
62 damage.)
40
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

66 assemblies.)
Fuel and Hydraulic

Operator's Cab

74 alarm.)

41
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

Electrical System
91 damage.)
94 and tightness.)
42
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

99 hoses.)
100 leaks.)
104 damage.)
Brakes
107 7/8" or 22mm.)
43
Supervisor: ________________
Date: _____________________
Hour Meter: _______________


System Services
114 H-1
115 G-1

118 system.)

44
Supervisor: ________________
Date: _____________________
Hour Meter: _______________

123 wheelmotors.) 13055-S-1 (2)
124 (Clean the hydraulic tank strainers.)
125 (Clean the steering and brake tank strainers.)

127 (Retorque all brake caliper bolts to 740 ft/lbs.)

(Retorque the front wheel spider bolts to 280
128 ft/lbs.)
(Retorque the rear wheel brake calipers to 460
129 ft/lbs.)
(Inspect and adjust the front wheel bearings if
130 necessary.)
(Inspect the bolts attaching the wheelmotor to
the axle box. Check the torque to verify 1,360
131 ft/lbs.)
(Verify that the steering arm pin retainers are
132 torqued to 80 ft/lbs.)
(Retorque the front wheel mounting bolts. 3/4"
133 bolts = 280 ft/lbs. 1" bolts = 680 ft/lbs.)
45
Page 121 of 167

_______________________________________________________
Michelin Tires
Training Material

Newport News, VA.
23607
Page 122 of 167
Mjfcifss!Njojoh!Frvjqnfou!
Dpnqboz
Michelin Tire Information Guide
Definitions:
1.) Aspect Ratio = {H/S} This is the ratio between the sidewall height and the
tire width.
2.) Load Index = This is a numeric code associated with the maximum Load a tire
can carry with a corresponding speed symbol under specified conditions.
3.) Load / Pressure Schedule = The correct tire pressure for a machine depends
on the working conditions and the use. This must be determined at the site by
a Michelin Technician.
4.) Maximum Distance Limit = The maximum distance traveled for one hour. It
is also a function of the Load and Pressure of the tire for operating under
economic conditions.
5.) Ply Rating = The numeric rating given to indicate the number of criss-crossed
plies. This is indigenous towards tires with Bias {diagonal} ply construction.
For this application, the crown and the side walls of the tire are formed by the
same ply structure. The tire tread is affected by the flexing of the tire contact
area with the ground. It also allows movement in the tread contact area.
6.) Speed Symbol = This is an Alpha or an Alpha / Numeric code indicating

MPH or KPH maximum speeds. Example = a speed symbol of “A2” dictates
a maximum speed of 10 KPH or 6 MPH.
1
Page 123 of 167
7.) Star Rating = With Michelin tires, this numeric / alpha rating indicates the
Radial tire ply. On Radial tire ply construction, the side wall and the tread
function separately, so there is no movement between the casing and the plies.
8.) Tire Families = There are three major tire families identified by the aspect
ratio. They are “Narrow Base, “Wide Base”, and “Low Profile”.
9.) TKPH / TMPH = Ton Kilometer Per Hour or Ton Mile Per Hour. These are
an expression of the working capacity of a tire, and a function of the
maximum allowed internal operating temperature of a tire.
10.) Tread Compound Rating = On Michelin tires, this Alpha / Numeric rating
indicates how the tread rubber was specifically manufactured. Generally
speaking the tread rubber is formulated with various resistances to heat,
abrasion, tearing, and cuts.
11.) Tread Depth = There are four Earth Mover Tire Families characterized by
their tread depth or height. These are chosen as a function of their use and the
ground types.
12.) Tread Pattern = Design of the tread to accommodate the use and condition
where the tire is working.
Examples of Tire Markings:
All Michelin tires are marked from manufacturing indicating specific design purposes.
The following example will be used as a break-down for information purposes:
750/65 R 25 XAD 65-1 Super E3T TL 190 B
750 = Nominal Section Width in MM or Inches.
65 = Aspect Ratio {H/S = 0.65}
R = Radial Construction
25 = Nominal Rim Diameter
X = Michelin Radial
2
Page 124 of 167
AD = Tread Pattern
65 = 65 Series {H/S = 0.65}
1 = First development of the tire.
Super E3 = Standardized ID Code
T = Michelin complementary ID {Traction Tire}
TL = Tubeless
190 = Corresponds to a load of 10600 Kg or 23370 Lb.
B = Corresponds to a maximum speed of 50 Km/h or 30 MPH.
Rigid Dumpers and Tire Pressures
Mine Haul Trucks are referred to as “Rigid Dumpers”. Calculating tire pressures for
specific mine locations (sites) is as complicated as a procedure can get.
In some mine locations the working tire pressures of Rigid Dumpers may vary from one
side of the mine to the other.
In the same instance the recommended tire pressures would need to vary during seasonal
changes. So, maintaining a vigilant watch over tire working pressures is no easy
endeavor.
To begin with, it is necessary to establish the gross vehicle weight with the vehicle fully
loaded to its maximum capacity. Divide that vehicle weight by the number of axles.
(The Liebherr Truck is considered to have two axles. Front and Rear.) You then need to
calculate the load per axle by dividing the axle loads by the number of tires attached to it.
(For the Liebherr trucks, divide the front axle weight by 2 and the rear axle weight by 4.)
Once you have established your weight distribution, you must establish your mine site
TKPH or TMPH. (You can refer to the documentation in this regard provided in this
guide, but it is a better practice to refer to the technical data for earthmoving tires
provided by Michelin.)
Once you have established your tire load and you’re TKPH/TMPH, then your values can
be referenced to a PSI/Bar/Kpa chart. Note: A chart is proved in this reference guide,
but it is only referencing the 55/80 R 63 tires utilized by the Liebherr T-282. A wiser
practice would be to utilize the technical data manual provided by Michelin.
3
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4
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5
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Tire Tread Patterns:
The following two pages depict the various tire tread patterns available from
Michelin:
6
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7
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8
Page 130 of 167

_______________________________________________________
T-282B Dash Computer

Programming
Training Material

Newport News, VA.
23607
Page 131 of 167
SBS Dash Computer Programming Information Guide
Dash PC7 BIOS Settings
This document provides specific BIOS settings that are required in the PC7 computer in
order for the applications to operate properly under normal circumstances.
A Setting not specifically provided in this document should be set to its default. Use the
“Auto Configuration with Optimal Settings” menu item on the main menu to revert the
system configuration back to the default factory values before making the following
changes:
Advanced CMOS Setup:
• 1st Boot Device IDE-HDD

• 2nd Boot Device Floppy
• 3rd Boot Device ATAPI CDROM
• Try Other Boot Devices Yes
Peripheral Setup:
• Onboard Serial Port 1 3F8h, IRQ4

• Onboard Serial Port 2 2F8h, IRQ3
• Onboard Parallel Port Disabled
• Onboard Serial Port 3 3E8h, IRQ11
• Onboard Serial Port 4 2E8h, IRQ10
• Onboard Parallel Port 2 Disabled
Auto-Detect Hard Disks:
• There are no options here. This will automatically adjust the system
configuration for the attached hard disk(s).
Save Settings and Exit:
• Select “Y” to save the current settings and exit.
Ghost Setup TCP/IP Address Numbers:
• 192.168.1.100 = IP Address (SBS) This is the “Master”.

• 192.168.1.101 = IP Address (Laptop) This is the “Slave”.
• 255.255.255.0 = Sub Net Mask
• 192.168.1.1 = Gateway
Page 132 of 167
To re-program or to initially program an SBS, it must be understood that this is a

“desktop” procedure. Therefore, specific hardware and software components are
necessary. The following items are necessary to perform this operation:
• DSE Display Unit or PC Monitor

• SBS PC7 Computer Unit
• Video Cable for DSE (if used)
• Calibrated Power Supply (24VDC to 12VDC)
• Calibrated Power Supply (110/240 ACV to 24VDC)
• Fabricated Watch Dog cable. (Fabricate with a DB9 adapter)
• Power Cable for DSE. (if used)
• Network Crossover Cable
• Keyboard (PS2 Windows)
• Power Cord for 110/240 VDC to 24 VDC Calibrated Power Supply
• Laptop with 40 meg free space on hard drive
• Norton “Ghost” Program
• Ghost Image File from LME
• Ghost Boot Disk
• Windows 98 boot disk with the “format” command. (Only suggested)
Preliminary Setup: (No particular order to these items. They just have to be completed
before programming a SBS.)
• 1.) Change the CMOS settings in the SBS to boot to floppy first.
• 2.) Make a Ghost Recovery Boot Disk with the Norton Ghost Program.
• 3.) Set the Ghost Program Utilities to reflect the TCP/IP address as listed above.
• 4.) Setup you desktop hardware according to the wiring diagram for the T-282B
(TI-2004-B)
• Note: It is not necessary to format an SBS hard drive to perform this ghost
imaging procedure. When it is decided that it is necessary to format a hard drive,
there must be very viable reasons for making this decision. This decision is left
entirely to the discretion of the Programmer.
Performing the Imaging Operation: (assuming your equipment is prepared and ready
to use.)
• 5.) Start the Laptop and connect the crossover cable to the SBS and the laptop
respectively. At the same time, start the SBS computer with the Ghost Boot Disk
inserted in the floppy drive.
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• 6.) Start the Ghost Program. (On the Laptop)
• 7.) Choose “Ghost Advanced”.
• 8.) Choose Peer-to-Peer

Page 134 of 167
• 9.) Choose TCP Peer to Peer and click “Next”.

• 10.) Choose “next” again when prompted.
• 11.) At the Advanced Settings menu, click “next”.

• 12.) At the Disaster Recovery menu, click “continue”.
Page 135 of 167
• 13.) At the Norton Ghost Task Summary menu, click “Run Now”.
• 14.) At the Re-Start option menu, choose OK.
• 15.) The SBS has been booted to the Ghost Recovery Disk. Hit enter for OK and
click OK on the laptop.
• 16.) On the laptop, choose Peer to Peer – TCP/IP – Slave. (Enter or click on
“Slave”)
• 17.) On the SBS, choose Peer to Peer – TCP/IP Master. (Hit “enter” on Master.)
• 18.) On the SBS Keyboard, Type in the “slave” (laptop) address 192.168.1.101,
tab to OK and hit enter.
• 19.) On the “Local”, choose Disk – From Image – “enter”.
• 20.) At the Image File Name Menu, use the “shift” tab buttons to move to the
pull-down menu.
• 21.) Select the drive for the Ghost Image File.
• 22.) Select the Ghost Image Folder.
• 23.) Select the Ghost Image file.
Page 136 of 167
• 24.) Tab to OK and hit “enter”.

• 25.) (again) Tab to OK and hit “enter”.
• 26.) Select “YES”, hit “enter”.
• 27.) You will see the Progress Bar indicating the Imaging Process taking
place.
• 28.) At the “Clone Complete” menu, choose “Continue” and enter.
• 29.) At the Main Menu, choose “Quit” and enter.
• 30.) At the “ARE YOU SURE?” menu, choose OK and enter.
• 31.) The SBS will go to the A:\Ghost> screen.
• 32.) Close out the Laptop menu and let the laptop return to Windows.
• 33.) Hit CTL – ALT – DEL keys on the SBS keyboard and remove the Ghost
Boot Disk.
• 34.) At the DHCP Client Menu, choose “NO” and enter.
You can now change the SBS CMOS settings as indicated on page 1 of this pamphlet.
Page 137 of 167

_______________________________________________________
Payload Weigh System
Training Material

Newport News, VA.
23607
Page 138 of 167
Liebherr “Scales”
Weigh Systems Operating Manual

The Liebherr Payload Weigh System System Maintenance
(Scales) monitors the pressures in the
vehicles suspensions and uses this data Turn on the System Power by turning
to calculate the weight of the load in the the Master Switch to the “ON” position.
dump body.
Note: The Weigh System Hibernates
With the data from the pressure when the truck is turned “OFF”, so it
transducers in the suspensions, the may take up to two minutes for the
system will automatically activate the Display Unit to respond once the truck is
load indicator lights (if so equipped) to switched “ON”. This statement is not
show the progress of the loading true in all applications.
operation.
Some of the old programming software
The system will also record the complete in TF Tools provided for a hibernation
loading process for later analysis. mode, the latest versions of the software
do not.
Activation of the Hand Brake and the
detection of the increased weight in the 1.) Turn on the portable laptop
dump body (from the first dipper load) computer and allow the
will activate the system’s recording booting sequence to complete
devices. before attaching WS
communication cable
Load Data is saved when the Hand between the laptop COMM 1
Brake is set and the Dump Body is and the Truck WS
raised. communication port. This
statement is especially
The system will record in excess of 3000 important if you are using
load/dump cycles. When the memory is Windows NT! Windows NT
“full”, the oldest data recorded will be programming will detect new
overwritten. hardware and try to install
drivers if the WS
System Components communication cable is
connected to the laptop
A.) Transducers during the boot-up process.
B.) PDM (Payload Display
Meter) Note: The SCALES program has not
C.) OBD (Outboard Display been fully tested with the Windows
Meter) XP operating systems at this time. It
D.) TFX-11 Tattletale Recorder is recommended that you use
(Weigh System Box) Windows 98 to Windows 2000 DOS
Page 139 of 167
until such time the testing for

compatibility with XP is completed.
2.) Open the MS Dos prompt

and go to the directory where
you have the SCALES
program installed.
Note: The SCALES program is a

DOS based program. It works best
when opened from within DOS. You
may certainly create a Desktop
Shortcut to this program and expect
good results. But, remember that it is Fig. 1
a DOS based program and it is
designed to work to its fullest potential 5.) Select Item 2 from the
and reliability within DOS and not displayed menu. (Figure 2)
Windows Desktop.
3.) When you are at the

C:\Scales directory, type
scales 1 (enter).
Note: The command “SCALES 1”

indicates that you are using Comm 1
on your laptop at 19200 baud rate.
The command “SCALES 2” indicates

that you are using Comm 2 on your
laptop at 19200 baud rate.
The command “SCALES 3” indicates Fig. 2

laptop at 9600 baud rate. 6.) Type M+ to go to the first
level of maintenance.
The command “SCALES 4” indicates (Figure 3)
laptop at 9600 baud rate.
4.) The LIEBHERR SCALES

Main Menu screen will now
appear. (Figure 1)
Page 140 of 167
Level Two Maintenance
Note: Only trained personnel should

access this level of maintenance.
Incorrect use may result in injury or
equipment damage.
1.) Select item number “2”. See

figure 2 on page 2. Then
type WISE to access the
Advanced Maintenance
Fig. 3 Menu.
At this level of maintenance, you can Note: The access password “WISE”
perform the following as required: is not the only level 2 password
available. If you do not know what
A.) To manually set the real time your password is, then go to your
clock, type “8”. Then enter SCALES folder in windows explorer
the correct time and date and open up the file named “PASS”.
using two digit numbers (i.e., When this file is accessed, it will
02 for 2); or type “9” to display your current password and
automatically set the system give you the option to change it. It is
clock to the same time as the recommended that you do not change
portable computer clock. your authorized password.
B.) To set the truck ID number,
type “1”. You may type in as 2.) Type “1” to select the
many as five numbers to transducer types used on the
identify the vehicle, however, truck. Type “1”, “2”, or “3”
when you download the WS and (enter) to select 3000,
data, only the last three digits 4000, or 5000 PSI
of the unit number will be transducers for the front
used to identify the vehicle. wheels. Repeat this process
C.) To select either Standard to select the transducer type
English or Metric ton units, used for the rear wheels.
type “2”. The option will When completed, the
automatically toggle from the Calibration Constants (Ks)
existing function to the next will be automatically updated
option. to match the transducer types
D.) To change the date selected.
configuration, such as from 3.) Type “2” to modify the
DD/MM/YY to MM/DD/YY, Empty Wheel Weights.
press “3”. The date These numbers can be used
configuration will toggle to to fine tune the system to
the next option automatically. match any other weighing
E.) To exit the Standard device, such as ground scales.
Maintenance Menu, type in The values, in order,
“4”.
Page 141 of 167
represent the left front, right less than one shovel dipper
front, left rear and right rear. will fill the truck to its rated
Increasing one of the load. The next number is the
numbers by one will reduce Flashing Red Light Level.
the measured load by one ton. This value should be 10 tons
(It makes no difference here greater than the truck rating.
if you are in the English (Example = 360 ton truck
mode or Metric mode. The rating + 10 = 370.) This
rule remains the same.) It is value signifies that the truck
recommended that you make is overloaded.
these adjustments on a 6.) Type “4” to return to the
vehicle that is fully loaded main menu.
and resting on a ground
scales unit. This way, you Note: All settings in the Advanced
can verify your changes Maintenance Menu are stored in a
accuracy and make non-volatile memory. Once the values
appropriate adjustments if have been set, they are retained even if
necessary. a new Weigh System Program is
4.) Type “5” to clear the Load flashed into the memory.
Data Memory. Any existing
load data will be erased and Checking Suspension Pressures Using
the Load Counter will be the “SCALES” System:
reset to zero.
5.) Type “6” to change the Light General:
Control Tonnage values.
This first number is the Checking the suspension nitrogen gas
Green Light Level. This charge pressure is extremely easy and
number should be 15 tons accurate using this system.
greater than the Total Load
Weight displayed when the 1.) Connect the portable laptop
truck is empty. The next computer and access the
value is the Amber Light SCALES system, the same
Level. This number is one way as described in the
shovel dipper load, less than System Maintenance section.
the truck rating. (Example = 2.) Suspension pressures can be
360 ton rating – 80 ton rated read directly from the Main
dipper from the loading Menu screen.
shovel = 280.) This number
signifies that one more dipper Use the values of the pressures
from the shovel will fill the displayed here as a reference for
truck to its rated load maintenance. Refer to chapter three
capacity. The third number is of the Maintenance Manual for the
the Flashing Amber Light proper procedures.
Level and the truck rating.
(Example = 360 ton rating – 3.) To exit the program, type
40.) This value signifies that “esc”, “Q”, or “0”. You will
Page 142 of 167
be questioned if you want to

exit. Type “y” for yes or “n” 190-02 = this indicates a 190 ton
for no. Pressing “4” will exit payload with a low right front
the program immediately. suspension charge which should be
investigated.
Payload Meter Weigh System Data Port
The LIEBHERR “LODE WEIGH” This connector is located on the dash in

payload meter system is on the accessory front of the passenger seat.
dash panel. The meter is a six digit LED
display unit. In addition to the payload Note: When a computer is connected
indication, the meter also displays to this port, updating of the Payload
system fault codes. The first three digits Meter (on the dash) is suspended. The
on the left side of the meter indicate the display on the Outboard meter is also
payload tons. The two digits on the right suspended. The weigh system will be
side of the meter indicate the fault codes. dedicated to communicating with the
(F/C) laptop.
Fault Codes Load data is down loaded and the

memory is reset by choosing “1” at the
00 = No Faults main SCALES menu. (Refer to figure 1
01 = Left Front on page 2.)
02 = Right Front
03 = Left Front and Right Front If you watch the bottom of the SCALES
04 = Left Rear display screen, you will see data being
05 = Left Front and Left Rear downloaded and you will be prompted
06 = Right Front and Left Rear when the download is complete.
07 = Left Rear, Left Front & Right Front
08 = Right Rear The downloaded data will automatically
09 = Right Rear & Left Front go to the SCALES folder where your
10 = Right Rear & Right Front scales.exe file is located.
11 = Right Rear, Left Front & Right
Front The file generated on the laptop will be
12 = Right Rear and Right Front named with the following format:
13 = Right Rear, Left Rear & Left Front
14 = Right Rear, Left Rear & Right Example = 22010216.457
Front
15 = Check All 22 = Day 01=Month 02=Year
16=Seconds 457=Last 3 digits of the
Example: truck unit number.
190-00 = this indicates a 190 ton load Once the data is downloaded, the
with no fault codes. memory is reset and the load cycles
begin again.
Example with a fault code:
Page 143 of 167
Importing Payload Data

The data from the Payload Weigh
system is generic ASCII type, which can
be viewed from the DOS “TYPE”
command or Windows Notepad.
The data can be imported into various

spreadsheet programs. If you import the
data into a spreadsheet program, you Fig. 2
will have more statistical number
manipulation flexibility. 3.) Select the folder where the
downloaded data is stored.
WordPerfect 7.0 or Office Excel would
be perfect examples.
The following example of importing

data will use the Microsoft Excel
spreadsheet program:
1.) Open Microsoft Excel.
Fig. 3
4.) Select “All Files” for the

“Files of Type” box.
Fig. 1
2.) Go to “File” and “Open”.
Fig. 4
Page 144 of 167
5.) Select the file you wish to “MDY” to “YMD”. Select

import and the “Text Import “Finish”.
Wizard – Step 1 of 3” box
will appear. The “Delimited”
box will automatically be
selected. Click “next”.
Fig. 7
8.) The data is now imported to

the Excel Spreadsheet.
Fig. 5
6.) This next screen allows you

to choose your delimiter. Put
a check mark in the
“Comma” box. You will
then see your columns
separated on the display.
Click “next”.
Fig. 8
9.) The data can now be

manipulated into useful
management information.
Fig. 6
7.) Column “1” will be

highlighted. Highlight
column “2”. Go to the
“Column Data Format” box
and select “Date”. Change
the date selection from
Page 145 of 167
Column 8 = Total Load. Adding up

columns 4, 5, 6, and 7 will total the
amount of tonnage recorded for the load.
Note: You can use the information in

columns 4, 5, 6, and 7 do determine
how the load was distributed in the
dump body when the truck left the
shovel.
Column 9 = Stored Event Number. This

Fig. 9 column will count the number of events
from 1 to 100. Then the cycle will begin
When developing the spreadsheet, the again. This column can be useful when
column divisions should be understood applying formulas to the spreadsheet,
as follows: because you can obtain an average
payload per 100 loads.
Column 1 = Event Number. This is a
continuous logging of events. These Column 10 = End Load Time. Literally,
numbers will continue from 1 to in when the operator of the vehicle releases
excess of 3000. his Hand Brake and leaves the shovel,
this is the time recorded.
Column 2 = Date. YY/MM/DD.
Column 11 = Dump Time. Literally,
Column 3 = Start Load Time. A 24 hour when the operator re-sets his Hand
clock reading is used to indicate the time Brake and Raises the Dump Body, this
of day that the first dipper load activated time is recorded.
the Payload System recording device.
Column 12 = Fault Codes. If there were
Column 4 = Left Front. When the any transducer fault codes logged during
loading cycle is completed, the numbers any operating cycle, they will be
here indicate the amount of tonnage recorded here. (See Page 5 for fault
recorded on the left front transducer. code listing and descriptions.)
Column 5 = Right Front. When the Column 13 = Truck ID. The Payload
loading cycle is completed, the numbers Weigh System records only the last three
here indicate the amount of tonnage digits of the Truck ID number as stored
recorded on the right front transducer. in SCALES.
Column 6 = Left Rear. Same Overview Points

description as 4 and 5.
1.) The LIEBHERR Payload
Column 7 = Right Rear. Same Weigh system is a “High
description as 4 and 5. Maintenance” system. It
requires diligent and constant
monitoring of the suspension
Page 146 of 167
pressures, transducer TF Tools

conditions, and WS clock
batteries.
Note: TF Tools is a Software
2.) The WS clock battery voltage
Programming Tool. It is used to
should be maintained
Program new WS boxes or re-
between 5 to 6 volts. If the
program WS boxes when an update is
battery voltage drops below 3
needed. Only trained technicians
volts, the WS box will lose
should be allowed to utilize this
any load data stored
program.
whenever the Master Key
Switch is cycled.
3.) Loose or corroded wires
anywhere in the Payload Readme.txt
System will radically affect
the accuracy of the readings. The imbedded object above
4.) Remember that all (Readme.txt) is the complete TF Tools
downloaded data setup and operation guide. It explains
automatically goes to the the method of setting up TF Tools on
SCALES folder on the your laptop computer with some
laptop. After a period of programming guides included.
time, this folder can get quite Double-click the imbedded object to
full and congested. It is open the programming guide.
suggested that a separate
folder (Example = This document will include a short
Downloaded WS Files.) be pictorial to augment the Readme.txt.
created. Then, periodically, The Pictorial will only display the steps
the downloaded files in in programming a WS Box. It is not
SCALES can be moved to intended to be a replacement for the TF
this folder for better Tools Readme.txt.
organization purposes.
5.) The Payload Weigh System Programming a WS Box
was developed to be a
“Management” tool. This
1.) The weigh system data cable
system can be a major tool
must be connected to the data
when properly applied to any
port on the dash and Comm 1
PM program.
on the laptop.
6.) The question is often asked,
2.) The 25 pin DB cable must be
“How often should a data
connected to the data port
download be performed?”
inside of the WS box and the
The answer should be, “At
LPT1 on the laptop.
each and every scheduled PM
Service.”
Page 147 of 167
Note: A WS Box can be

programmed with using only the
WS Data Cable. However, the
programming will not go to the
TFX-11 flash memory, and the
programming will be lost if the WS
clock battery voltage drops below
3 volts.
3.) Open up the Windows

Explorer program and go to
the TF Tools folder located in Fig. 2
drive C:\. (It is assumed that
Windows is running at this 5.) Use the laptop keyboard and
point.) Double-click the TF hit “Ctrl C”. This will stop
Tools.exe icon. (Fig. 1) the data from scrolling.
6.) Go to the “FILE” menu and

select “OPEN”. Figure 3
Fig. 1
4.) The TF Tools program will

open and you will start to see Fig. 3
the current programming data
scrolling up the screen. 7.) The “Dialog Box” will
(Provided that the WS box appear. Figure 4.
was previously programmed.)
Figure 2.
Page 148 of 167
9.) With the .tfb file showing in

the foreground. Go to the
“TATTLETALE” menu and
click to display the options.
Figure 6.
Fig. 4
8.) When this dialog box appears

(Fig. 4), you must select “All
Files” for the Files of Type
Box. Notice that the dialogue
box is displaying the Fig. 6
SCALES folder. This is
where TF Tools goes to look 10.) At this point the command
for your programming files. “LAUNCH” should be dark
The programming files have and visible. (In this example,
a .tfb extension. You must Fig. 6, the command
choose the correct .tfb file LAUNCH is not dark, so it
and select “OPEN” in the indicates that there is a
dialogue box. When you problem with reading the .tfb
select “OPEN”, the .tfb file file.) You must refer back to
will be displayed in the the Readme.txt if you get to
foreground on the TF Tools this point and the command
display. Figure 5. LAUNCH is not dark and
ready to be initiated.
11.) Initiate the LAUNCH

command by double-clicking.
A programming indicator bar
will appear and you can see
the programming percentages
as they complete.
12.) 12.) Upon completion of the

programming, the TF Tools
screen will begin scrolling up
Fig. 5 with the new programming
information. Do not hit Ctrl
C at this time!
Page 149 of 167
13.) Use the mouse pointer to

close the TF Tools dialogue
box with the information still
scrolling.
The programming is complete at this

point. See the following notes:
Note: Many times situations occur

during a programming effort that
requires the programmer to have
considerable computer skills in order
to diagnose the problem.
Programming a WS Box should be left

to such individuals who possess those
skills.
Page 150 of 167
Payload Weigh System, Windows Version
Note: At this current time (printing) there are three versions of the Liebherr Payload
System. There are versions 1.143, 1.144, and 1.145.
Version 1.143 is the version that is currently being utilized by technicians and mine
personnel that are “able” to do so. Versions 1.144 and 1.145 are versions still in the
“developmental” phase and are not quite ready for field use.
This new Scales Program can only be described as a “memory hog”, as it requires a
tremendous amount of memory to function. Whenever this program is being run, no
other windows based programs can be open. (It simply requires too much memory)
The System Requirements for running the Windows Based Payload Program are as
follows:
• 1 GB Processor
• 256K Ram (Bare Minimum)
• Pentium III or IV (IV is better)
• Windows 98 or Higher (The program works best with Windows 2000)
Version 1.143 is user friendly software that is desirable to use. This “user friendly”
statement is true for the other two versions, as the software tabs and functions are the
same. The only upgrade to the program is the issue of memory usage. The programming
engineers are trying to downgrade the amount of memory required to run the program.
As of yet…no luck.
Page 151 of 167
It should be noted here that “if” your field laptop computer does not meet the
specifications for Payload Weigh System Version 1.143, then you can still utilize the
Scales DOS version with every bit of management success that the windows version
offers.
One advantage that the Payload Weigh System offers over the Scales DOS version is that
this program allows the usage of the USB port for communication with the WS Box.
However, there is a definite drawback to this improvement.
That drawback is that the user now has to purchase a USB / Serial Port adapter for his/her
laptop. This is an expensive item, and when you purchase one, you must make sure that
the adapter that you purchase is compatible with the Windows operating system that you
have on your laptop.
The following pages will highlight and outline the new screen visuals available with the
Payload Weigh System Program.
Page 152 of 167
Whenever you turn on the program, it is going to automatically look for Comm ports
available for use. In this example, Comm 3 and Comm 4 are available. Notice that this
example is showing that the program is using Comm 4. This Comm port selection is
done manually by using the mouse to click the Comm 4 button. There will be no
readings available in the display screen until an active Comm port is chosen.
Notice in this example that both Truck folders are open.

Page 153 of 167
From here, you can view the current Truck Configuration and Load Values. The
information scrolling across the bottom / right window baud communication signals.
Using the mouse to open up the Codes folder, you can view the active fault codes.
Page 154 of 167
When you open up the Com Port folder, you can view you baud rate selection and the
active Comm Port. Both of these can be changed here without the use of a pass word.
Opening up the Controls Folder will allow you to set Truck IDs, change Date Styles,
change from English to Metric, etc. Making changes within this folder does not require
the use of a password.
Page 155 of 167
When you open the Configuration folder, you have access to the Truck Configuration
Files and can make changes only with the use of a password. The password is case
sensitive and must be typed in capital letters only! The default password for this version
is FAB3. You must use this password the first time you seek authorization for making
changes. You may change this password to one of your own choosing thereafter. It is
recommended that you do so for your own location’s security. Simply remember to use
four letters or digits or a combination of both, and make your password all capital letters.
Important note: Never, under any circumstances, make any numeric changes to the Set
Calibration Ks listings. To do so would negate any transducer accuracy that you have
programmed into the software. This was true for the Scales DOS version and it remains
true for this version. Furthermore, if your Liebherr vehicle ever experiences any
structural or component failures due to overloading situations, and it is discovered that
the Calibration Constants have been modified from the factory settings, all warranty
issues and claims become voided.
Page 156 of 167
The Buffer Data Folder allows you to view your Program information and Operating
Systems Data. Plus, you can check the historic downloads file.
You can see by these user friendly folders and tabs, the Payload Weigh System Program
operates in the same manner as the Scales DOS program. The information you desire to
download for management purposes remains the same.
Page 157 of 167
One major change in the Windows Payload Weigh System is the “Download and Reset”
button operation. All of us are used to going to the “Scales” folder in DOS to retrieve
any data that we have downloaded. With this program, a new folder named
“WS_DATA” will be created in your “C” drive directory whenever you install the
program. When you download and reset using this program the data will automatically
go to the WS_DATA folder.
Page 158 of 167

_______________________________________________________
Super Jack Walk-Around

Inspection Procedures
Training Material

Newport News, VA.
23607
Page 159 of 167
Super Jack III and IV Super Jack III
Maintenance / Safety Overall Length = 119 3/8 inches (3.0 m)

Guide Width = 91 3/8 inches (2.3 m)
Lowered Height = 73 3/4 inches (1.9 m)
Raised Height = 109 3/4 inches 2.6 m)
Unit Weight = 15,800 Lbs (7165 kg)
Lift Capacity = 90 tons (81,720 kg)
Safety First
General Maintenance Points
Before beginning any maintenance,
And Component Locations
service or repairs, read the section which
applies to the task being performed.
Make special note of all CAUTIONS
and WARNINGS.
It is virtually impossible to anticipate

every condition or situation which may
be encountered; therefore, each task
must be evaluated individually so it can
be accomplished in the safest manner
possible.
If maximum safety cannot be assured,

DO NOT PROCEED; contact your
supervisor or a Liebherr Representative.
Tongue and Axle Assembly
Failure to do so could cause damage to
the Super Jack, or worse, to oneself or
others.
General Specifications:
Super Jack IV
Overall Length = 163 inches (4.14 m)

Width = 87 ¼ inches (2.21 m)
Lowered Height = 105.33 inches (2.68 m)
Raised Height = 122 3/4 inches (3.11 m)
Unit Weight (calculated) = 19,000 lbs Operator Step Assembly
(8620 kg)
Lift Capacity = 120 Tons (108,864 kg)
1
Page 160 of 167
Operator Controls Carriage Tire and Rim with Lift

Cylinder
Steering Cylinder Drive Motor
Main Carriage Assembly
Safety Lock Rack
2
Page 161 of 167
The Super Jack III and IV are

convenient propelled service tools that
require periodic maintenance to maintain
their serviceability and safety factors.
Specific maintenance procedures and
recommendations are outlined in the
Super Jack III and IV Operation,
Maintenance, and Replacement Parts
Manual.
It is a recognized fact that the Super Jack

will not be utilized on a daily or even a Operator controls should be checked for
“frequent” basis. Therefore, it is freedom of movement prior to startup of
recommended that a standard procedure the machine. Note the condition of the
of pre-inspecting the machine prior to handles and the control labels.
usage be adopted by all locations
possessing the Super Jack.
Use the following pictorial guides as a

suggested Walk-a-round inspection
procedure, but keep in mind that it is
highly recommended that the responsible
parties for the equipment develop and
implement a pre-trip inspection check-
off sheet.
The back-up alarm is part of the

equipments safety features. Check the
physical condition of the unit and the
units wiring harness prior to start-up.
Check the Operator Platform for

damage, retainer pin condition,
positioning chain condition, and freedom
of movement.
Control valves, hoses, connections and

filter housings should be checked for
cleanliness and leakage.
3
Page 162 of 167
Proper lubrication and sufficient

lubrication of the Pawl will ensure
smooth operation.
Check the condition of the Operators

steering indicator. This component
should always be easily seen from the
operator’s platform. Painting the
indicator red is only a suggestion. Be sure to check underneath the Super
Jack and take note of the exhaust piping
condition.
The towing tongue should be free of any

external damage. Any distortion or
damage to any area of the towing tongue
should be immediately repaired or
replaced.
The engines oil level dipstick is located

on the right rear side of the engine block.
Make sure the unit is on level ground
when checking the oil level.
Pawl operation can become restrained

due to extended periods of inactivity.
4
Page 163 of 167
The engines throttle and controls should The hydraulic pressure gauge indicator
be visually inspected for dirt, corrosion, is important for maintaining a constant
serviceability, and function. This should awareness of hydraulic system
be done prior to unit start-up. condition. Make sure to check the gauge
visually for condition and fluid level /
condition.
Lifting points should be inspected

closely due to the fact that many times it Make sure that the hydraulic tank is
requires the use of a crane to properly properly filled before starting the unit.
position the Super Jack.
The hydraulic pump connections and

Visually inspect the carriage for damage. mounting fixtures need to be inspected
for serviceability prior to any start-up.
5
Page 164 of 167
The hydraulic drive motor needs to be As exhaust piping must be inspected

visually inspected prior to any start-up behind the engine, it must also be
and the motor head bolts need to have inspected underneath the engine with
the torque value checked every 3 months attention directed towards the chassis
or 50 hours. The torque value of these mounting fixtures.
bolts should be verified through the use
of the Super Jack Maintenance Manual.
If the Super Jack is operated on rough
terrain, the frequency should be
adjusted.
Fuel tank levels need to be kept at the

maximum capacity. Again, due to long
periods of inactivity, the Super Jack fuel
tank may have a tendency to develop
moisture if not maintained “full” at all
The steering cylinder hoses, connections, times.
and rod condition needs to be inspected
for damage, leaks, contamination and
loose fittings.
Battery selectors should be “off” until

needed.
6
Page 165 of 167
The Super Jack battery box must be The carriage guide chain needs to be
inspected externally and internally. lubricated with a high quality chain type
Battery maintenance for vehicles with lubricant. Refer to the Super Jack
relatively low usage rate is important to Maintenance Manual for proper
maintain good starting capabilities of the recommendation.
machine when the machine is required.
Lubrication Point Checks:
Steering King Pin The Super Jack III and IV upper carriage
bushing has a grease point located at the
top of the carriage.
Carriage Swivel – Rear
7
Page 166 of 167
Cylinder pivot points do not come with

The lower front boom swivel joint has grease points, but should be lubricated
two grease points located on the left and with a chain type lubricant, or a spray
right side respectively. type pin lubricant. Refer to the
Maintenance Manual for recommended
lubricant types.
The upper boom swivel has two grease

points on the left and right side
respectively.
In order to properly lubricate the lower
lift cylinder pin, the Carriage has to be
raised slightly to gain access.
The lower rear boom swivel has two

grease points on the right and left side
respectively.
8
Page 167 of 167
Super Jack Lifting Points
Warning: There are three lift points

built on to the Super Jack. Each lift
point has a specific purpose. Make sure
you understand the purpose for each lift
point and do not mis-use any of them!
This is the Unit Lift Point with an

attached sling. There are two of these
lift points on the right and left side
respectively.
Lifting Adapters
The Super Jack is a very adaptable piece

of equipment that was designed to be
This lift point is strictly for servicing or used with a variety of large earth moving
removing the canopy. It is not to be equipment from different manufacturers.
used for lifting the entire unit. It would be virtually impossible to give a
pictorial reference to the numerous
adapters available for this unit.
When inspecting the serviceability of

any adapter, use common sense and
close scrutiny.
This is the carriage lift point and is for

carriage servicing only.

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Page 1 of 167

Liebherr Mining Equipment Co.

Product Support Division

T-282 Systems Overview

For Training Purposes Only

T-282 Systems Overview and Operation Manual

Hydraulic System Overview 3 – 29

Husco Split Spool System 30 – 49

Danfoss Flow Amplifier 50 – 55

Contamination and Wear Limits 67 – 74

Preventative Maintenance 75 – 120

Michelin Tires 121 – 129

Dash Computer Programming 130 – 136

Payload Weigh System 137 – 157

Super Jack 158 - 167

Liebherr Mining Equipment Co.

Product Support Division

T-282B Hydraulic Systems

Liebherr Mining Equip. Co Technical Training Department

Split Spool System

• Complete pressure control is provided by a main relief valve.

Main Dump Valve Component Descriptions and Operations:

1. INLET = the port connection(s) for the system pump lines.

11. FLOW CONTROL or DAMPENING POPPET = this is an orifice / check valve

Dump Sucton Lines

Total output from dump pumps

inside dia = 4.00 in

V = Q/A = 3.83 ft/s

Dump Cylinders Area Ratios

Extend Volume = 72 GAL

Without Counter Balance Valve

If we consider taking one section out of gear pump

With Counter Balance Valve

Pump output satisfies valve max flow rate

Dump System Return Lines

Q (per cylinder) = 412 GPM (RETRACT CYLINDER AT FULL THROTTLE)

inside dia = 2.00 in

V = Q/A = 42.08 ft/s

V = Q/A = 37.40 ft/s

PUMP DRIVE SPEED INCREASE

Flow Rate per

Inlet Pressure @ above listed flow rate

Brake and Steering System

Flow Rate @ full stroke of pump

Hydraulic HP w/pump @ full stroke

Hydraulic HP w/pump compensated (off stroke)

PUMP DRIVE SPEED INCREASE

Flow Rate per

Inlet Pressure @ above listed flow rate

Brake and Steering System

Flow Rate @ full stroke of pump

Hydraulic HP w/pump @ full stroke

Numbers below are calculated based on 13017-W dump cylinder

Stage 1/Stage 2 extend area ratio = 1.817

Total extend/cyl 16529.7 in3 or 71.6 gallons

numbers above are assuming cylinder is in use, has been ran

Difference between extend and retract for both cylinders

once truck has been running long enough to fill up cylinders is

Time to extend cylinder

Time to Extend Stage 1 19.5 seconds

Numbers below are calculated based on 13017-X dump cylinder

Stage 1/Stage 2 extend area ratio = 1.16

Total extend/cyl 19671.1 in3 or 85.2 gallons

numbers above are assuming cylinder is in use, has been ran