The complete power module weighs approxi- mately 22,000 lbs. (9 988 kg). Make sure lifting device to be used is of an adequate capacity.
1. Position the truck in a work area with a flat, level surface and adequate overhead clearance to per- mit raising the dump body.
2. Apply parking brake and block wheels to prevent truck movement. Raise body and install safety sling.
Do not work under raised body without first making sure the safety sling is installed.
3. Tag or mark all air lines, oil lines, fuel lines and electrical connections to assure correct hookup at time of power module installation. Plug all ports and cover all hose fittings or connections when disconnected to prevent dirt or foreign material from entering.
4. It is not necessary to remove the radiator prior to the removal of the power module. If radiator re- moval is desired or if only radiator repair is neces- sary, refer to “Cooling System” in this section.
Removal
1. Disconnect batteries using the following proce- dure in this order:
a. Open battery disconnect switch located at bat- tery equalizer box at the bottom step of the left ladder, above bumper of truck.
b. Remove battery equalizer GND (-) terminal. c. Remove + 12V (output) terminal at equalizer. d. Remove + 24V (input) terminal at equalizer. e. Disconnect battery negative (-) terminal at bat-
tery box.
f. Disconnect battery positive (+ ) terminal. 2. Remove driveshaft guard and disconnect hydrau-
lic pump drive shaft (1, Figure 2-1) at the drive shaft U-joint companion flange.
3. Remove main alternator blower duct (Refer to Figure 2-2):
a. Remove clamps and disconnect power cables from the rectifier diode and resistor panels (3, 4) located on the rear of the blower intake duct. Remove cover and disconnect cables (routed to main alternator) from front side of transition structure (6).
b. Attach a lifting device to the rear center deck structure (5), remove attaching hardware and remove from truck.
FIGURE 2-1. HYDRAULIC PUMP DRIVE SHAFT 1. Pump Drive Shaft 2. Hydraulic Pump
c. Remove clamps and disconnect air hose (8) at electrical cabinet and main alternator.
d. Attach hoist to lifting eyes on blower inlet duct assembly. Remove hardware attaching duct transition structure (6) to main alternator inlet. Remove hardware attaching upper duct mounts to electrical cabinet. Remove hardware attaching duct to deck at right and left sides. e. Recheck for any other cables or hoses and lift
duct assembly from the truck. Cover all open- ings to prevent entrance of foreign material. 4. Remove clamp and remove the outlet hose to rear
axle on the blower assembly.
5. Open drain valve located below main air tank and bleed off air pressure.
6. Disconnect all (already marked) electric, air, oil and fuel lines that would interfere with power module removal. Cover or plug all lines and their connections to prevent entrance of dirt or foreign material. To simplify this procedure, most connec- tions utilize quick disconnects.
7. Disconnect the air cleaner restriction indicator hoses (4, Figure 2-3). Disconnect electrical wiring and hoses etc. that would interfere with front center deck removal. If equipped with electric start, disconnect starter motor cables.
8. Attach hoist to the front center deck (9, Figure 2-2). Remove all capscrews, flat washers, lockwashers and nuts securing the deck. Lift deck and remove from truck.
9. Close cab heater shutoff water valves, disconnect water lines and drain water from the heater core. Secure water lines away from engine compart- ment so as not to interfere with power module removal.
10. If equipped with air conditioning, refer to Air Con-
ditioning System, Section M for procedures re-
quired to properly remove the refrigerant. After the system has been discharged, disconnect refriger- ant hoses routed to cab at the compressor and receiver/dryer.
Federal regulations prohibit venting air condition- ing system refrigerants into the atmosphere. An approved reovery/recycle station must be used to remove the refrigerant from the air conditioning system.
11. Remove clamps securing the air inlet ducts to the plenum chambers (10, Figure 2-3), and engine turbochargers (5). Remove air ducts. Cover all openings to prevent entrance of foreign material. 12. Disconnect exhaust ducts (9), on left and right side
of engine. Cover turbocharger exhaust openings to prevent entrance of foreign material.
13. Remove right and left deck support brackets from hood structure. (Refer to Section B, Structural
Components.)
14. Disconnect grounding straps from engine sub- frame.
FIGURE 2-2. MAIN ALTERNATOR BLOWER DUCT 1. Electrical Cabinet
2. Intake Duct 3. Resistor Panel (2) 4. Rectifier Diode Panel 5. Rear, Center Deck
6. Transition Structure 7. Main Alternator 8. Air Hose
9. Front, Center Deck
15. Remove capscrews and lockwashers (1, Figure 2-4) securing front subframe support to main frame (2).
Install safety chain around the front engine sub- frame cross member and main frame to prevent the power module from rolling when the subframe rollers are installed.
16. Remove capscrews (4, Figure 2-5) and caps (6) securing subframe mounting bushings to the sub- frame support bracket (3) at rear of subframe. 17. Check engine and alternator to make sure all
cables, wires, hoses, tubing and linkages have been disconnected.
Only lift power module at the lifting points on subframe and engine/alternator cradle structure. (Refer to Figure 2-6.)
FIGURE 2-3. ENGINE AIR INLET & EXHAUST PIPING 1. Air Cleaner Assembly
2. Flexible Elbow 3. Support Clamp 4. Air Cleaner Restriction
Indicator Line Port
9. Exhaust Duct 10. Plenum 11. Hanger Clamp 5. Turbocharger 6. Clamp 7. Hump Hose
8. Air Compressor Supply Port
FIGURE 2-4. FRONT SUBFRAME SUPPORT 1. Subframe Capscrews
2. Main Frame 3. Capscrews4. Engine Subframe
18. Attach hoist to lift points at engine/alternator cradle structure. Raise the rear portion of engine sub- frame and install subframe rollers (Refer to Figure 2-6). Lower the rear portion of the subframe care- fully until the rollers rest on the main frame guide rail.
NOTE: Subframe rollers are supplied in the truck tool group and can be installed in the storage position after use, as shown in Figure 2-7.
19. Reposition hoist to front subframe lifting points. Raise the engine subframe until the engine is on a level plane. Remove the safety chain.
The engine, alternator, radiator and subframe weigh approximately 22,000 lbs. (9 988 kg). Make sure the lifting device used is of an adequate capacity.
20. Roll the power module forward sufficiently so that adequate clearance is provided for the lifting de- vice to be attached to the engine/alternator cradle structure and front subframe lifting points. Place stands or block under front of subframe and lower hoist until front of subframe is supported. Install safety chain to prevent subframe from rolling.
21. Attach lifting device to hoist and attach to engine/al- ternator cradle structure and front subframe lifting points. Remove safety chain.
22. Raise the power module slightly to determine if module is on an even plane. Move the power module straight out of truck to a clean work area for disassembly.
For further disassembly of the engine, alternator, and radiator, refer to the appropriate section of this manual. FIGURE 2-5. REAR SUBFRAME MOUNTS
1. Subframe 2. Main Frame 3. Mounting Bracket 4. Capscrews 5. Bushing 6. Mounting Cap
FIGURE 2-6. POWER MODULE LIFT POINTS 1. Module Lifting Tool
2. Main Alternator 3. Module Lift Points
4. Engine 5. Power Module
Subframe
FIGURE 2-7. SUBFRAME ROLLERS 1. Roller Assembly
2. Subframe 3. Capscrews
Installation
1. Inspect the main frame guide rails. Remove any debris which would interfere with power module installation.
2. Clean the main frame rear support brackets. Apply a light film of soap solution to each rubber bushing (5, Figure 2-5) located at the rear of the subframe. 3. Check the subframe rollers making sure they roll freely and are in the “roll–out” position. ( Figure 2-7).
4. Attach a lifting device to engine/alternator cradle structure and front subframe lifting points (Figure 2-6).
The complete power module weighs approxi- mately 22,000 lbs. (9 988 kg). Make sure lifting device to be used is of an adequate capacity.
5. Raise the power module and align the subframe rollers within the main frame guide rails (Figure 2-8).
6. Lower the power module to the subframe guide rails, relax the hoist slightly and roll the power module into truck frame until lifting chains contact cross frame.
7. Place stands or blocking under front of subframe to support assembly while repositioning hoist. 8. Install a safety chain around the truck frame and
the front subframe cross member. The safety chain will prevent the power unit from rolling for- ward.
9. Place a small block behind each rear subframe roller to prevent rolling.
10. Lower hoist to allow subframe to rest on stands and rollers. Remove lifting device.
11. Attach hoist to front lifting eyes on subframe. 12. Remove the small blocks behind the subframe
rollers, remove safety chain, and slowly roll the power module into position over the main frame mounts. Lower hoist until front subframe mount is aligned and seated on the front, main frame mount. Reinstall safety chain.
13. Relocate hoist to the rear portion of the engine/al- ternator cradle structure and raise just enough to permit removing the subframe rollers.
14. Lower the rear portion of the subframe until the subframe rubber bushings (5, Figure 2-5) are seated in the mounting brackets (3) located on the main frame of the truck.
15. After subframe is seated in frame mounts, the safety chain may be removed from the front sub- frame member.
16. Install capscrews and lockwashers in the front mount and tighten capscrews to 407 ft.lbs. (551
N-m) torque. (Refer to Figure 2-4).
17. Install the rear subframe mounting caps and secure caps in place with lubricated capscrews. Tighten capscrews to 407 ft.lbs. (551 N-m) torque. (Refer to Figure 2-5).
18. Install all ground straps between frame and sub- frame.
19. Attach hoist to the front center deck and lift into position. Install rubber dampeners and attach in- ner, front deck supports to grille structure. Tighten capscrews to standard torque.
20. Install air duct supports and connect exhausts at engine turbochargers. Connect all engine air in- take ducts. Tighten clamps securely to insure a positive seal is made. (Refer to Figures 2-3 & 2-9). 21. Connect the cab heater inlet and outlet hoses and
open both valves.
FIGURE 2-8. POWER MODULE INSTALLATION
22. Connect wheel motor cooling blower air outlet hose. Tighten all clamps securely to insure a posi- tive air seal.
23. Lift main alternator blower intake duct into position and install hardware at mounts. (Refer to Figure 2-2)
a. Install hardware at transition structure to blower inlet joint, electrical cabinet, and deck mounts. b. Install control cabinet air hose, electrical cables and any other hoses and wiring removed dur- ing power module removal.
c. Lift rear, center deck structure in place and install hardware.
24. Connect the hydraulic pump drive shaft from the alternator to the companion flange on the pump. (Refer to Figure 2-1). Tighten capscrews to stand- ard torque. Install driveshaft guard.
25. If equipped with an air system, connect hoses from air compressor to tubes routed to the main air tank. Reconnect the air compressor air supply hose at the engine air inlet duct.
26. Connect all remaining electric, oil, and fuel lines. 27. Connect the air filter restriction indicator hoses. 28. Connect the batteries as follows:
a. Install battery positive (+ ) cable. b. Install battery ground (-) cable.
c. Install battery equalizer + 24V (input) terminal. d. Install equalizer + 12V (output) terminal. e. Install equalizer GND (-) terminal. f. Close battery disconnect switch.
29. If truck is equipped with air conditioning, connect hoses routed from cab to receiver/drier and air- conditioning compressor.
30. Service radiator and engine with appropriate fluids. Refer to Section “P” for capacity and fluid specifi- cations.
31. Recharge air conditioner system per instructions in Section M, Air Conditioning System.
FIGURE 2-9. AIR INLET PIPING CONNECTIONS
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