BREVE REFERENCIA A LA REGULACIÓN EN EL CP

1. If radiator removal is required, refer to Section B, Structural Components, for hood and grille removal instructions. The power module may be removed with the hood installed if desired.

2. Remove bottom drive shaft cover (2, Figure 2-1). Disconnect pump drive shaft (3) at drive shaft U-joint companion flange (4) mounted on the alternator.

3. Remove the main alternator blower ducts to provide clearance to raise the engine off the subframe mounts. Refer to Figure 2-2.

a. Disconnect cables and hoses as required.

b. Remove alternator inlet transition structure (8) and the gasket.

c. Remove wheel motor duct transition structure (5).

d. Cover all openings to prevent foreign material from entering the system.

4. Remove engine air intake duct support rods (9, Figure 2-3). Remove any hoses or electrical cables attached to center deck structure.

5. Attach an overhead hoist to the center deck structure. Remove the deck mounting hardware. Lift the deck from the truck and move it to a storage area.

6. Disconnect the air cleaner restriction indicator nylon tubes at the inlet ducts.

7. Loosen clamps (5) on hump hoses (4) between the four engine air inlet ducts and air cleaner outlet ducts.

8. Disconnect the inlet ducts at each of the four turbochargers. Remove the inlet ducts from FIGURE 2-1. HYDRAULIC PUMP DRIVE SHAFT

1. Hydraulic Pump 2. Bottom Drive Shaft

Cover

3. Pump Drive Shaft 4. Companion Flange

FIGURE 2-2. MAIN ALTERNATOR BLOWER DUCT 1. Control Cabinet

2. Intake Duct

3. Alternator Inlet Duct 4. Blower Assembly 5. Wheel Motor Duct

Transition Structure

6. Wheel Motor Duct 7. Main Alternator 8. Alternator Inlet

Transition Structure

C02028 Power Module C2-5 FIGURE 2-3. ENGINE AIR INLET PIPING

1. Air Cleaner Assemblies 2. Left Rear Intake Duct 3. Left Front Intake Duct 4. Hump Hose

5. T-Bolt Clamp 6. T-Bolt Clamp

7. Reducer Elbow 8. T-Bolt Clamp 9. Duct Support Rod 10. Right Front Intake Duct 11. Right Rear Intake Duct

9. Remove exhaust duct clamps (6, Figure 2-4).

Remove capscrews (1), lock washers (2) and nuts (3) retaining the exhaust pipes to the turbocharger outlet flange. Remove exhaust ducts (4) and (5). Cover the opening on the engine exhaust outlets.

10. Remove the alternator power cable protective cover. Disconnect all electrical cables, oil and fuel lines that would interfere with power module removal (see Figure 2-5). Cover or plug all lines and their connections to prevent entrance of dirt or foreign material. To simplify this procedure, most connections utilize quick disconnects.

11. Close the cab heater shutoff water valves, disconnect the water lines and drain the water from the heater core. Secure the water lines away from engine compartment to prevent interference with power module removal.

12. Drain the engine coolant into clean containers for re-use after engine installation. Coolant capacity is approximately 738 L (195 gal).

13. Disconnect and remove heat exchanger piping (6, Figure 2-5) from the engine water pump and

15. Remove the mounting hardware from the diagonal ladder mounting pads. Lift the ladder from truck and move it to a storage area.

16. Refer to Section N4, Heater/Air Conditioner, for the procedures required to properly remove the refrigerant. After the system has been discharged, disconnect the refrigerant hoses that are routed to the cab at the compressor and receiver/drier (10).

NOTE: The system contains HFC-134A refrigerant.

Federal regulations prohibit venting air conditioning system refrigerants into the atmosphere. An approved recovery/recycle station must be used to remove the refrigerant from the air conditioning system.

REMOVAL

1. Remove capscrews, nuts and washers (8, Figure 2-5) that secure the front subframe support to the main frame.

2. Install a safety chain around the engine subframe cross member and the main frame to prevent the power module from rolling when the subframe rollers are installed.

3. Remove the capscrews and caps that secure the subframe mounting bushings to subframe support bracket (3) at the rear of the subframe.

4. Check the engine and the alternator to ensure that all cables, wires, hoses, tubing and linkages have been disconnected.

FIGURE 2-4. ENGINE EXHAUST PIPING 1. Capscrew

C02028 Power Module C2-7 FIGURE 2-5. POWER MODULE REMOVAL & INSTALLATION

1. Alternator

2. Rear Power Module Lift Eye 3. Rear Frame/Subframe Mount 4. Engine/Alternator Cradle

Structure

5. Power Module Subframe 6. Heat Exchanger Piping 7. Heat Exchanger

8. Front Frame/Subframe Mount 9. Front Power Module Lift Eye 10. Receiver/Drier

11. Upper Radiator Support Rod

5. Place a jack under the rear of the power module. Raise the rear portion of engine subframe and install the subframe rollers (see Figure 2-6). Lower the rear portion of the subframe carefully 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 2-6.

The complete power module, including the hood and grille, weighs approximately 17,000 kg (37,500 lbs). Make sure that the lifting device to be used has adequate capacity.

Lift the power module only at the lifting points on the subframe and engine/alternator cradle structure. Refer to Figure 2-5 and 2-7.

6. Position the hoist to front subframe lifting points

7. Roll the power module forward so that adequate clearance is provided in front of the control cabinet for the lifting device to be attached to engine/alternator cradle structure (2, Figure 2-5) and front subframe lifting points (9). Place stands or blocks under the front of the subframe and lower the hoist until the front of the subframe is supported. Install a safety chain to prevent the subframe from rolling.

8. Attach lifting device (1, Figure 2-7) to the hoist and attach it to the engine/alternator cradle structure and the front subframe lifting points as shown in Figure 2-7. Remove the safety chain.

9. Raise the power module slightly to determine whether it is on an even plane. Move the power module straight out of the 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 2-6. SUBFRAME ROLLERS 1. Roller Assembly

2. Subframe 3. Capscrews

FIGURE 2-7. POWER MODULE LIFTING POINTS 1. Module Lifting Tool

C02028 Power Module C2-9

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 (3, 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 (see Figure 2-6).

4. Attach a lifting device to engine/alternator cradle structure and front subframe lifting points (Figure 2-7).

The complete power module, including the hood and grille, weighs approximately 17,000 kg (37,500 lbs). Make sure that the lifting device to be used has adequate capacity.

5. Raise the power module and align the subframe rollers within the main frame guide rails.

6. Lower the power module to the subframe guide rails, relax the hoist slightly, and roll the power module into truck frame as far as possible before the lifting chains contact the control cabinet.

7. Place stands or blocks under the front of the subframe to support the assembly while repositioning the hoist.

8. Install a safety chain around the truck frame and the subframe to prevent the power module from rolling forward.

9. Place a small block behind each rear subframe roller to prevent rolling.

10. Lower the hoist to allow the subframe to rest on the stands and rollers. Remove the lifting device.

11. Attach the hoist to the front lifting eyes on the subframe.

12. Remove the small blocks behind the subframe rollers. Remove the safety chain and slowly roll the power module into position over the main frame mounts. Lower the hoist until the front subframe mounts are aligned and seated on the front main frame mounts. Install the safety chain.

13. Place a jack under the rear of the subframe to support the power module. Raise the power module just enough to permit removal of the subframe rollers.

14. Lower the rear portion of the subframe until the subframe rubber bushings are seated in mounting brackets (3, Figure 2-5) on the main frame of the truck.

15. After the subframe is seated in the frame mounts, the safety chain may be removed from the front subframe member.

16. Install the rubber bushings, capscrews, washers and nuts in front mounts (8, Figure 2-5). Tighten the capscrews to 1017 ± 72 N•m (750 ± 53 ft lbs).

17. Install the rear subframe mounting caps and secure caps in place with lubricated capscrews.

Tighten capscrews to 552 ± 20 N•m (407 ± 15 ft lbs). Refer to Figure 2-5.

FIGURE 2-8. POWER MODULE INSTALLATION

HOOKUP

1. Install all ground straps between the frame and subframe. Reconnect the electrical harnesses at the power module subframe connectors.

2. Install the diagonal ladder on the front platform.

3. Attach a hoist to the front center deck and lift it into position. Install the capscrews, flat washers, lockwashers and nuts at each mounting bracket. Tighten the capscrews to the standard torque.

4. Install the engine air intake duct supports.

Install the intake ducts between the turbochargers and air cleaner outlet ducts (see Figure 2-3). Clamp them securely to ensure that a positive seal is made. Refer to Figures 2-3 and 2-9 for correct installation and alignment examples.

5. Install exhaust ducts (4) and (5, Figure 2-4) on the turbocharger outlet flanges and pipes at the frame crossmember.

6. Connect the cab heater inlet and outlet hoses, then open both valves.

7. Install piping (6, Figure 2-5) between heat exchanger (7) and the engine water pump and radiator.

8. Inspect the alternator/wheel motor cooling duct gaskets and replace them if damaged. Install alternator inlet transition structure (8, Figure 2-2) and wheel motor duct transition structure (5).

9. Connect hydraulic pump drive shaft companion flange (4, Figure 2-1) to alternator (5). Tighten the capscrews to the standard torque. Install driveshaft guard (2).

10. Connect all remaining electrical, oil, and fuel lines. Connect the air filter restriction indicator hoses.

11. Close the battery disconnect switches.

12. Connect the hoses routed from the cab to the receiver/drier and air conditioning compressor.

13. Refill the radiator and service the engine with appropriate fluids. Refer to Section P, Lubrication and Service, for capacity and fluid specifications.

14. Recharge the air conditioner system. Refer to Section N4, Heater/Air Conditioner.

C03034 7/07 Cooling System C3-1

SECTION C3