It's That Time Of Year

[Kranky 1]

....To fix last season's problems before this year's construction season starts.

This week's project: Take the dump box off of #30 and fix the smashed top rails, loose tailgate pins, loose hinge pins, and go over the truck with a fine tooth comb.

Dump box off of truck and sitting on a wagon in my playpen:

http://i80.photobucket.com/albums/j188/HKJr23/Trico123020.jpg

Top rail all smashed & sh*t (Boss doesn't like his trucks looking like that):

http://i80.photobucket.com/albums/j188/HKJr23/Trico123015.jpg

....So I cut out the smashed part:

http://i80.photobucket.com/albums/j188/HKJr23/Trico123017.jpg

....And welded in new metal:

http://i80.photobucket.com/albums/j188/HKJr23/Trico123024.jpg

....Then added an inverted angle iron "cap" to the top rails, so any material spilled when loading will either fall into the box or fall off the side, but will not "sit" on top of the rail waiting to fall off while going down the road:

http://i80.photobucket.com/albums/j188/HKJr23/Trico123021.jpg

Truck #30 with dump box removed:

http://i80.photobucket.com/albums/j188/HKJr23/Trico123023.jpg

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[Big_Dave]

Our shop is doing the same thing Kranky. They're going over our belly dumps right now. Replacing tires, brakes, making sure that the micro switches for the gates work properly, etc.......

Once they get the bellys done, they'll work on the end dump, then move onto the lowboy, lowboy conveyor and the new conveyor (they'll be making several improvements and modifications based on comments made by me, Byron and Borgy :hi5[1]:)

They're also looking at another TerraGator with 5 wheels (instead of 3). :wow:

[LSMR]

As much as I don't miss wrenching I do miss the welding & fab work part of the job.

Nice work Kranky.

That shop looks pretty clean & organized.You keep it that way or just clean up to take pics???:lmao[1]:

[Kranky 1]

Update:

It's finished.

Dump box back on, everything all hooked back up.

Re -bushed & re -pinned the rear hinge, Did a brake job complete with new cams & bushings, drained sampled & refilled rears & trans, Complete PM with engine oil sampled, cleaned out & detailed interior of cab, repaint frame, polish wheels.

http://i80.photobucket.com/albums/j188/HKJr23/Trico123028.jpg

http://i80.photobucket.com/albums/j188/HKJr23/Trico123026.jpg

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[Big_Dave]

You didn't 'iron out' the dents in the box sides. :nenernener: :rofl:

[Rockjockey]

You also forgot the mudflaps over the rear duals...

[Kranky 1]

You also forgot the mudflaps over the rear duals...

Dammit!

I knew I was forgettin' sumthin'.:duh2[1]:

[Big_Dave]

Looks pretty good Herb! Seriously...........

[Bikerboy]

You also need to extend out the mudflaps on the front tires, looks like they are factory still, and i have driven paystars with factory front flaps, and they throw mud all over the steps and side of cab.

[Kranky 1]

You also need to extend out the mudflaps on the front tires, looks like they are factory still, and i have driven paystars with factory front flaps, and they throw mud all over the steps and side of cab.

You are correct.

We have put wider flaps on a couple of 'em to prevent that, but that wasn't on the big boss's "to do" list for this one.

BTW, have you guys had a problem with your Paystars regarding harsh clutch engagement, in other words when you let up the clutch pedal, the clutch grabs real hard all at once?

If so, we've devised a cure for that problem.

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[saddletramp]

Herb,

Of course our 08 IH's aren't Paystars, but they are 9400 series with Cummins power and 10 speed Fullers behind them, and we have the same problem with the clutch engaging hard at the end of the throw.
Every time they go in to get the clutch brake adjusted the clutch ends up with that "direct drive" engagement!...............

[Kranky 1]

Herb,

Of course our 08 IH's aren't Paystars, but they are 9400 series with Cummins power and 10 speed Fullers behind them, and we have the same problem with the clutch engaging hard at the end of the throw.
Every time they go in to get the clutch brake adjusted the clutch ends up with that "direct drive" engagement!...............

Mornin' Bob.

The Paystars were using a piss poor rear engine mount setup up which allowed the engine/trans to twist due to torque reaction when engaging the clutch. During this torque reaction, the left side of the engine/trans would lift about 1/2 to 3/4 inch due to the poor design of the rubber insulators used on the mounts. Since the clutch linkage on these trucks is the rod type (not cable or hydraulic) this "lifting" of the left side of the engine/trans would cause the linkage to suddenly fully engage the clutch, even though the driver has not fully released the clutch pedal.

One day not too long after I started working at my current job, I had to drive one of the Paystars that was suffering from this condition, and I thought to myself "WTF, this sucks, I gotta figure this out, it ain't right".

What I did was to use some steel shims (washers) to take up the clearance on the bottom side of the poorly designed rubber engine mount insulators, thereby preventing the "lifting" of the engine/trans during clutch engagement, and stabilizing the relationship between the clutch throwout arm on the side of the bellhousing and the linkage coming from the cab.

Once you eliminate the excess clearance in the engine mounts, the clutch engagement is "smooth as silk" the way it should be.

Here are some photos to illustrate:

New rubber engine mount insulator:
http://i80.photobucket.com/albums/j188/HKJr23/Trico02076.jpg

One of the steel shims I used on the bottom side of the isulators to take up the excess clearance:
http://i80.photobucket.com/albums/j188/HKJr23/Trico02074.jpg

Shims on an insulator:
http://i80.photobucket.com/albums/j188/HKJr23/Trico02075.jpg

View of an engine mount with the shims installed on the bottom side of the insulators (this is the right side, as the PTO is in the way of getting a good photo of the left side engine mount, but both mounts must be shimmed for proper results):
http://i80.photobucket.com/albums/j188/HKJr23/Trico02079.jpg
I did have to use slightly longer thru bolts due to the shims being there, as you can see in the photo, those were the original thru bolts and weren't long enough to get a "full nut"

I have noticed that our newer (2004 on up) Paystars have a different and much more heavy duty engine mount setup, and we have not had harsh clutch engagement issues with those. Evidently IH realized there was a problem and re engineered the mounts at that point.

Don't know whether the newer road tractors such as the 2008 you've got would have the old type mounts, but it's possible based on the symptoms you're describing.

[McGee]

:bravo:.....Kranky...another problem fixed....:18_1_35[1]:

[Big_Dave]

You're a man of many talents Herb. :cheers: Good pics and thorough explanation each time.:23_11_60:

[Duster]

Question about the first picture.....
it that plywood lining the inside of the bed ??
Can't tell from the picture what it is.....

[Kranky 1]

Question about the first picture.....
it that plywood lining the inside of the bed ??
Can't tell from the picture what it is.....

Custom fitted UHMW plastic liner.

Makes even the stickiest material dump out "Lickety Sh*t".

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[Bikerboy]

I used to drive an '02 paystar that had a grabby clutch, i just got used to it.
But what you describe is probably the problem.

I have noticed all the '06 and '07 don't have that problem, but they all have different engines and transmissions too.

What engine does that truck in the pic have? dt 530? or cummins N14 or ISX?

our paystars had mostly cummins and two had the little dt 530

[Kranky 1]

I used to drive an '02 paystar that had a grabby clutch, i just got used to it.
But what you describe is probably the problem.

I have noticed all the '06 and '07 don't have that problem, but they all have different engines and transmissions too.

What engine does that truck in the pic have? dt 530? or cummins N14 or ISX?

our paystars had mostly cummins and two had the little dt 530

The truck with the dump box overhaul etc. is #30, a 2002 with a C12 Cat @ 430 HP. That was one of the trucks that required the engine mount modifications.

The photos of the actual engine mount mods were from # 24, a 1999 Paystar with a C12 Cat @ 430 HP.

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[saddletramp]

I sent the pics and text to one of our mechanics and he called me to say that UPS came out with a service bulletin about the same time I sent him the info!!

Sounds like our particular tractors are set up similar to those and will have a rehab done to them like you did................

Warranty is off my tractor already; 13 months of service and it has 260,000 miles on it already. It never gets shut off during the week and only rests on the weekends!:7_5_139[1]:

[EagleAce]

You are indeed a man of many talents, Herb!

[Kranky 1]

The boss just bought another brand new Paystar, so today after work I got a photo of the updated engine mount setup that International is using now.

http://i80.photobucket.com/albums/j188/HKJr23/3-19-08005.jpg

This one is destined to be a quad axle dump truck.

I started working on the "upfit" today.

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