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Necessary Parts
Installation Procedure
Use the procedure that follows to install an engine overspeed alarm on D250D Articulated Trucks.
Illustration 1. Location of the engine overspeed components on the back of the fuse panel. 1. Park the machine on level ground and turn battery disconnect switch to the OFF position.2. Remove the bolts holding the fuse panel and adjacent panel to gain access to the rear of the fuse panel inside the cab.3. Install the 132-3815 Control Group (4) on the 133-2855 Plate (3) using three 4M-5282 Bolts (5), three 8T-4205 Washers (6), three 6V-8185 Nuts (7), and a 2V-3216 Clip (8). Note the location of the clip on the plate.4. On the rear of the fuse panel, install the 133-2855 Plate (3) and 132-3815 Control Group (4) assembly with two 6V-8801 Nuts (2) and two 8T-4896 Washers (1). Connect the 134-0581 Harness Assembly (10) to the 132-3815 Control Group (4). Secure the 134-0581 Harness Assembly (10) in place with two 9G-3659 Clips (9). Loosen the nut on the ground stud by the control and install the 200-Blk ground wires on the ground stud.
Illustration 2. Location of the original plate under the dash. (11) 7U-7900 Plate.5. Remove the 7U-7900 Plate (11) from under the left side of the dash. Retain the nuts and washers holding the 7U-7900 Plate (11). They will be used again. Do not remove the grommet from the wiring harness.6. Remove the dash trim piece (or surround) and loosen all dash panels. Pull the dash panels out of the dash to gain access to the rear of the panels.
Illustration 3. Internal view of the back of the dash. (12) 2U-4997 Strap. (13) 9G-2264 Clip.
Illustration 4. View A-A. (14) 2U-8170 Plate. (15) 2U-4500 Grommet. (16) 9G-9813 Alarm Group.7. Route the 134-0581 Harness Assembly (10) behind the fuse panel, through the side wall of the cab, up to the dash panel through a 2U-4500 Grommet (15) and the 2U-8170 Plate (14), and into the area behind the dash. The Sure Seal connector will remain on the outside of the area under the dash.8. Install the 9G-9813 Alarm Group (16) and the 2U-8170 Plate using the nuts and washers retained in Step 5.9. Connect the harness connector to the 9G-9813 Alarm Group (16) and secure with a 9G-2264 Clip (13) and 2U-4497 Strap (12).
Illustration 5. Front view of the dash. (17) 134-0579 Panel Assembly. (18) 7N-1996 Lamp. (19) 7N-1995 Lens. (20) 6T-6329 Bezel. (21) 6T-6066 Switch. (22) 6V-8927 Screw. (23) 2U-4729 Blank Grommet.10. Transfer the components from the original 7U-3662 or 7U-3661 Panel Assembly to the new 134-0579 Panel Assembly (17). Discard the original panel assembly.11. Install a 7N-1996 Lamp (18) and 7N-1995 Lens (19) on the 134-0579 Panel Assembly (17) as shown.12. Install the 6T-6329 Bezel (20), 6T-6066 Switch (21) using two 6V-8927 Screws (22) and install a 2U-4729 Blank Grommet (23).
Illustration 6. Engine overspeed alarm wiring connections on the back of the 134-0579 Panel Assembly (17). (18) 7N-1996 Lamp. (21) 6T-6066 Lamp.13. Connect the 200-BK and 919-GN wires to the back of the 6T-6066 Switch (21). Connect the 918-OR and 200-BK wires to the 7N-1996 Lamp (18).
Illustration 7. Engine overspeed alarm wiring harness connections to the tachometer.14. Connect the 123-WH wire to Terminal (I) on the back of the tachometer. Connect the 200-BK wire to Terminal (G) and the 788-YL wire to Terminal (S) on the back of the tachometer. DO NOT remove any existing wires from the terminals on the back of the tachometer. Only add the additional wires under each nut on the tachometer.
Illustration 8. Engine overspeed alarm wiring harness connections to the engine oil pressure indicator.15. Remove the 405-GY wire from the back of the engine oil pressure indicator lamp. Connect the 405-GY wire with the adapter terminal on the engine oil pressure indicator lamp.16. Install the 405-GY wire, that was removed in Step 15, on the terminal that was installed on the engine oil pressure indicator lamp.17. Secure all loose wires to existing harnesses inside the fuse panel area and dash area with 3S-2093 Straps and 1S-9593 Straps as needed.18. Install all panels and trim pieces that were removed. Turn the battery disconnect switch to the "ON" position.19. Test the machine for proper operation of the engine overspeed alarm system and troubleshoot as needed.Systems Operation
Introduction
The purpose of the Engine Overspeed Indicator is to alert the operator when the engine speed is excessive.The warning indicators activate when the engine speed exceeds a predetermined RPM. The warning indicators alert the operator that the engine is overspeeding. At this time the operator should change the machine operation to reduce the engine speed and possibly prevent damage to the engine.D250D Articulated Trucks equipped with the Engine Overspeed Indicator system have a dash warning lamp and a warning horn mounted in the cab. The basics of the Engine Overspeed Indicator System on the D250D Articulated Truck are:* The Overspeed Indicator Control must be connected to battery voltage.* There will be two wires going to the control from machine ground. One of these wires provides machine ground for the control, the other ground wire provides machine harness code information. This allows the control to identify what machine it is installed on.* The control must receive an engine speed signal. This signal is generated from an engine speed pickup (sensor) mounted on the engine flywheel housing.* The control must receive an engine oil pressure signal. This signal is provided by an engine oil pressure switch connected directly to the control.* When the control is receiving the proper input signals it will output a signal to activate the alarm indicators when the engine RPM exceeds a predetermined point.Engine Overspeed Alarm Control
Illustration 9. Engine overspeed alarm control.
(1) Diagnostic Lamp #1. (2) Diagnostic Lamp #2. (3) Diagnostic Lamp #4. (4) Diagnostic Lamp #4. (5) Connector Plug A. (6) Connector Receptacle B.The signals the engine overspeed alarm control processes are:* Engine speed (RPM) - from the engine speed pickup.* Test signal - from the test switch activated by the operator.* Harness code signal - from the