Tài liệu sửa chữa xe Terex TR50

Terex TR50 Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50Tài liệu sửa chữa xe Terex TR50

CLICK HERE FOR TABLE OF CONTENTS TR50 Off-Highway Trucks Service Manual CLICK HERE TO RETURN TO MAIN LIBRARY INDEX PART No SM N20050 TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF NO SM817 IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all motor vehicles The service procedures recommended and described in this publication, are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tools should be used when, and as recommended It is important to note that this publication contains various WARNINGS and NOTES which should be carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper service methods will be followed which may damage the vehicle or render it unsafe It is also important to understand these WARNINGS and NOTES are not exhaustive It is not possible to know, evaluate and advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible hazardous consequences of each way Consequently, no such broad evaluation has been undertaken Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service method he/she selects Two types of heading are used in this manual to attract your attention WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly followed could result in personal injury or loss of life Look for this symbol to point out important safety precautions It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment WARNING Never use parts which are altered, modified, or weakened in operation This can seriously jeopardize the integrity of the machine and could result in property damage or serious personal injury SM 222 Rev 9-93 TABLE OF CONTENTS Section No Description 000 GENERAL INFORMATION Rev No 0000 TR50 Off-Highway truck TR50-05 0010 Welding Procedure 2172 100 0010 110 CHASSIS Chassis, Hood and Fenders 1570 ENGINE 0030 Engine and Mounting N1667 0050 Air Cleaner N1572 0130 Power Take Off N1867 0180 Air Compressor Governor (Type D-2) 1868 120 TRANSMISSION 0010 Transmission and Mounting N1612 0070 Transmission CEC2 2128 0100 Transmission Oil Filter 1576 130 DRIVELINE 0010 Front Driveline 1577 0020 Rear Driveline 1578 140 0040 160 FRONT AXLE Wheel, Rim and Tyre N20055 REAR AXLE 0020 Differential 1298 0030 Rear Axle Group N1326 0050 Wheel, Rim and Tyre N1327 165 BRAKE PARTS 0020 Brake Parts – Front Axle 1333 0030 Brake Parts – Rear Axle N1878 0072 Slack Adjuster N1329 180 SUSPENSION SYSTEM 0030 Ride Cylinder - Front 1584 0050 Ride Cylinder - Rear 1302 190 ELECTRICAL SYSTEM 0000 Circuit Diagram See Note 0270 Switches and Sensors See Note 200 FUEL SYSTEM 0010 Fuel Tank and Mounting N20059 0040 Fuel Lines N200510 210 COOLING SYSTEM 0000 Cooling System 1872 0040 Radiator, Header Tank and Mounting 1613 0060 Transmission Oil Cooler See Note Note: sections in process for issue later TR50 SM INDEX REV * 05-05 TABLE OF CONTENTS Section No Description 220 STEERING SYSTEM 0000 Steering System Schematic 1850 0050 Steering Pump N1204 0080 Accumulator 1205 0090 Steering Valve 1206 0110 Double Relief Valve 1208 0120 Steering Cylinder and Linkage 1304 0130 Accumulator Valve 1848 230 BODY SYSTEM 0000 Body System Schematic N20054 0040 Oil Tank and Mounting N20056 0050 Hydraulic Pump 1839 0060 Body Control Valve N2296 0081 Body Control Joystick 1831 0090 Kick-over Valve 1835 0121 Pilot Supply Valve 1837 0130 Body Cylinder 2297 250 AIR SYSTEM 0000 Air Braking System Schematic 1880 0070 Treadle Valve N20051 0120 Relief Valve (Safety Valve) 1885 0120 One way Check Valve 1854 0180 Limiting and Quick Release Valve N20052 0190 Park/Emergency Control Valve 1877 0191 Control Valve (Dry/Slippery) 1852 0210 Moisture Ejection Valve N20058 0250 Safety Chamber 1859 0260 Rear Brake Chamber 1858 0280 Relay Emergency Valve (RE-6) 1853 0290 Pressure Protection Valve N20057 0300 Synchro Valve 1857 260 OPERATORS COMPARTMENT 0010 Cab and Mounting 1862 0010 RH Door 1862 0010 LH Door 0090 Driver Seat 0110 Passenger Seat and Mounting 1603 0120 Heater and Mounting 13537 0130 Air Conditioning 1620 270 0010 300 Rev No 1862 See Note BODY Body and Mounting N1354 MISCELLANEOUS 0020 Lubrication System N1355 0040 Central Lubrication System N200511 0070 Service Tools 1621 0080 Standard Bolt and Nut Torque Specifications 1238 0090 Unit Storage 1239 TR50 SM INDEX REV * 05-05 GENERAL INFORMATION – TR50 Off-Highway Truck Section 000-0000 Max Body Depth 085 (13-4) 345 (4-5) 810 (12-6) 530 (11-7) 885 535 (2-11) (1-9) 345 (4-5) 730 (8-11) Vehicle Clearance Diameter (SAE) 21.m (69 ft) 665 (25-2) 240 (13-11) 460 (24-5) 490 (18-0) 58o 345 (13-3) 870 (12-7) 15o 635 (2-1) 400 (11-2) 505 (1-11) 765 (9-1) 325 (10-11) 420 (7-11) 960 (13-0) 875 (29-1) 965 (13-0) Dimensions in mm (ft-in) Fig - Machine Dimensions ENGINE TRANSMISSION Make / Model …………… ………….…… … Cummins KTA19C Make / Model …………………………………… Allison M5610AR Type ……………………… Cycle, turbocharged / Aftercooler Allison M5610AR automatic electronic control with Soft Shift feature Mounted mid-frame for ease of access Integral torque converter and planetary gearing Six speeds forward, Two reverse Automatic lock-up in all speed ranges Downshift inhibitor Hydraulic retarder Gross Power @ 100 rev/min ………………… 392 kW (525 hp) Net Power @ 100 rev/min ………….………… 368 kW (493 hp) Gross power rated to SAE J1995 Jun 90 Speeds with standard differential Net power is after deductions for fan, alternator and air compressor Turbocharged engines require no deration to 600 m (12 000 ft) altitude Forward 1st Maximum Torque …… 337 Nm (1650 lbf ft @ 300 rev/min Cylinders / Configuration …………………….…………… in line Bore x Stroke …………………… 159 x 159 mm (6.25 x 6.25 in) 2nd 3rd 4th Reverse 5th 6th R1 R2 Ratio 4.00 2.68 2.01 1.35 1.00 0.67 5.12 3.46 Km/h 11.3 16.8 22.4 33.4 45.2 65.0 7.1 12.9 mile/h 7.0 4.4 8.0 10.5 13.9 20.8 28.1 40.4 Displacement …………………………….…….18.9 litre (1 150 in ) Starting …………………………………………………… Electric Maximum Speed, Full Load ……………… ……… 100 rev/min DRIVE AXLE TEREX heavy duty axle with full floating axle shafts, single reduction spireal bevel gear differential and planetary gearing at each wheel Maximum Speed, No Load ……………… …….… 450 rev/min Idle Speed ……………………………………….…… 700 rev/min Standard Ratios Optional Differential ……… … 1.5:1 3.73:1 Planetary ……… … 5.66:1 5.66:1 Total Reduction … … 17.89:1 21.11:1 o Safe Operating Angle …………………………… 30 / 60% Grade TR50-05 GENERAL INFORMATION – TR50 Off-Highway Truck Section 000-000 SUSPENSION STEERING Front: Independent hydrostatic steering with closed-centre steering valve, accumulator and pressure compensating piston pump Accumulator provides uniform steering regardless of engine speed In the event of loss of engine power it provides steering of approximately two lock-to-lock turns A low pressure indicator light warns of system pressure below 83 bar (1 200 lbf/in²) Steering conforms to ISO 5010, SAE J53 King pin strut-type independent front wheel suspension by self contained, variable rate, nitrogen/oil cylinders Rear: Variable rate nitrogen/oil cylinders with A-frame linkage and lateral stabilizer bar System Pressure .…… 137.9 bar (2 000 lbf/in²) Maximum Strut Stroke Front ……………………………………… …… 251 mm (9.9 in) Rear ………………………………….….….…… 182 mm (7.2 in) Maximum Rear Axle Oscillation ………….……… ± 6.5 degrees Relief Pressure … 206.8 bar (3 000 lbf/in²) Steering Cylinders …… Double Acting, Single Stage Accumulator: Oil Capacity ………… 14.3 litres (3.7 US gal) WHEELS AND TYRES Nitrogen Precharge Pressure .………… 55 bar (800 lbf/in²) Rim Width …………………………………….…….………… 15 in Steering Angle (Left and Right) ……… 39° Standard Tyres (Front & Rear) ……….… 21.00 – 35 (36 PR) E4 Pump: Optional Tyres (Front & Rear) ……….…… 21.00R35 ** Radial Note: It is recommended that for tyres both listed and unlisted, the user should consult the tyre manufacturer and evaluate all job conditions in order to make the proper selection Type ……… Piston Capacity at 100 rev/min ……… 1.1 litres/s (17.5 US gal/min) BODY HYDRAULICS BRAKES Two body hoist cylinders are mounted between the frame rails Cylinders are two-stage with power down in the second stage Service: Dual Shoe, external expanding, mechanically actuated by air pressure Independent front and rear systems actuated by single treadle valve with auxiliary manual control Operator controlled wet / dry road valve reduces front brake pressure 50% for improved control and slippery conditions System Relief Pressure ……… 172.4 bar (2 500 lbf/in²) Pump: Type ……… Gear Capacity at 100 rev/min … 210 litres/min(55.5 US gal/min) Front Linings: Diameter x Width ……………….… 660 x 127 mm (26 x in) Control Valve …… Servo Controlled, Open Centre Area, Front Axle ……………… …… … 980 cm (617 in ) Body Raise Time 13 Seconds Rear Linings Body Lower Time Seconds Diameter x Width ……………… 660 x 254 mm (26 x 10 in) 2 Area, Rear Axle …………… ……….… 960 cm (1 234 in ) 2 Total lining area ……………… ………… 11 940 cm (1 851 in Air compressor capacity ……….…… 5.7 litres/sec (12 ft /min) ELECTRICAL Type ……………………………… … 24 volt, Negative Ground Battery ……………………………… Two, 24 Volt, 165 Ah each Accessories …………………………………………….… 24 Volt Emergency: Alternator ………………………………………………… 75 Amp Warning light in cab indicates when air pressure drops below 5.5 bar (80 lbf/in²) Starter …………………………………………………… 8.9 kW Front and rear brakes automatically actuate if system air pressure falls to 3.1 bar (45 lbf/in²) Total brake air reservoir capacity .… 81 litre (4 950 in³) Parking: Service brakes act as parking brakes when applied by manual control valve on the instrument panel Retardation: Non-wearing hydrodynamic retarder integral with transmission Brakes conform to ISO 3450, SAE J1473 Oct90 TR50-05 GENERAL INFORMATION – TR50 Off-Highway Truck Section 000-0000 BODY SERVICE CAPACITIES Longitudinal 'V' type floor with integral transverse box-section stiffeners The body rests on resilient impact absorption pads Engine Crankcase and Filters ……… 55 14.5 Transmission and Filters …………… 68 18.0 Body wear surfaces are high hardness (360-440 BHN) abrasion resistant steel Yield strength of plates 000 Mpa (145 000 lbf/in²) Cooling System ……………………… 125 33.0 Fuel Tank ……………………………… 470 125.0 Steering Hydraulic System (Total) … 38 10.0 Plate Thickness: Floor …………… 15 mm (0.59 in) Side .……… 10 mm (0.39 in) Front, lower ………… 10 mm (0.39 in) litres US gal Steering Hydraulic Tank ……………… 30 8.0 Body Hydraulic System (Total) ……… 121 32.0 Body Hydraulic Tank ………………… 83 22.0 ROPS Cabguard SAE J1040 Feb 86 ISO 3471 Planetaries (Total) …………………… 49 13.0 Volumes: Struck (SAE) .………… 21.5 m³ (28.1 yd³) Heaped 2:1 (SAE) .………… 27.5 m³ (36.0 yd³) Differential …………………………… 47 15.8 Front Ride Strut (Each) ……………… 14 3.7 Rear Ride Strut (Each) ……………… 17 4.5 Power Takeoff ………………………… 1.0 VEHICLE WEIGHTS (MASS) Chassis, with hoists Body, standard Net Weight kg lb 25 180 55 512 800 19 400 33 980 74 913 PAYLOAD, maximum 45 000 99 208 Maximum Gross Weight * 80 000 176 370 FOR UNIT EQUIPPED WITH OPTIONAL HEAVY DUTY ROCK BODY Chassis, with hoists 25 180 Body, Heavy Duty, Rock 10 300 55 512 22 708 Net Weight 35 480 78 220 PAYLOAD, maximum 43 500 95 900 Maximum Gross Weight * 80 000 176 370 * Maximum permissible gross vehicle weight with options, attachments, full fuel tank and payload WEIGHT DISTRIBUTION Front Axle Rear Axle Empty % 48 52 Loaded % 34 66 * * * * TR50-05 OPTION – Central Lubrication System Section 300-0040 Pump Front Distribution Section Brake Slack Adjuster (Left) Steering Cylinders Steering Pivot Pin (Down) Steering Cylinders Linkage (Add) Front Ride Cylinders Steering Draglink Steering Draglink 1T 2T 2T 2T 2T 1T 1T Brake Slack Adjuster (Right) 2T 2T 2T 1T 2T 2T 1T 1T 2T A-Frame Spherical Bushing Steering Cylinders Steering Pivot Pin (Up) Steering Cylinders Linkage (Add) Front Ride cylinders Steering Draglink Steering Draglink Front Distribution Section Body Hoist Bushings (Up) Body Hoist Bushings (Down) Body Hinge Pins Body Hinge Pins Rear Ride Cylinder (Up) Brake Slack Adjuster (Left) Brake Camshaft (Rear) Rear Ride Cylinder (Down) Body Hoist Bushings (Up) Body Hoist Bushings (Down) Body Hinge Pins Body Hinge Pins Rear Ride Cylinder (Up) Brake Slack Adjuster (Right) Brake Camshaft (Rear) Rear Ride Cylinder (Down) Fig - Lubrication Points INSPECTION AND MAINTENANCE SPECIAL TOOLS For complete details of inspection, servicing and troubleshooting instructions refer to the manual, GENERAL OPERATING INSTRUCTION FOR PROGRESSIVE SYSTEMS, shipped with this machine There are no special tools required for procedures outlined in this section Refer to Section 300-0070, SERVICE TOOLS, for part numbers of general service tools required These tools are available from your dealer LUBRICATION WARNING Refer to Fig for components lubricated by the Central Lubrication System installed on this machine Refer to the manual, GENERAL OPERATING INSTRUCTION FOR PROGRESSIVE SYSTEMS, for recommended lubricant and service intervals For lubrication of machine components which are not lubricated by the installed central lubrication system, refer to Section 300-0020 LUBRICATION SYSTEM for recommended lubricant and service intervals Before working on this system, to prevent personal injury and property damage, park the vehicle on a level working area, chock wheels, apply parking brake, shut-off engine, and relieve pressure in the steering and brake systems Turn off Master Battery Switch WARNING In the manual, GENERAL OPERATING INSTRUCTION FOR PROGRESSIVE SYSTEMS supplied with this machine, texts marked with this pictogram provide reference to particular hazards or important actions and jobs * * * * SM N200511 MISCELLANEOUS - Service Tools Section 300-0070 INTRODUCTION Contained in this section are recommended service tools and equipment required for maintenance, overhaul and troubleshooting In certain instances, both Metric and Imperial equivalents of the same tools are listed These tools are available from your dealer Note: The Company reserves the right to make changes in the design or construction of tools and equipment without obligation to incorporate such changes in tools and equipment previously sold Note: A tool may be of one piece construction or consist of a number of parts General *15269784 - Multi-Gauge - Pressure range of 30 in of vacuum to 000 lbf/in² 15269785 - Non-contact Infrared Thermometer 15268968 - Strap Type Filter Wrench 15268969 - Socket Type Filter Wrench 15268970 - Universal Belt Tension Gauge 15269680 - Window Seal Installer and Remover Tool 15269858 - Digital Tachometer 15269859 - Multimeter 15269813 - Water Manometer 15269802 - Dial Indicator Gauge - Metric 15269803 - Dial Indicator Gauge - Imperial 15269804 - Magnetic Base for Dial Indicator Gauge 15269805 - Micrometer - to 25 mm 15269806 - Micrometer - to in 15269807 - Micrometer - 400 to 500 mm 15269808 - Micrometer - 16 to 20 in 15269809 - Internal Micrometer - 50 to 210 mm 15269810 - Internal Micrometer - to in 15269860 - 92 Piece Heavy Equipment Tool Kit 15269861 - Torque Wrench - 3/8 in drive, 20 - 100 Nm (15 - 80 lbf ft) range 15269862 - Torque Wrench - 1/2 in drive, 60 - 330 Nm (45 - 250 lbf ft) range 15269863 - Torque Wrench - 3/8 in drive, - 20 Nm (40 - 180 lbf in) range 15269864 - Torque Wrench - 3/4 in drive, 300 - 000 Nm (200 - 750 lbf ft) range 15269865 - Torque Wrench - 3/4 in drive, 700 - 500 Nm (500 - 000 lbf ft) range 15269866 - Torque Multiplier - 1/2 in to in drive, 25:1 Ratio, 000 Nm (2 200 lbf ft) range * - The following items should be added to the multi-gauge to enable the gauge to be used on diagnostic test points: 15018226 - Diagnostic Coupling 00118748 - Connector (2 off) 15004085 - Hose Assembly (-4 HP, 84 in long) SM 1621 Rev 4-03 Engine The following tools are recommended for Engine Maintenance Procedures and should be used in conjunction with procedures outlined in the engine manufacturers service manual 15270022 - Valve Seat Inserter Tool 15270024 - Valve Spring Compressor 15270075 - Dial Depth Gauge 15269956 - Standard Puller 15270056 - Water Pump Bearing Mandrel 15269957 - Torque Wrench Adaptor 15272177 - Compressor, Piston Ring 15270031 - Fuel Passage Cleaning Brush 15270431 - Hydrostatic Tester 15270078 - Manometer 15270972 - Main Bearing Cap Puller 15270007 - Dowel Pin Extractor 15272204 - Mandrel, Air compressor Bushing 15269959 - Main Bearing Cap Puller 15272178 - Concentricity Gauge 15270436 - Crosshead Guide Spacer 15270437 - Piston Ring Expander 15272179 - Gauge, Belt Tension 15270440 - Water Tube Driver 15270441 - Valve Seat Extractor 15269960 - Dial Gauge Attachment 15272180 - Compressor, Valve Spring 15272205 - Torque Wrench (0-150 in lbs) 15272206 - Wrench, Oil Filter 15270443 - Pressure Regulator Removal Tool 15270446 - Head Water Testing Kit 15269962 - Dial Bore Gauge Kit 15270448 - Connecting Rod Guide Pins 15270040 - Valve Spring Tester 15272207 - Set, Fillet Ball Gauges 15272208 - Puller, Water Pump Impeller 15272209 - Puller, Idler Shaft 15270060 - Water Pump Bearing Mandrel 15270061 - Water Pump Bearing Separator 15272210 - Tube, Fuel Line Sight #12 15272181 - Kit, Valve Seat Grooving (check voltage) 15270452 - Liner Installation Tool 15270010 - Crack Detection Kit 15270458 - Gear Puller Assembly 15269969 - Universal Cylinder Liner Puller 15269961 - Dial Indicator Gauge 15269975 - Pulley Installation Tool 15272183 - Cutter, Oil Filter 15272211 - Wrench, Injector Preload Torque 15270047 - Slide Hammer Assembly 15270070 - Coupling Puller 15269993 - Driver Handle 15270480 - Valve Seat Extractor 15272184 - Dolly,Valve Insert Staking Miscellaneous - Service Tools Section 300-0070 15272182 - Fixture, Cylinder Head Water Test 15270481 - Cup Plug Driver 15270482 - Cup Plug Driver 15270483 - Cup Plug Driver 15272185 - Dolly, Valve Seat Staking 15272186 - Driver, Compressor Seat Installation 15272187 - Driver, Compressor Seat Remover 15269992 - Expansion Plug Driver 15270982 - Set, Cylinder Liner Clamp 15272188 - Blowby Check Tool (0.406") 15272189 - Kit, Digital Thermometer 15272190 - Fixture, Rod Bolt Checking 15272191 - Kit, Air Compressor Valve Seat 15272192 - Compressor, Piston Ring 15269999 - Gauge Block 15270068 - Pump Seal Driver 15272193 - Kit, Cylinder Head Leak Test 15272194 - Kit, Guide Stud 15272195 - Handle, T Lift Stud 15272196 - Kit, Pulley Installation Adapter 15271475 - Insite Data Reader 15272197 - Driver Low Temperature Thermostat Seal 15272198 - Gauge, Piston Ring Groove 15272199 - Gauge, Valve Head Thickness Check 15272211 - Kit, Rail Line Pressure 15272200 - Gauge, Valve Clearance 15272201 - Driver Oil Seal 15272202 - Fixture, Injector Timing 15272203 - Gauge, Head Bolts 15272204 - Mandrel, Air compressor Bushing 15272205 - Torque Wrench (0-150 in lbs) 15272206 - Wrench, Oil Filter 15272207 - Set, Fillet Ball Gauges 15272208 - Puller, Water Pump Impeller 15272209 - Puller, Idler Shaft 15272210 - Tube, Fuel Line Sight #12 15272211 - Kit, Rail Line Pressure The following tools are contained in CEC Off-Highway Diagnostic Service Kit - 15269231: 15269232 - Wire Cutter, Stripper and Terminal Crimper 15269233 - Jumper Wire Set 15269234 - Terminal Crimper 15269235 - Terminal Remover - Metri Pack (J1A, J1B, J3 and Shift Selector Connector Terminals) 15269236 - Terminal Remover - Speed Sensor and Throttle Position Sensor Terminals 15269237 - Terminal Remover - Depress holding prong on ECU and DDL Connector Terminals 15269238 - PROM Remover 15269239 - High Impedance Digital Multimeter Kit 15269240 - AMP Pin Remover - Remove terminal pins from interface and shift selector Terminals 15269241 - Terminal Crimper - Weatherpac Transmission 15275726 - Remover - Deutsch Connector CEC Electronic Diagnostic 15275098 - DDR Multikit (Reader, Cartridge, Cables) 15275180 - CEC & Diagnostic Card (For Above) 15268971 - PRO-LINK Diagnostic Data Reader (DDR) 15268973 - CEC I and II Cartridge For DDR 15268975 - DDR and CEC I and II Cartridge Assembly 15269231 - CEC Off-Highway Diagnostic Service Kit 15270344 - LPS NoFlash Electro Contact Cleaner 15269038 - Portable Printer for use with DDR, complete with 110 V AC Adaptor 15269039 - Portable Printer for use with DDR, complete with 220 V AC Adaptor 15269040 - Printer Paper for use in above printers rolls 15275727 - Crimper - Throttle Position Sensor, Delphi Packard (DDL Connector) The following tools are required for CEC harness wiring repairs; 15275719 - Sealed Splice (14-16 AWG) 15275720 - Sealed Splice (18-22 AWG) 15275721 - Crimper - Deutsch Connector, Trans Harness Bulkhead, J1939 Conector 15269234 - Crimper (Alternate) - Delphi Packard (DDL connector) 15275722 - Crimper (Alternate) - Throttle Position Sensor 15275723 - Wire Stripper 15275724 - Remover - Delphi Packard (DDL Connector), Sump Temperature Sensor 15275725 - Remover - Throttle Position Sensor 15275728 - Crimper - Speed Sensors, Throttle Position Sensor, 15275729 - Crimper - Repair of broken cable using appropriate Sealed Splice 15275730 - Remover - Deutsch Connector(Optional DDL) 15269241 - Crimper (Alternate) - Throttle Position Sensor 15275731 - Remover - ECU Connectors, Shift Selector Connection 15275732 - Connector Repair Kit - Transmission Harness Bulkhead Connector SM 1621 Rev 4-03 Miscellaneous - Service Tools Section 300-0070 15275733 - Guide Pin - Transmission Harness Bulkhead Connector 15275734 - Insertion Tool - Transmission Harness Bulkhead Connector 15269844 - Portable High Vacuum Charging Station - R-134a Gas 15269845 - Halogen Leak Tester Cab 15275735 - Terminal Remover - Transmission Harness Bulkhead Connector 15271016 - Glass Removal Tool 15271017 - Bonding Kit (Quick Dry) 15275736 - Crimper - ECU Connectors, Shift Selector Connection OCDB Brake Packs The following tools are recommended for Transmission Maintenance Procedures and should be used in conjunction with procedures outlined in the transmission manufacturers service manual 15269783 - Seal Installation Kit 15269781 - Seal Installation Tool 15269782 - Seal Installation Tool 15270422 - Stator Assembly Installing Tool 15270423 - Support Legs 15270424 - Switch Sequence Gauge 15270425 - Shift Inhibitor Clutch Drilling Feature 15270426 - Harness Adaptor 15270427 - Torque Converter Spanner Wrench 15270428 - Belville Assembly Spring Compressor 09122784 - Grease Gun Assembly 09175662 - High Pressure Bucket Pump Lube Kit Wheel, Rim and Tyre 09202013 - Fishtail Wrench 15251192 - Tyre Inflation Kit (Air) 15269121 - Tyre Inflation Kit (Nitrogen) 15270392 - Hydraulic Bead Breaking Kit Accumulators/Ride Cylinder Charging 09359489 - Charging Assembly The following parts can be assembled for simultaneously charging the rear ride cylinders: 09359489 - Charging Assembly 00454145 - Tee Piece 15269788 - Hose 15269789 - Chuck Valve 15269790 - Valve Extension The following parts can be assembled for simultaneously charging the front ride cylinders: 09359489 - Charging Assembly 00454145 - Tee Piece 00444355 - Coupling 15269788 - Hose - required 15269789 - Chuck Valve 15269790 - Valve Extension Lubrication Adhesives and Sealants 15269103 - Loctite 221 09362529 - Loctite 225 09029849 - Loctite 242 09244598 - Loctite 270 09985300 - Loctite 271 15269104 - Loctite 275 15269245 - Loctite 277 15233715 - Loctite Prism 406 15269111 - Loctite Prism 410 15269105 - Loctite 515 09007209 - Loctite 574 (50 ml) 09379518 - Loctite 574 (160 ml) 15269106 - Loctite 577 (Superflex) 15270244 - Loctite 592 Pipe Sealer with Teflon 15023696 - Loctite 635 09371048 - Loctite 638 15269107 - Loctite 641 15269108 - Loctite Superclean Safety Solvent 706 15229541 - Loctite Activator 'N' 09243825 - Loctite Activator 'T' 09175039 - General Adhesive 15269114 - Tectyl 280 Wax Based Rust Preventive 09380475 - Hylosil RTV Silicone Compound 15270516 - Wynn's STP 15234244 - Sealant Cord (Ref Sec 160-0020) Steering Valve Fabricated Tools 15270489 - Spring Installation Tool The service tools shown in Figs through can be fabricated as shown Cooling and Air Conditioning 15269814 - DCA4 Test Kit - Metric 15269816 - Refractometer - °C Scale 15269817 - Refractometer - °F Scale SM 1621 Rev 4-03 Miscellaneous - Service Tools Section 300-0070 SM - 112 ACME THD ONE-4340 STL OR EQUIV.-HDN.-GRIND ONE-4340 STL.-HDN.-GRIND APPROX in mm 1/8 3.2 1/4 6.4 3/8 9.5 7/16 11.1 1/2 12.7 5/8 15.9 3/4 19.1 29/32 23.0 25.4 1/8 28.6 1/4 31.8 3/8 34.9 1/2 38.1 7/8 47.6 50.8 1/32 51.6 1/8 54.0 15/32 62.7 3/4 69.9 3/4 120.7 7/8 123.8 1/2 139.7 3/4 146.0 31/32 151.6 7/8 174.6 1/2 190.5 1/2 241.3 Fig - Spider Bearing Spreader Tool Dimensions (Section 160-0020, DIFFERENTIAL) SM - 1485 40.5 765 684 65 25 HOLES 28 32.5 5/16-3/4in DRIVE SOCKET Note: Dimensions are approximate and in mm, unless otherwise stated Measure diagonally between wheel studs prior to fabrication Fig - Dimensions of Fabricated Tool (Section 160-0050, WHEEL, RIM AND TYRE) SM 1621 Rev 4-03 Miscellaneous - Service Tools Section 300-0070 SM - 126 0.56 - HOLES EQUALLY SPACED in MATERIAL: PLAIN CARBON STEEL mm 0.12 3.0 0.50 12.7 0.56 14.22 0.62 15.7 1.00 25.4 1.62 41.1 2.00 50.8 2.50 63.5 3.25 82.5 3.31 84.0 9.38 238 15.88 403 26.25 668 Fig - Fabrication of Lifting Tool (Section 165-0030, BRAKE PARTS) SM - 1487 ½in NPT R0.13/0.25 Fig - Fabrication of Blanking Plate for Port 'B' (Section 165-0030, BRAKE PARTS) SM 1621 Rev 4-03 108 77.8 R51.6 16 7.1 +- 0.13 42.9 42.9 R0.50 /0.76 R15 14 28.4 66.7 +- 0.25 7.1 +- 0.13 4.45 +- 0.13 4.45 +- 0.13 66.7 +- 0.25 16 57 42.9 14 117 77.8 R51.6 SM - 1488 R0.50 /0.76 R15 R0.13/0.25 Fig - Fabrication of Blanking Plate for Port 'C' (Section 165-0030, BRAKE PARTS) 0.12 0.06 0.03 INCHES 3.3 3.0 1.52 0.76 mm 1.00 0.81 0.75 0.72 INCHES 28.4 25.4 20.5 19.0 18.2 mm ITEM #2 - BASE (WELDMENT) 100 SQ STOCK ITEM #1 - HANDLE 250 DIA HOLE THRU KNURL DIA HOLE ITEM #5 - 'T' HANDLE (WELDMENT) 19 SQ STOCK 8-32 UNC 2B X 38 MIN FULL THD MINOR DIA .130/.139 X 72 DEEP - Handles - Base - Pivot Block - Retainer (2 Req’d) - ”T” Handle - Capscrew # 8-32 x 38 in long (4 Req’d.) - Plain Washer # 10 (2 Req’d.) - Nut # 10-24 (4 Req’d.) - Roll Pin 25 in Dia x 1.12 in long ITEM #4 - RETAINER #16 DRILL (.1770) 2-HOLES 22 DIA HOLE ROUND HD MACHINE SC 10-24 X 3.00 LG FULL THD SM - 134 SM 1621 Rev 4-03 ITEM #3 - PIVOT BLOCK Miscellaneous - Service Tools 0.130 1.12 63.5 3.5 2.50 65.0 0.139 4.8 2.56 76.2 42.7 0.19 5.6 3.00 101 1.68 0.22 6.3 4.00 140 4.5 0.25 6.6 5.50 152 0.177 0.26 9.6 6.00 508 50.8 0.38 11.9 20.00 2.00 0.47 15.7 12.7 4.6 0.50 0.18 0.62 Fig - Fabrication of Spring Compressor Tool (Section 165-0030, BRAKE PARTS) MATERIAL: PLAIN CARBON STEEL Section 300-0070 SPRING COMPRESSOR TOOL Miscellaneous - Service Tools Section 300-0070 SM - 391 HEAVY WALL TUBING ALUMINIUM RING PRESS RING ON END OF TUBING Fig - Shaft Seal Driver (Section 220-0050, STEERING PUMP) SM - 393 SM - 390 USE FOR 'A' Driveshaft bearing installation 150 mm (6 in) NOMINAL PIPE BORE mm (in) Driveshaft bearing removal 228 mm (9 in) 38 (1.5) 100 (4.0) 41 (1.62) 48 (1.89) 50 (2.0) 100 (4.0) 54 (2.12) 60 (2.38) Intermediate shaft bearing installation 100mm (4 in) 38 mm (1.50 in) Heavy Wall Tubing Fig - Shaft Bearing Removal and Installation Tool (Section 220-0050, STEERING PUMP) * SM 1621 Rev 4-03 'A' mm (in) 'B' mm (in) 'C' mm (in) Fig - Bearing Inner Race Installation Tools (Section 220-0050, STEERING PUMP) * * * MISCELLANEOUS - Standard Bolt and Nut Torque Specifications Section 300-0080 and to establish a uniform value to which these fasteners can be safely tightened, the following torque tables have been compiled WARNING Some fasteners are important attaching parts which could affect the performance of vital components and systems, and/or, could result in major repair expense Fasteners should be replaced with parts of the same part number, or with equivalent parts, if replacement becomes necessary Do not use replacement parts of lesser quality or substitute design The torque values shown in the following tables should be used in all cases, unless otherwise specified elsewhere in this manual, in order to avoid possible personal injury or property damage The torque values listed in the tables have been established over a period of years and cover all conditions of assembly The maximum torque values for standard bolts and nuts are based on 75% of the specified minimum proof strength of the bolt steel in order to provide a safety factor to compensate for the variation in the accuracy of torque wrenches, skill of the assembler, and variance in fractional conditions All torque values are for lubricated threads The term 'lubricated' includes the application of thread lubricants, cadmium plating or the use of hardened washers The following torque specification tables are based on GM Standard Materials for bolts, nuts, studs and selflocking fasteners based on SAE bolt steel classifications, or, prevailing torque specifications for self-locking fasteners To prevent the threaded bolts and nuts used on this equipment from being overstressed during assembly, To provide a quick method for determining the GM material classification of a particular standard bolt or nut, compare the bolt head markings to those in the appropriate tables, then locate the maximum torque value for that bolt size in the column under that marking RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% SAE Symbol GM 260-M Steel (SAE GR 2) Size 0.25 0.25 0.31 0.31 0.38 0.38 0.44 0.44 0.50 0.50 0.56 0.56 0.62 0.62 0.75 0.75 0.88 0.88 1.00 1.00 1.00 - 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 14 12 14 SM 1238 2-98 SAE Symbol GM 280-M Steel (SAE GR 5) SAE Symbol GM 290-M Steel (SAE GR 7) TABLE144 SAE Symbol GM 300-M Steel (SAE GR 8) 12 Point Cap Screws Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft 11 12 20 23 33 37 50 56 75 81 102 115 176 203 169 190 258 285 285 15 17 24 27 37 41 55 60 75 85 130 150 125 140 190 210 210 10 18 19 31 34 47 54 75 88 108 122 149 169 271 298 434 488 651 719 732 13 14 23 25 35 40 55 65 80 90 110 125 200 220 320 360 480 530 540 11 12 22 24 38 43 59 68 94 106 136 149 190 210 332 366 536 590 800 881 902 16 18 28 32 43 50 69 78 100 110 140 155 245 270 395 435 590 650 665 12 14 24 27 43 49 68 79 106 122 156 176 217 244 380 420 610 678 915 003 030 10 18 20 32 36 50 58 78 90 115 130 160 180 280 310 450 500 675 740 760 14 15 27 30 49 56 75 87 119 134 171 191 237 270 420 472 679 751 021 119 148 10 11 20 22 36 41 55 64 88 99 126 141 175 199 310 348 501 554 753 825 847 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% SAE Symbol GM 260-M Steel (SAE GR 2) SAE Symbol GM 280-M Steel (SAE GR 5) TABLE145 SAE Symbol GM 290-M Steel (SAE GR 7) SAE Symbol GM 300-M Steel (SAE GR 8) 12 Point Cap Screws Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft 1.12 - 1.12 - 12 1.25 - 1.25 - 12 1.38 - 1.38 - 12 1.50 - 1.50 - 1.50 - 12 1.75 - 1.75 - 12 1.88 - 1.88 - 12 2.00 - 4.5 2.00 - 2.00 - 12 2.25 - 4.5 2.25 - 2.25 - 12 2.50 - 12 366 407 515 569 664 759 881 936 990 - 270 300 380 420 490 560 650 690 730 - 800 902 132 254 478 688 966 088 217 - 590 665 835 925 090 245 450 540 635 - 132 274 600 776 095 393 786 962 145 393 091 006 304 623 342 687 701 10 629 11 050 15 280 835 940 180 310 545 765 055 185 320 240 755 430 650 885 415 670 155 840 150 11 270 302 451 830 034 400 739 186 390 593 016 830 874 213 565 406 786 11 090 12 148 12 636 17 463 960 075 350 500 770 020 350 500 650 700 300 070 320 580 200 480 180 960 320 12 880 447 624 043 267 676 056 556 781 010 604 497 664 048 448 367 811 12 377 13 566 14 102 19 500 067 198 507 672 974 254 623 789 958 133 792 653 936 231 909 236 129 10 006 10 401 14 383 Note: Where materials other than GM Standards are used, refer to the conversion table below Types of Steel Rockwell Hardness Range Applicable Torque Values Plain Low Carbon (eg SAE 1018 or 1020) Rockwell "B" 85-100 GM 260-M Plain Medium Carbon (eg SAE 1035, 1038 & 1045) Rockwell "C" 19-30 GM 280-M Medium Carbon Alloy (eg SAE 4140, 8642 & 5157) Rockwell "C" 28-34 GM 290-M Medium Carbon Alloy (eg SAE 4140, 8642 & 5147) Rockwell "C" 32-38 GM 300-M SAE Bolt Head Symbols SM 1238 2-98 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (METRIC) ± 10% Class 8.8 Size M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M 1.6 - 0.35 1.6 - 0.20 2.0 - 0.40 2.0 - 0.25 2.0 - 0.45 2.5 - 0.35 3.0 - 0.50 3.0 - 0.35 3.5 - 0.60 4.0 - 0.70 4.0 - 0.35 5.0 - 0.80 5.0 - 0.50 6.0 - 1.00 6.3 - 1.00 6.0 - 0.75 8.0 - 1.25 8.0 - 1.00 10.0 - 1.50 10.0 - 1.25 12.0 - 1.75 12.0 - 1.25 14.0 - 2.00 14.0 - 1.50 16.0 - 2.00 16.0 - 1.50 18.0 - 2.50 18.0 - 1.50 20.0 - 2.50 20.0 - 1.50 22.0 - 2.50 22.0 - 1.50 24.0 - 3.00 24.0 - 2.00 27.0 - 3.00 27.0 - 2.00 30.0 - 3.00 30.0 - 2.00 30.0 - 1.50 36.0 - 4.00 36.0 - 3.00 SM 1238 2-98 Class 9.8 TABLE146 Class 10.9 Class 12.9 Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft 169 181 234 263 330 367 451 495 571 623 837 903 135 258 300 985 102 122 130 169 190 239 265 325 357 412 450 605 652 820 908 939 433 517 0.20 0.25 0.25 0.45 0.25 1 3 10 10 21 23 42 45 74 81 118 128 - 0.15 0.20 0.20 0.30 0.20 0.75 0.75 0.75 1.5 2 4 15 17 31 32 53 58 85 92 - 13 12 27 29 54 57 94 103 151 163 234 250 323 363 457 507 623 684 790 861 158 250 570 740 799 745 907 10 20 21 39 41 68 74 109 118 169 180 234 262 330 366 450 494 570 622 836 902 134 256 299 982 099 0.20 0.40 0.45 0.45 0.45 2 13 16 14 32 34 63 67 110 121 176 190 274 292 378 425 531 593 728 800 923 007 354 461 835 034 102 208 398 0.15 0.30 0.30 0.30 0.30 0.75 1.5 1.5 3 6 10 11 10 23 25 46 48 80 87 127 137 197 211 273 307 386 423 526 577 667 727 977 055 325 468 516 317 453 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 SELF-LOCKING FASTENERS has been used Do not use a self-locking fastener more than five times Self-locking fasteners develop a measured gripping action or torque and provide a renewed locking action after being removed and reinstalled to their original mating part The self-locking fasteners used on this equipment meet specifications necessary to allow the fasteners to be reused up to five times Whenever a self-locking fastener is removed, the head of the fastener should be deeply scribed or otherwise marked to record the number of times the fastener The following table shows the minimum torque specifications allowed to remove self-locking fasteners after the initial break-away torque has been achieved Any self locking fastener that can be removed with less than the prevailing torque value shown in the table should be discarded, even if the fastener has not yet been reused five times MINIMUM PREVAILING TORQUE - REMOVAL TABLE537 Lockscrews Locknuts SAE Grade & and ASTM A-574 SAE Grade SAE Grade Size Nm lbf in Nm lbf in Nm lbf in 0.25 - 20 0.25 - 28 0.31 - 18 0.31 - 24 0.38 - 16 0.38 - 24 0.44 - 14 0.44 - 20 0.50 - 13 0.50 - 20 0.56 - 12 0.56 - 18 0.62 - 11 0.62 - 18 0.75 - 10 0.75 - 16 0.88 - 0.88 - 14 1.00 - 1.00 - 12 1.00 - 14 0.3 0.3 0.6 0.6 1.0 1.0 1.4 1.4 1.8 1.8 2.5 2.5 3.4 3.4 5.1 5.1 7.3 7.3 9.6 9.6 - 3 5 9 12 12 16 16 22 22 30 30 45 45 65 65 85 85 - 0.4 0.4 0.6 0.6 1.0 1.0 1.4 1.4 1.7 1.7 2.4 2.4 3.1 3.1 4.6 4.6 7.0 7.0 9.5 9.5 9.5 3.5 3.5 5.5 5.5 8.5 8.5 12 12 15 15 21 21 27 27 41 41 62 62 84 84 84 0.5 0.5 0.9 0.9 1.3 1.3 1.8 1.8 2.3 2.3 3.2 3.2 4.1 4.1 6.1 6.1 9.3 9.3 12.7 12.7 12.7 4.5 4.5 7.5 7.5 11.5 11.5 16 16 20 20 28 28 36 36 54 54 82 82 112 112 112 * * * * SM 1238 2-98 MISCELLANEOUS - Unit Storage Section 300-0090 GENERAL The storage of machines for short periods of time or during the off-season is an important item if major damage to components is to be avoided Failure to take the necessary steps to protect the various assemblies while the machine is being stored can result in an expensive overhaul job and delay in returning the machine to work TEMPORARY STORAGE When storing a machine for a period of 30 days or less, the following precautions must be taken: INSPECTION AND REPAIR - Thoroughly inspect and test the machine and make any necessary repairs or adjustments which may be necessary to prepare the machine for service This will enable you to put the machine back into use immediately at the end of the storage period LUBRICATION - Lubricate the machine completely according to the instructions given in Section 300-0020, LUBRICATION SYSTEM of this manual PARKING - After thoroughly cleaning the entire machine, park it on a hard, dry, level surface that is free from grease and oil The oil and grease would cause tyre deterioration Apply the parking brake BATTERIES - Where moderate temperatures are expected, the batteries may be left in the machine Up to 30 days, the batteries may require a boost at the end of the storage period Preferably place the batteries in the shop where they can be inspected, brought up to full charge and placed on a trickle charge to keep them at full charge In very cold or hot climates, store the batteries where they will be protected from temperature extremes RUST PREVENTION - Remove all evidence of rust from the machine and repaint In addition, cover all exposed machine surfaces with a good rust preventive SUPPLY TANKS - Fill fuel and hydraulic tanks to prevent moisture condensation within the tanks TYRES - Inflate all tyres to correct pressure During storage, check inflation pressure approximately once every two weeks Maintenance Manual for complete information on storing the engine for periods shorter than 30 days TRANSMISSION - Fill transmission sumps to the proper level EXTENDED STORAGE - Under Six Months When storing a machine for periods of longer than 30 days, but under six months, the following procedure must be followed: INSPECTION AND REPAIR - Same as Step given under 'Temporary Storage' LUBRICATION - Same as Step given under 'Temporary Storage' PARKING - Same as Step given under 'Temporary Storage' Machines should be blocked up so the tyres are off the ground or floor BATTERIES - Remove batteries from the machine and store them in a suitable place where they can be inspected and charged at least every 30 days or placed on a trickle charger RUST PREVENTION - Same as Step given under 'Temporary Storage' SUPPLY TANKS - Same as Step given under 'Temporary Storage' TYRES - With the machine on blocks, as called for in Step 3, deflate the tyres to 0.7 bar (10 lbf/in²) pressure Remove all traces of grease and oil and protect the tyres from direct sunlight and water with a suitable cover TRANSMISSION - Consult the relevant Transmission Maintenance Manual for storage data involving periods longer than 30 days ENGINE - Consult the relevant Engine Maintenance Manual for storage data involving periods longer than 30 days 10 VENTS AND BREATHERS - Remove all vents and breathers and plug openings with pipe plugs If it is not possible to this, seal vents and breathers with waterproof tape ENGINE - Consult the relevant Engine SM 1239 2-98 Miscellaneous - Unit Storage Section 300-0090 EXTENDED STORAGE - Over Six Months When a machine is to be stored for a period over SIX MONTHS, the following procedure must be followed: TYRES - Inflate tyres to the proper pressures Refer to Section 140-0040, WHEEL RIM AND TYRE, of this manual Note: These steps are in addition to those given previously under 'Extended Storage - Under Six Months' LUBRICATION - Completely lubricate the machine according to the instructions contained in Section 300-0020, LUBRICATION SYSTEM of this manual FUEL AND HYDRAULIC TANKS - Drain off condensation and fill tanks to proper level, remove breather covers and install air breathers Be sure breathers are clean before installation VENTS AND BREATHERS - Remove seals and plugs from all breather openings, then install all breathers and vents WHEEL BEARING - Remove, clean, inspect and repack all wheel bearings Note: The above steps must be repeated for every Six Month period the machine is in storage ENGINES - Consult the relevant Engine Maintenance Manual for instructions on removing an engine from storage REMOVAL FROM EXTENDED STORAGE PAINT - Check machine for rust Remove all rust spots and repaint rusted areas General LUBRICATION - Completely lubricate the machine according to the instructions in Section 300-0020, LUBRICATION SYSTEM of this manual * 2 BATTERIES - Install batteries and check for a full charge Charge batteries as required * TRANSMISSION - Consult the relevant Transmission Maintenance Manual for instructions on removing from storage * * SM 1239 2-98