Terex TA30 User manual

TA30
Articulated Dumptruck
Maintenance Manual
SM 1936 Rev 3 10-02
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED
MOTHERWELL, SCOTLAND ML1 5RY
REF. NO. SM 799
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TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. [phone] Tlx. 77141 Fax. [phone]
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. [phone] Fax. [phone]
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
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SM 222 Rev 1 9-93
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.
1. 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!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
IMPORTANT SAFETY NOTICE
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.
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SM 1935 Rev 3 10-02 1
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 Technical Data - TA30 1937 Rev 1
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 1960 Rev 1
0020 Articulation and Oscillation Pivot - Pre May 2000 Production 1975
0020 Articulation and Oscillation Pivot - From May 2000 Production 1988 Rev 1
0040 Hood and Mounting 1984 Rev 1
0070 Fenders and Mounting 1963
110 ENGINE
0030 Engine and Mounting 1964
0040 Kysor DST Fan 1974
0050 Air Cleaner 1958
120 TRANSMISSION
0010 Transmission and Mounting 1965
130 DRIVELINES
0010 Front and Rear Drivelines 1534 Rev 1
140 FRONT AXLE GROUP
0020 Axle Group (Hub) (Refer to Section 160-0030) -
0040 Wheel Rim and Tyre (Refer to Section 160-0050) -
0060 Differential Drive Head (Refer to Section 160-0020) -
150 CENTRE AXLE
0020 Differential Drive Head 1971
160 REAR AXLE GROUP
0020 Differential Drive Head 1969
0030 Axle Group (Hub) 1968
0050 Wheel Rim and Tyre 1970
165 BRAKE PARTS
0010 Brake Parts - Rear 1962
0020 Brake Parts - Front 1961
170 PARKING BRAKE
0010 Parking Brake and Mounting 1967
180 SUSPENSION SYSTEM
0020 Front Suspension 1979
0021 Air Spring 1480
0022 Levelling Valve 1481
0040 Rear Suspension 1978
190 ELECTRICAL SYSTEM
0000 Circuit Diagrams 1946 Rev 1
0270 Switches and Sensors 1959 Rev 1
200 FUEL SYSTEM
0040 Fuel Tank, Lines and Mounting 1942
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SM 1935 Rev 2 04-02
2
TABLE OF CONTENTS
Section No. Description SM No.
210 COOLING SYSTEM
0000 Cooling System 1983
0040 Radiator, Header Tank and Mounting 1987
0060 Transmission Oil Cooler 1977
0100 Hydraulic Oil Cooler 1976
220 STEERING SYSTEM
0000 Steering System Schematic 1943
0050 Steering Pump (Refer to Section 230-0050) -
0090 Steering Valve 1986 Rev 1
0105 Priority Valve 1947
0120 Steering Cylinder 1955
0140 Emergency Valve 1944
230 BODY SYSTEM
0000 Body System Schematic 1949 Rev 1
0040 Hydraulic Tank 1950
0050 Main Hydraulic Pump 1951
0060 Body Control Valve 1952
0081 Body Control Joystick 1953 Rev 2
0121 Pilot Supply Valve 1954
0130 Body Cylinder 1956
250 BRAKING SYSTEM
0000 Air Braking System Schematic 1948
0000 Hydraulic Braking System Schematic 1982
0070 Treadle Valve 1939
0170 Air Tanks and Mounting 1941
0190 Park Emergency Control Valve 1940
0200 Air Drier 1985 Rev 1
0260 Pressure Converter 1508
0270 Air Breather 1509
0280 Relay Emergency Valve 1945
0290 Pressure Protection Valve (4 way) 1938
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1957
0090 Driver Seat and Mounting 1981
0130 Air Conditioning 1966
270 BODY
0010 Body and Mounting 1980
300 MISCELLANEOUS
0020 Lubrication System 1972
0070 Service Tools 1973
0080 Axle Bolt and Nut Torque Specifications 1521
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
* * * *
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Section 000-0000
SM 1937 Rev 1 11-00 1
SM - 2476
ENGINE
Make/Model .....................................Cummins MTA11-C300
Type .......... Four cycle, low emission, direct injection diesel,
water-cooled, turbocharged and aftercooled.
Gross power at 2 100 rev/min.......224 kW (300 hp, 304 PS)
Net power at 2 100 rev/min...........214 kW (287 hp, 291 PS)
Note: Gross power rated to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
EU NRMM (non-road mobile machinery) directive.
Maximum Torque ... 1 376 Nm (1 015 lbf ft) at 1 300 rev/min
Number of cylinders/configuration ........................... 6, in line
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in)
Total Displacement ................................. 10.8 litres (660 in³)
Air cleaner..................................... Dry type, double element
Starting...................................................................... Electric
Maximum Speed (No load) ............................. 2 450 rev/min
Maximum Speed (Full load)............................ 2 100 rev/min
Idle Speed................................................... 675/750 rev/min
Safe Operating Angle ...................................43°/94% Grade
TRANSMISSION
Make/Model ..................................ZF 6WG 260 II Automatic
with manual override. The transmission assembly consists
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
differential transmits drive permanently to front and rear
axles. This differential may be locked by the driver for use in
difficult traction conditions. Standard integral hydraulic
retarder which is automatically operated should the engine
Fig. 1 - Machine Dimensions
overspeed. Blocked filter indicator and filter bypass system
provide valve block with additional protection from unfiltered
oil.
Pressures:
Main .......................................... 16 + 2 bar (232 + 30 lbf/in²)
Lockup (Wk).............................. 14 ± 1 bar (190 ± 15 lbf/in²)
Converter 'IN' ............... 7.6 bar (110 lbf/in2) at 2 300 rev/min
Converter 'OUT' ............. 4.8 bar (70 lbf/in2) at 2 300 rev/min
Converter Relief Valve ............................8.5 bar (123 lbf/in2)
Retarder ....................................................5.5 bar (80 lbf/in2)
Temperatures:
Normal ......................................80° - 110° C (176° - 230° F)
Maximum ..................................................... 120° C (248° F)
Stall Speed.............................................. 1 655 ± 50 rev/min
Ratios:
Torque Converter........................................................ 1.84:1
Transmission....................................................Refer to table
Forward
Gear 1 2 3 4 5 6
Ratio 5.35 3.45 2.21 1.42 0.97 0.62
km/h 5.0 8.0 12.5 19.5 29.0 45.0
mile/h 3.0 5.0 8.0 12.0 18.0 28.0
Reverse
Gear 1 2 3
Ratio 5.35 2.21 0.97
km/h 5.0 12.5 29.0
mile/h 3.0 8.0 18.0
GENERAL INFORMATION - Technical Data
25˚
2 400
(7-10) 1 260
(4-2)
3 310
(10-10)
1 435
(4-8)
Max.
Body
Depth
3 190
(10-6)
505
(1-8)
2 200
(7-3)
2 820
(9-3)
3 405
(11-2)
45˚
65˚
2 820
(9-3) 1 720
(5-8) 1 245
(4-1)
9 445
(31-0)
660
(2-2)
1 835
(6-0)
2 860
(9-4)
5 885
(19-4)
4 390
(14-5)
4 840
(15-10)
Vehicle Clearance
Turning Diameter
17.6 m (58-0)
2 615
(8-7)
2 815
(9-3)
1 580
(5-2)
Dimensions in mm (ft-in)
30/65 R 25 tyres increase width over tyres to 3 000 mm (9-10)
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General Information -Technical Data
Section 000-0000
SM 1937 Rev 1 11-00
2
AXLES
Three axles in permanent all-wheel drive with differential
coupling between each axle to prevent driveline wind-up.
Heavy duty axles with fully-floating axle shafts and outboard
planetary reduction gearing.
Automatic limited slip differentials in each axle. Centre axle
incorporates a through-drive differential to transmit drive to
the rear axle. Locking of this differential is actuated
simultaneously with the transmission output differential lock.
Ratios:
Differential ............................................................... 3.44:1
Planetary ................................................................. 6.35:1
Total Reduction ..................................................... 21.85:1
SUSPENSION
Front: Axle is carried on the leading arms of a sub-frame
pivoting on the main frame. Suspension is by flexible air
bellows with four heavy duty hydraulic dampers.
Axle Vertical Travel ..................................... 127 mm (5 in)
Rear: Each axle is coupled to the frame by three rubber-
bushed links with lateral restraint by transverse link.
Pivoting inter-axle balance beams equalise load on each
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and
underside of balance beam ends.
Axle Vertical Travel ............................. ± 130 mm (5.12 in)
Axle Oscillation .......................................................... ± 12°
BRAKES
Air assisted hydraulic dry disc on each wheel with two
heavy-duty callipers per disc at the front and a single
heavy-duty calliper per disc at the rear. Independent circuits
for front and rear brake systems. Overstroke actuates
warning light. Brake system meets ISO 3450, SAE J1473.
Air System Pressure ...............................7.6 bar (110 lbf/in²)
Total Air Reservoir Capacity ................... 55 litres (3 356 in³)
Hydraulic Brake Fluid Capacity ...... 2.64 litres (0.68 US gal)
Parking: Spring-applied, air-released disc on rear
driveline.
Emergency: Emergency brake control actuates the
service brakes. Automatic application of
service brakes should pressure fall in the
brake air system.
Retardation: Hydraulic retarder integral with transmission.
WHEELS AND TYRES
Wheels: ............ 5-piece earthmover rims with 12 stud fixing
Size:
Standard .......................25 x 19.50 in for 23.5 R25** tyres
Optional ...................... 25 x 22.00 in for 30/65 R25** tyres
Tyres:
Standard ........................................................... 23.5 R25**
Optional .......................................................... 30/65 R25**
Inflation Pressures (Bridgestone):
Front Rear
23.5 R25** 4.0 bar (58 lbf/in²) 4.8 bar (69 lbf/in²)
30/65 R25** 4.3 bar (62 lbf/in²) 4.3 bar (62 lbf/in²)
Note: Tyre pressures should be regarded as nominal only.
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.
HYDRAULIC SYSTEM
Steering and Body Hoist
The steering and body hoist systems are supplied with oil
from a common tank by the main hydraulic pump. Gear
pump driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
line.
Pump:
Type .............................................................................. Gear
Capacity at 2 300 rev/min ...........4.49 litre/s (71 US gal/min)
Steering System
Hydrostatic power steering by two single-stage, double-
acting, cushioned steering cylinders. Emergency steering
pressure is provided by a ground driven pump mounted on
the rear of the transmission. An audible alarm and warning
light indicates should the emergency system activate.
Conforms to ISO 5010, SAE J53.
System Pressure................................. 241 bar (3 500 lbf/in²)
Steering Angle to either side............................................ 45°
Lock to Lock Turns, steering wheel .................................... 4
Vehicle Clearance Circle (SAE)....................... 17.6 m (58 ft)
Body Hoist System
Two single-stage, double-acting hoist rams, cushioned at
both ends of stroke. Electro servo assisted hoist control.
System Pressure................................. 221 bar (3 200 lbf/in²)
Control Valve ...........................Pilot Operated, Open Centre
Body Raise Time (loaded) ..........................................12 sec
Body Lower Time (power down) ................................7.5 sec
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Section 000-0000
SM 1937 Rev 1 11-00 3
General Information -Technical Data
ELECTRICAL SYSTEM
Type .............................................. 24 volt, Negative Ground
Battery......................................... Two, 12 Volt, 143 Ah each
Accessories................................................................ 24 Volt
Alternator .................................................................. 70 Amp
BODY
Of all welded construction, fabricated from high hardness
(min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength
steel. 25° tail chute angle provides good load retention
without tailgate.
Plate Thicknesses:
Floor and Tailchute................................... 15 mm (0.59 in)
Sides......................................................... 12 mm (0.47 in)
Front ........................................................... 8 mm (0.31 in)
Volume:
Struck (SAE)..........................................13.0 m³ (17.0 yd³)
Heaped 2:1 (SAE) .................................16.0 m³ (21.0 yd³)
SERVICE CAPACITIES
Fuel tank ............................................. 330 litres (87 US gal)
Hydraulic System
(steering & body) .......................... 200 litres (52.8 US gal)
Engine Crankcase ............................. 40 litres (10.5 US gal)
Cooling System .................................. 59 litres (15.6 US gal)
Transmission & filters (dry fill)............ 52 litres (13.8 US gal)
Transmission & filters (wet fill) ............. 26 litres (6.9 US gal)
Differentials - Front & Rear (each)....... 11 litres (2.9 US gal)
Differential - Centre.............................. 14 litres (3.7 US gal)
Planetaries (each)............................... 3.5 litres (0.9 US gal)
Service Brakes..................................... 3 litres (0.79 US gal)
Air Conditioning Compressor...... 0.125 litres (0.033 US gal)
TYPICAL NOISE LEVELS
Operator Ear (ISO 6394)............................................ 79 dbA
*Exterior Sound Rating (SAE J88 JUN 86)............. TBA dbA
*- The above result is for the mode giving the highest
exterior sound level when measured and operated as per
the prescribed procedures of the standard. Results shown
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to
buildings, rock piles, machinery, etc.. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
Vehicle Weights
Standard Vehicle kg lb
Net Distribution
Front Axle 10 585 23 335
Centre Axle 5 000 11 025
Rear Axle 4 970 10 955
Vehicle, Net 20 555 45 315
Payload 27 000 59 525
Gross Distribution
Front Axle 14 450 31 860
Bogie Axle, leading 16 545 36 470
Bogie Axle, rear 16 560 36 510
Vehicle, Gross 47 555 104 840
Bare Chassis 16 025 35 330
Body 4 000 8 820
Body Hoists (Pair) 530 1 170
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Section 000-0010
SM 2172 10-02 1
Welding
WARNINGS
Before any welding is done on a machine
equipped with any electronic systems,
disconnect the following (if applicable) in this
order: Battery earth cable, battery supply
cable, alternator earth cables, alternator supply
cables and electrical connections at the engine
ECM, transmission ECU, body control lever,
hydraulics ECU and cab bulkhead to avoid
damage to electrical components. Turn off
battery master switch to isolate the batteries
before disconnecting any components.
After welding connect all of the above in the
reverse order.
Before any welding is done ensure all paint has
been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. Since the nature and extent of damage
to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Customer Support
Department can be consulted regarding the feasibility
of welding repairs.
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
will provide protection against cadmium,
fumes and metallic oxides. The 'Gasfoe'
respirator has been approved by the U.S.
Bureau of Mines: Approval number 23B-10,
and is designed to protect against gases,
vapours, and/or metal fumes.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
performed on the front frame, the current must pass a
frame connection to return to the welding machine.
Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
increase the wear rate of these components.
General Welding Procedure
The following general procedure should be used for
the repair of defects outwith the vicinity of alloy steel
castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 100° C (212° F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
GENERAL INFORMATION - Welding Procedure
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General Information - Welding Procedure
Section 000-0010
SM 2172 10-02
2
3. Pre-heat area to 100° C (212° F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
5. Allow repair weld to cool slowly.
6. Grind and blend repair to original contour. Paint
heat damaged areas.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the
welds joining steel castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 200° C (392° F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
5. On completion of welding, post-heat repair area to
400° C (752° F), measure 3 - 4" either side of repair.
6. If welding has to be interrupted for any reason, e.g.
overnight, post-heat immediately as in Step 5.
* * * *
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Section 100-0010
1
SM 1960 Rev 1 4-02
CHASSIS - Frames
SM - 2475
Fig. 1 - General Arrangement of Frame Assemblies
DESCRIPTION
The chassis consists of two separate frame
assemblies which provide the articulation of the unit.
The front and rear frames are constructed of all
welded high-grade steel fabrications with rectangular
box section beams forming main, side and cross
members. The frames are coupled to provide 45°
articulation to each side as well as oscillation.
The front frame is fabricated to form a rigid structure
which carries the cab, power train and suspension
system.
The rear frame is fabricated to form a rigid structure
which carries the body, body hydraulics, suspension
and rear drive axles.
Oscillation between the front and rear frames is
provided by a large diameter cylindrical coupling
carried on nylon bushes located in the rear frame.
Longitudinal shocks are absorbed by the thrust faces
of the nylon bushes. A large thrust nut, which is
threaded to the end of the coupling and locked to the
frame, secures the coupling in position. Wear on the
thrust faces of the bushes is compensated by
tightening this thrust nut.
INSPECTION AND MAINTENANCE
Inspection
Inspect the frames and attached parts at intervals not
exceeding 250 hours for cracked or broken welds and
bending of the frame. Any defects found should be
repaired before they progress into major failures.
Straightening
Hydraulic straightening or aligning equipment should
be used to straighten bent or twisted frames whenever
possible. However, if heat must be applied, never heat
the metal beyond a dull, cherry red colour, as too
much heat will weaken the metal. When it is necessary
to heat the metal, apply heat uniformly over the area to
be straightened and protect the heated surface from
sudden cooling. Frame parts that cannot be
straightened should be renewed.
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SM 1960 Rev 1 4-02
2
Chassis - Frames
Section 100-0010
Welding
WARNINGS
Before any welding is done on a machine,
disconnect connections at body hydraulics
joystick, all battery connections at both positive
and negative terminals and ground cable to
alternator to avoid damage to electrical
components. Turn battery master switch to the
'Off' position before disconnecting any
components. Remove battery ground cable
first, and reconnect last, to avoid damaging
electrical components.
Before any welding is done ensure all paint has
been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Prior to welding, switch off/disconnect the
following in the order given. Failure to do so may
seriously damage the machines electrical components.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
d - Battery supply cables
e - Alternator earth cables
f - Alternator supply cables
g - Body hydraulics joystick
h - Transmission (Est-37) connector
After welding, connect all of the above in the reverse
order.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. Since the nature and extent of damage
to the frame cannot be predetermined, no definite repair
procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Service Department
can be consulted regarding the feasibility of welding
repairs.
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A respiratory
protective device such as the M.S.A. 'Gasfoe'
respirator with G.M.A. cartridge will provide
protection against cadmium, fumes and
metallic oxides. The 'Gasfoe' respirator has
been approved by the U.S. Bureau of Mines:
Approval number 23B-10, and is designed to
protect against gases, vapours, and/or metal
fumes.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
performed on the front frame, the current must pass a
frame connection to return to the welding machine.
Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
increase the wear rate of these components.
Reinforcement
Frame reinforcement can be made with channel or
angle or flat structural stock. Whenever possible, the
reinforcement should extend well beyond the bent,
broken or cracked area. The reinforcement stock
thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Painting
A check of the condition of the paint should be made
approximately twice a year and chassis repainted if
necessary.
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Section 100-0010
3
SM 1960 Rev 1 4-02
* * * *
WARNING
Welding, burning, heating or dressing surfaces
previously painted using polyurethane paint
produces fumes which are toxic. Surfaces must
be prepared using paint stripper prior to area
being reworked. Recommended Industrial
Hygiene and Safety Rules should be followed
for protection of the welding operator from the
fumes.
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frames is highly recommended.
If painting of a frame is required, thoroughly clean the
areas to be painted. Apply a primer coat of
polyurethane red oxide and then a finish coat of
polyurethane enamel.
Chassis - Frames
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Section 100-0020
1
SM 1975 4-00
DESCRIPTION AND OPERATION
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and
tilt laterally (oscillation) with respect to each other. It is
also the main load bearing coupling between the two
frames. The pivot assembly houses the driveshaft
connecting the drive between the front and rear
frames.
Articulation bearings, oscillation bushes, pivot
driveshaft bearings and associated parts can be
removed, inspected and replaced or renewed by
following the procedures outlined in this section.
Fig. 1 - Articulation and Oscillation Pivot
CHASSIS - Articulation and Oscillation Pivot
SM - 2483
1
2,3,50
4
51
52
5
6
13
14
7,8,9
10
11
55
17
33 46
14
47
14
29
12
54
53
25
20
16
31
14
40
30
19
29
37
38
38
18
18
15
21
14
20
19
30
39
22
24 2
23
41
35
25
26
1436
41
43
34
44 4514 36
56 57 58
28
26
27
32
22
6
48
48 49
49
59
42
LUBRICATION POINT
* Lower bearing shims not shown
33 - Bolt
34 - Thrust Nut
35 - Lockplate
36 - Bolt
37 - Shaft
38 - Bush
39 - Washer
40 - Seal
41 - 'V' Ring
42 - Adaptor
43 - Bush
44 - Pin
45 - Washer
46 - Bolt
47 - Washer
48 - Lube Line
49 - Connector
50 - Lube Fitting
51 - Nut
52 - Spacer
53 - Bolt
54 - Hardened Washer
55 - Pin
56 - Bolt
57 - Lockwasher
58 - Bracket
59 - Lube Fitting
1 - Pivot
2 - Coupling
3 - Pipe
4 - 'O' Ring
5 - Retainer
6 - Bearing
*7 - Shim
*8 - Shim
*9 - Shim
10 - 'O' Ring
11 - Retainer
12 - Seal
13 - Bolt
14 - Lockwasher
15 - Lube Fitting
16 - Brake Yoke
17 - Retainer
18 - 'O' Ring
19 - Spacer
20 - Bolt
21 - Retainer
22 - Nipple
23 - Elbow
24 - Lube Fitting
25 - Locknut
26 - Washer
27 - Front Yoke
28 - Housing
29 - Seal
30 - Bearing
31 - Housing
32 - Pin
Courtesy of Machine.Market

2SM 1975 4-00
Chassis - Articulation and Oscillation Pivot
Section 100-0020
PIVOT DRIVESHAFT BEARINGS
Removal
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
Note: It is not necessary to separate the frames in
order to remove the pivot driveshaft assembly.
WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
equipment is properly secured and of adequate
capacity to do the job safely.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Open drain cocks on air tanks to drain air pressure
from the tanks. Close air tank drain cocks when air
has exhausted from the air tanks.
Note: Take extra care when handling drivelines as any
deformity on a rotating mass creates vibration and
excessive wear during any operation.
4. Match mark yokes and mating surfaces of
transmission - pivot driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and
remove driveline from the machine.
Note: Take care to avoid damaging pipe (3) when
performing Step 5.
5. Remove locknut (25) and washers (26) from front
Fig. 2 - Drivelines
yoke (27). Remove yoke (27) from shaft (37).
6. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3),
nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted,
from beneath rear of pivot housing.
WARNING
Tensioned spring on adjuster.
7. Slacken adjuster (14, Fig. 3) until brake pads
(13, Fig. 3) are sufficiently clear of parking brake disc
(5, Fig. 3) to permit removal of calliper (7, Fig. 3).
8. Note positions of front and rear wedge plates
(8 & 9, Fig. 3) to aid in 'Installation'. Remove bolts
(6, Fig. 3), washers (11, Fig. 3), nuts (12, Fig. 3), front
and rear wedge plates (8 & 9, Fig. 3) and left hand
torque plate (10, Fig. 3).
9. Move and secure calliper (7, Fig. 3) clear of parking
brake disc (5, Fig. 3).
Note: Take extra care when handling drivelines since
any deformity on a rotating mass creates vibration and
excessive wear during any operation.
10. Match mark brake yoke (16) and mating surface of
pivot - centre axle driveline (Fig. 2) to aid in
'Installation'. Remove bolts, lockwashers and caps and
remove driveline from the machine.
11. Remove bolts (57) and lockwashers (14) from rear
housing (31).
Note: Take extra care when handling driveshafts as
any deformity on a rotating mass creates vibration and
excessive wear during any operation.
Transmission - Pivot Pivot - Centre Axle
SM - 002
Courtesy of Machine.Market