Terex TR45 User manual

SM 1606 Rev 2 02-02
TR45
Off-Highway Trucks
Service Manual
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM754/781

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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 1607 Rev 2 02-02 1
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 TR45Off-HighwayTruck 1608
100 CHASSIS
0010 Chassis, Hood and Fenders 1570
110 ENGINE
0030 EngineandMounting 1571
0050 Air Cleaner 1572
0130 Power Takeoff 1296
120 TRANSMISSION
0010 Transmission and Mounting 1612
0070 Commercial Electronic Control (CEC) Shift System 1575
0070 Commercial Electronic Control 2 (CEC2) 2128
0090 Power Takeoff 1178
0100 Transmission Oil Filter 1576
130 DRIVELINE
0010 Front Driveline - Pre June 1998 Production 1180
0010 Front Driveline - From June 1998 Production 1577
0020 Rear Driveline - Pre June 1998 Production 1311
0020 Rear Driveline - From June 1998 Production 1578
140 FRONT AXLE
0040 Wheel, Rim and Tyre 1303
160 REAR AXLE
0020 Differential 1298
0030 Axle Group 1299
0050 Wheel, Rim and Tyre 1300 Rev 1
165 BRAKE PARTS
0020 Brake Parts - Front Axle 1186
` 0030 Brake Parts - Rear Axle 1301
180 SUSPENSION SYSTEM
0030 Ride Cylinder - Front 1584
0050 Ride Cylinder - Rear 1302
190 CIRCUIT DIAGRAMS
0000 CircuitDiagrams 1585
0270 Switches and Sensors 1586
200 FUEL SYSTEM
0010 Fuel Tank and Mounting 1587
0040 Fuel Lines 1195
0051 Electronic Foot Pedal 1196
210 COOLING SYSTEM
0000 Cooling System 1305
0040 Radiator,Header Tank and Mounting 1613
0050 Disc Brake Oil Cooler 1589
0060 Transmission Oil Cooler 1590
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SM 1607 Rev 2 02-02
2
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1591
0040 Steering and Brake Control Tank 1592
0050 Steering Pump 1204
0080 Accumulator 1205
0090 Steering Valve 1206
0110 Double Relief Valve 1208
0120 Steering Cylinder and Linkage 1304
0130 Accumulator Valve 1209
0150 SteeringFilter 1593
230 BODY SYSTEM
0000 Body System Schematic 1594 Rev 1
0040 Body and Disc Brake Cooling Tank 1595
0050 TandemPump 1213
0060 Body Control Valve 1596 Rev 1
0081 Body Control Joystick 1597
0090 Kick-over Valve 1218
0120 Relief Valve 1598
0121 Pilot Supply Valve 1599
0130 BodyCylinder 1221
250 BRAKING SYSTEM
0000 Braking System Schematic 1222
0050 Brake Manifold Valve 1223
0060 Accumulator 1600
0070 TreadleValve 1225
0090 Directional Control Valve 1226
0100 Monoblock Brake Valve 1227
0130 Retarder Control Valve 1609
0140 Shuttle Valve 1229
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1602
0110 Passenger Seat and Mounting 1603
0130 Air Conditioning and Mounting 1620
270 BODY
0010 Body and Mounting 1610
300 MISCELLANEOUS
0020 Lubrication System 1611
0070 Service Tools 1621
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
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Section 000-0000
1
SM160812-98
GENERAL INFORMATION - TR45 Off-Highway Truck
ENGINE
Make/Model ................................... Cummins QSK 19-C525
Type .................... 4 Cycle, Turbocharged/Low Temperature
Aftercooled. Electronic Management.
Gross Power at 2 100 rev/min ......392 kW (525 hp, 532 PS)
Net Power at 2 100 rev/min ..........370 kW (495 hp, 502 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
proposedEUnon-roadmobilemachinerydirective.
Maximum Torque .............................. 2 407 Nm (1 775 lbf ft)
at 1 300 rev/min
Number of Cylinders/Configuration .........................6, in line
Bore x Stroke ........................ 159 x 159 mm (6.25 x 6.25 in)
Total Displacement ..............................18.9 litres (1 150 in³)
Starting...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min
Maximum Speed, No Load ............................. 2 300 rev/min
Idle Speed................................................... 700/750 rev/min
Safe Operating Angle .................................. 30°/60% Grade
TRANSMISSION
Make/Model ................................................. Allison M5600A
Automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral torque converter
and planetary gearing. Six speeds forward, two reverse.
Automaticconverter lockupactionin allspeed ranges.
Downshiftinhibitor.
Fig. 1 - Machine Dimensions
Speeds With Standard Differential
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 10.0 14.5 19.5 29.0 39.0 60.0
mile/h 6.0 9.0 12.0 18.0 24.5 36.0
Reverse
Gear 1 2
Ratio 5.12 3.46
km/h 7.5 11.5
mile/h 4.5 7.0
SM - 2014
2 350 (7-9) 3 940 (12-11) 2 410 (7-11)
8 700 (28-7)
585 (1-11)
15˚ 3 430
(11-3)
7 455
(24-6)
4 700 
(15-5)
5 485 
(18-0)
7 120
(23-4)
58˚
3 855
(12-8)
430
(1-5)
Vehicle Clearance Diameter (SAE) 21m (69ft)
3 530
(11-7)
3 800
(12-6)
4 060
(13-4)
Max
Body
Depth

1 195 
(3-11)
1 440 
(4-9)
885
(2-11) 525
(1-9)
2 710 (8-11)
3 980 (13-1)
4 240 (13-11)
Optional
Spillguard
4 630 (15-2)
4 370 (14-4)
4 525
(14-10)
4 245
(13-11)
4 135
(13-7)
585
(1-11)
2 685 (8-10)
3 325 (10-11)
3 965 (13-0)
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Section 000-0000
General Information - TR45 Off-Highway Truck
SM160812-982
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios: Standard Optional
Differential ............................................. 3.15:1 3.73:1
Planetary ............................................... 5.66:1 5.66:1
TotalReduction.................................... 17.83:1 21.11:1
SUSPENSION
Front:Kingpinstrut typeindependentfront wheelsuspension
byself-contained,variablerate,nitrogen/oilcylinders.
Rear:Variableratenitrogen/oilcylinderswithA-framelinkage
andlateralstabilizerbar.
MaximumStrutStroke
Front........................................................... 251 mm(9.9 in)
Rear ........................................................... 182mm (7.2in)
MaximumRearAxleOscillation ....................... ± 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 13 in
Wheel Rim Width (Optional) ......................................... 15 in
Standard Tyres (Front & Rear) ..............18.00 R33 ** Radial
Optional Tyres (Front & Rear) ...............21.00 R35 ** 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.
BRAKES
Service
All hydraulic brake system. Transmission mounted pressure
compensatingpump provideshydraulic pressurefor brakes
andsteering.Independent circuitsfront andrear. Eachcircuit
incorporatesanitrogen/hydraulicaccumulatorwhichstores
energyto provideconsistentbraking response.
Front Brake Circuit Pressure ................ 159 bar(2 300lbf/in²)
Rear Brake Circuit Pressure ....................52 bar (750 lbf/in²)
Accumulators:
NitrogenPrecharge Pressure ................. 55bar(800lbf/in²)
Front:
Type............................... Dry Disc with 1 calliper per wheel
DiscDiameter .......................................... 660mm(25.5in)
PadArea,Total ..................................... 1 395 cm²(216 in²)
Rear:
Type..................Oilcooled,multiple frictiondiscs(14 total),
completelysealedfromdirtandwater.
Braking Surface, Total ....................38 310 cm² (5 938 in²)
Cooling Flow, Max. .......... 553 litres/min (146 US gal/min)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure ..................................83 bar (1 200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.
Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes.Automaticallyapplies whenengine isswitchedoff.
Parking brake applies should system pressure fall below a
predeterminedlevel.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
STEERING SYSTEM
Independenthydrostaticsteeringwithclosed-centresteering
valve,accumulatorandpressurecompensatingpistonpump.
Accumulatorprovidesuniformsteeringregardlessofengine
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 meets ISO 5010, SAE J53.
System Pressure................................ 159 bar (2 300 lbf/in²)
Relief Pressure ...................................207 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Oil Capacity .................................. 14.0 litres (3.70US gal)
NitrogenPrecharge Pressure .................55bar (800lbf/in²)
SteeringAngle(LeftandRight) .........................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min ..........1.4 litres/s (22 US gal/min)
BODY HYDRAULICS
Twobody hoistcylinders aremounted betweenthe frame
rails. Cylinders are two-stage with power down in the
second stage.
System Relief Pressure ..................... 190 bar (2 750 lbf/in²)
Pump:
Type........................................................................... Gear
Capacity at 2 100 rev/min.............................227 litres/min
(60 US gal/min)
Control Valve ...................... Servo Controlled, Open Centre
Body Raise Time................................................ 13 Seconds
Body Lower Time ................................................. 9 Seconds
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Section 000-0000
3
SM160812-98
General Information - TR45 Off-Highway Truck
ELECTRICAL
Type ............................................. 24 Volt, Negative Ground
Battery......... Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories................................................................ 24 Volt
Alternator ..................................................................70 Amp
Starter ........................................................................ 8.9 kW
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasionresistant steel.Yield strength ofplates 1 000MPa
(145 000 lbf/in²).
Plate Thicknesses:
Floor ............................................................. 19 mm (0.75 in)
Side .............................................................. 10 mm (0.39 in)
Front, lower .................................................. 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE) ............................................. 19.6 m³ (25.6 yd³)
Heaped 2:1 (SAE).................................... 26.0 m³ (34.0 yd³)
SERVICE CAPACITIES
Engine Crankcase and Filters............ 66 litres (17.4 US gal)
Transmission and Filters....................... 68 litres (18 US gal)
Cooling System................................ 135 litres (35.5 US gal)
Fuel Tank .......................................... 606 litres (160 US gal)
Steering Hydraulic Tank ....................... 61 litres (16 US gal)
Steering System................................. 85 litres (22.5 US gal)
Body and Brake Cooling Tank ............ 235 litres (62 US gal)
Body and Brake Cooling System ........ 368 litres (97 US gal)
Planetaries (Total) ............................. 66 litres (17.4 US gal)
Differential.......................................... 60 litres (15.8 US gal)
Front Ride Strut (Each) ........................ 14 litres (3.7 US gal)
Rear Ride Strut (Each)......................... 17 litres (4.5 US gal)
Power Takeoff........................................... 4 litres (1 US gal)
* * * *
Typical Noise Levels
Operator Ear (ISO 6394)............................................ 80 dbA
*Exterior Sound Rating (SAE J88 JUN 86)................ 88 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 (MASS) kg lb
Chassis, with hoists 25685 56610
Body,standard 9600 21170
NetWeight 35285 77780
PAYLOAD,maximum 40825 90000
MaximumGrossWeight* 76110 167780
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
Chassis, with hoists 25685 56610
Body,standard 11100 24470
NetWeight 36785 81080
PAYLOAD,maximum 39325 86700
MaximumGrossWeight* 76110 167780
*Maximum permissiblegross vehicleweight withoptions,
attachments, full fuel tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 48 52
Loaded % 34 66
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Section100-0010
1
SM 1570 12-98
CHASSIS - Chassis, Hood and Fenders
REMOVAL
WARNING
Toprevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
To remove any of the components shown in
Figs. 1, 2, 3, 4 or 5 (or similar components) the
followingproceduresshouldbecarriedout.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Turn steering wheel in both directions several times
to relieve pressure in the steering circuit. Block all road
wheels.
3. Attach a suitable lifting device to the component and
removemountinghardware.Removethecomponent
from the vehicle.
INSTALLATION
Note: Tighten all fasteners to standard torques listed in
Section300-0080,STANDARDBOLTANDNUT
TORQUESPECIFICATIONS.
WARNING
Toprevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
Using a suitable lifting device, align the component to
be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardwareremovedduringremoval.
Fig. 1 - Exploded View of Chassis and Guards
1 - Frame Assembly
2 -Bushing
3 -EngineGuard
4 -Channel
5 - Bolt
6 - Nut
7 -Lockwasher
8 -Washer
9 - Bolt
10 -TransmissionGuard
11 - Bolt
SM-1785
12 -HardenedWasher
13 - Locknut
14 - Spring Disc
15 -Washer
9
8
7
6
4
35
8
7
6
10
11
1514
12
13
1
2
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Chassis - Chassis, Hood and Fenders
Section100-0010
2SM 1570 12-98
SM-1958MAINTENANCE
Inspection
Inspect the frame and attached parts at intervals not
exceeding250 hoursfor cracked or broken weldsand
bending/twisting of the frame. Any defects found
shouldberepairedbeforetheyprogressintomajor
failures.Contactyourdealerforrecommendedweld
andrepairinstructions.
Welding
Note: It is important that the electrical connections are
disconnectedinthefollowingordertopreventdamage
to the electrical components:
a. Disconnectbatteryequalizergroundcables.
b. Disconnect battery cables from terminal posts
(groundcablefirst).
c. Disconnect battery equalizer positive cables.
d. Disconnect electrical connections at the ECU.
After welding, reconnect all of the above in the reverse
order.
WARNING
Welding and flame cutting cadmium plated
metalsproduce odourless fumes whichare
toxic.Recommendedindustrialhygiene
practicefor protectionofthe weldingoperator
from the cadmium fumes and metallic oxides
requiresenclosureventilationspecifically
designedfor the welding process. A respiratory
protectivedevice suchasthe M.S.A.'Gasfoe'
respirator with G.M.A. cartridge will provide
protectionagainst cadmium, fumes and
metallicoxides.The'Gasfoe'respiratorhas
been approved by the U.S. Bureau of Mines:
Approvalnumber
23B-10,and is designedtoprotectagainst
gases,vapours, and/or metal fumes.
Electric arc welding is recommended for all chassis
welding. Since the nature and extent of damage to the
framecannotbepredetermined,nodefiniterepair
procedurecan beestablished. Asa generalrule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or twisted, no welding should be done
untilthepartsarestraightenedorrealigned.
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.
Painting
A check of the condition of the paint should be made
approximately twice a year and chassis repainted if
necessary.
WARNING
Welding,burning, heating or dressing surfaces
previouslypaintedusingpolyurethanepaint
producesfumes which are toxic. Surfaces must
be prepared using paint stripper prior to area
beingreworked.RecommendedIndustrial
Hygiene and Safety Rules should be be
followedfor protection of the welding operator
fromfumes.
If painting of the actual frame of the unit is required,
thoroughly clean the areas to be painted. Apply a
primer coat of red oxide and then a finish coat of
polyurethaneenamel.
To keep rust and corrosion to a minimum, periodic
paintingof abrasionsand otherexposed metalareas on
theframe is highly recommended.
Fig. 2 - Exploded View of Hood and Mounting
1 - Hood Assembly
2 - Plate
3 - Bolt
4 -HardenedWasher
5 - Nut
6 - Baffle
7 - Baffle
8 -Beading
543
2
543
1
7
8
6
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Section100-0010
3
SM 1570 12-98
SM-1959
Chassis - Chassis, Hood and Fenders
Fig. 3 - Exploded View of Fenders and Mounting
39 - Plate Bent
40 - Plate bent
41 - Bolt
42 -Washer
43 - Nut
44 - Bolt
45 -Washer
46 - Nut
47 - Kick Plate
48 - Kick Plate
49 - Bolt
50 - Hardened Washer
51 - Nut
1 - LH Fender Assembly
2 - LH Platform Assembly
3 - RH Fender Assembly
4 - RH Platform Assembly
5 -Crossmember
6 -Support
7 -Support
8 - Bolt
9 -Lockwire
10 -HardenedWasher
11 - Bolt
12 -Washer
13 - Engine Access Cover
14 - Bolt
15 - Locknut
16 -HardenedWasher
17 - Bolt
18 - Locknut
19 -HardenedWasher
20 -Mirror
21 -LHHandrail
22 - Bolt
23 -MirrorWideAngle
24 - Nut
25 - Washer
26 - Bolt
27 - Bolt
28 - Bolt
29 -Mudguard
30 -Mudguard
31 - Bolt
32 - Bolt
33 - FenderExtension RH
34 -RHHandrail
35 - Mirror Bracket
36 - Bolt
37 - Lockwasher
38 - Washer
34
13
221
22
10
20
35
3210
23
34
22 10
4950 18 17 41
42
42
43 41
42
42
43
39
19
18
181928
17
18
19
30
33
48
4
31
19
22
10
18 1928
313
7
27
25
24 17
19
18
26
25
24 12
11
5
1
6
29
A
20
38
37
36
1
14 15
16
18 19 17
221
47
22
10
10 89
1922
46
45
40
45
44
18
19
17
51 49
50
51
DETAIL A
SEC.
260-0010
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Chassis - Chassis, Hood and Fenders
Section100-0010
4SM 1570 12-98
SM-1960
1 - LH Step Assembly
2 - RH Step Assembly
3 - Plate
4 - 'U' Bolt
5 - Step
6 - Bolt
7 -Washer
8 - Bolt
9 - Locknut
10 - Nut
11 - Bolt
12 -HardenedWasher
13 - Nut
14 -HardenedWasher
Fig. 4 - Exploded View of Ladders and Handrails
33
614 1413
6141413
1112
4
14
4
1210
11121210
2
5
5
11
12
12
10
11
12
12
10
8779
8779
1
4
14
4
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Section100-0010
5
SM 1570 12-98
Chassis - Chassis, Hood and Fenders
1 -RadiatorGuard
2 - Cover Plate
3 -Washer
4 - Bolt
5 - Bolt
6 - Nut
7 - Bolt
8 -Grille
9 - Bolt
Fig. 5 - Radiator Guard and Mounting
* * * *
SM-1961
10 - Bracket
11 - Bolt
12 -HardenedWasher
13 - Plate
11
12
5
12
12
6
11
10
13
712
612 12 9
18
234
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Section 110-0030
SM 1571 12-98 1
ENGINE - Engine and Mounting
DESCRIPTION
Numbers in parentheses refer to Fig. 1.
For engine make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For
engine servicing and repair data refer to the engine
manufacturers service manual.
The engine is mounted to the frame at three points by
a mounting bracket (6) at the front of engine (1) and
two rear mounts (5). Rubber isolation mounts (12)
through engine mounts provide sufficient flexibility to
absorb varying engine vibration and torsional loads.
There are two full-flow oil filters (36) mounted on the
left hand side of engine (1) in a downward position.
The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
filters (36) before reaching the various moving parts of
engine (1). The oil is forced by pump pressure through
a passage in the filter adaptor and into the elements.
Impurities are filtered out as the oil passes through the
Fig. 1 - Engine and Mounting
1 - Engine
2 - Locknut
3 - Bolt
4 - Alternator Guard
5 - Rear Mount
6 - Front Mount
7 - Bolt
8 - Lockwasher
9 - Support Bracket
10 - Bolt
11 - Snubbing Washer
12 - Isolation Mount
13 - Bolt
14 - Locknut
15 - Plate Support
16 - Damper
17 -Lockwasher
18 - Bolt
19 - Flange Coupling
20 - Bolt
21 - Clamp
22 - Bolt
23 - Lockwasher
24 - Washer
25 - Bolt
26 - Washer
27 - Padlock
28 - Key
29 - Bolt
30 - P-Clip
31 - P-Clip
32 - Bracket
33 - Latch Assembly
34 - Latch Assembly
35 - Bolt
36 - Oil Filter
37 - Fuel Filter
38 - Coolant Filter
39 - Breather Line
40 - Filler Hose
41 - Clamp
42 - Lockwasher
43 - Locknut
44 - Plate
45 - P-Clip
46 - Bolt
47 - Lockwasher
48 - Locknut
49 - Filler Assembly
50 -Alternator
51 - Bolt
52 - Lockwasher
53 - Eye Bolt
54 - Jam Nut
55 - Link
56 - Nut
57 - Eye Bolt
58 - Lockwasher
59 - Bolt
60 - Locknut
61 - Lockwasher
62 - Bolt
63 - Bracket
64 - Bolt
65 -Washer
66 - Locknut
SECURITY KIT
ENGINE DIPSTICK SECURITY KIT
ENGINE OIL FILL
A
BB
A
POSITION A
POSITION B
29
26 9
26
25
4
38
15
44 31 4748
45
46
13
3
11
12
11
24
2
35
32 42 43
30
6
14
3427
28
37
36
33
41
49
40
66
65
6564
63
27
28
41
10
11
12
11
24
2
587
20
16 17 18
19
39
21
21 39
1
22,23
S.W.E.
51 52 53 54
55 56 57
59
60
61
62
50
58
SM-1962
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Section 110-0030
Engine - Engine and Mounting
SM 1571 12-98
2
elements and out through another passage in the filter
adaptor.
Engine coolant filter (38) and conditioner is a compact
bypasstypeunitwithareplaceablespin-ontypeelement
mounted on the gear case cover at the front right hand
side of engine (1). Refer to Section 210-0000,
COOLING SYSTEM.
There are two spin-on type fuel filters (37) mounted on
the left hand side of engine (1). The primary fuel filter
is in the fuel flow and acts as a strainer and the
secondary fuel filter filters the fuel after having passed
through the primary fuel filter.
QUANTUM ELECTRONIC FUEL CONTROL
SYSTEM
Description
Refer to Fig. 2.
WARNING
Before any welding is done on a machine
equipped with the Quantum Electronic Fuel
System, disconnect the following in this order:
Battery earth cable, battery supply cable,
alternator earth cables, alternator supply
cables, transmission black box connector,
ECM interface harness connector (30 pin RHS),
ECM power harness connector (5 pin RHS) and
ECM sensor harness connector (30 pin LHS).
Turn off ignition key switch to isolate the
batteries before disconnecting any
components.
After welding connect all of the above in the
reverse order.
The engine is equipped with Quantum Electronic Fuel
System which controls the timing and amount of fuel
injection by the electronic fuel system injectors. The
system also monitors several engine functions using
electrical sensors which send electrical signals to the
electronic control module (ECM). The ECM then
computes the incoming data and determines the
correct fuel output and timing for optimum power, fuel
economy and emissions.
The Quantum Electronic Fuel System also takes
action to prevent damage to the engine and, provides
the serviceman with diagnostic capabilities so that
problems can be corrected quickly and easily.
1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
mounted sensors that provide information
electronically, such as oil pressure and temperature
and intake manifold pressure. This information is
used to control both the quantity of fuel injected and
injection timing.
2. Programmable Read Only Memory (PROM) -
Located in the ECM and encoded with the operating
software. Additional information is programmed into
the EEPROM. This information controls the
horsepower rating, torque curve, maximum engine
speed and engine protection devices. The ECM
processes this information and sends electronic
signals to the Electronic Fuel System Injectors where
the precise amount of fuel is injected into the engine.
3. Electronic Fuel System Injectors -The injector is
a lightweight, compact unit that injects diesel fuel
directly into the combustion chamber. The amount of
fuel injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
The injector performs four functions:
a - Creates the high fuel pressure required for efficient
injection.
b - Meters and injects the exact amount of fuel
required to handle the load.
c - Atomizes the fuel for mixing with the air in the
combustion chamber.
d - Permits continuous fuel flow for component cooling.
Electronic fuel system injectors are self compensating
and virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the
injector as it will burn out. Before removing injectors,
the fuel passages must be blown out to prevent fuel
flow from entering the cylinder head.
4. Batteries - Two 12 volt maintenance free batteries
supply the machine with electrical power to operate
all electrical components.
5. Electronic Foot Pedal - The electronic foot pedal
provides an electrical signal to the engine's fuel
control system in proportion to the degree of pedal
actuation.
Note: The electronically controlled engine will override
the electronic foot pedal position until the engine is
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