Terex TR60 User manual

SM 1564 Rev 3 02-02
TR60
Off-Highway Truck
Maintenance Manual
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM750/782
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TABLE OF
CONTENTS

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 1565 12-98 1
TABLE OF CONTENTS
SectionNo. Description SM No.
000 GENERALINFORMATION
0000 TR60Off-HighwayTruck 1566
0010 WeldingProcedure 2172
100 CHASSIS
0010 Chassis,HoodandFenders 1570
110 ENGINE
0030 EngineandMounting 1571
0050 AirCleaner 1572
0130 PowerTakeoff 1573
120 TRANSMISSION
0010 TransmissionandMounting 1574
0070 Commercial Electronic Control (CEC) Shift System 1575
0090 PowerTakeoff 1178
0100 Transmission Oil Filter 1576
130 DRIVELINE
0010 FrontDriveline -Pre June1998 Production 1180
0010 FrontDriveline- FromJune1998Production 1577
0020 RearDriveline-PreJune1998Production 1181
0020 RearDriveline-FromJune1998Production 1578
140 FRONTAXLE
0040 Wheel,Rim andTyre 1579
160 REARAXLE
0020 Differential 1580
0030 AxleGroup 1184
0050 Wheel,Rim andTyre 1582
165 BRAKEPARTS
0020 Brake Parts - Front Axle 1186
` 0030 Brake Parts - Rear Axle 1583
180 SUSPENSION SYSTEM
0030 Ride Cylinder - Front 1584
0050 RideCylinder-Rear 1189
190 CIRCUITDIAGRAMS
0000 CircuitDiagrams 1585
0270 SwitchesandSensors 1586
200 FUEL SYSTEM
0010 FuelTankandMounting 1587
0040 FuelLines 1195
0051 Electronic Foot Pedal 1196
210 COOLINGSYSTEM
0000 CoolingSystem 1197
0040 Radiator,HeaderTankandMounting 1588
0050 Disc Brake Oil Cooler 1589
0060 TransmissionOilCooler 1590

SM 1565 Rev 3 02-02
2
* * * *
TABLE OF CONTENTS
SectionNo. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1591
0040 SteeringandBrakeControlTank 1592
0050 SteeringPump 1204
0080 Accumulator 1205
0090 SteeringValve 1206Rev1
0110 DoubleReliefValve 1208
0120 SteeringCylinderandLinkage-PreOctober1999Production 1207Rev1
0120 SteeringCylinderandLinkage-FromOctober1999Production 1908
0130 AccumulatorValve 1209
0150 SteeringFilter 1593
230 BODY SYSTEM
0000 Body System Schematic 1594Rev 2
0040 Body and Disc Brake Cooling Tank 1595
0050 TandemPump 1213
0060 BodyControl Valve 1596Rev1
0081 Body Control Joystick 1597
0090 Kick-over Valve 1218
0120 Relief Valve 1598
0121 Pilot Supply Valve 1599
0130 BodyCylinder 1221
250 BRAKINGSYSTEM
0000 Braking System Schematic 1222Rev 1
0050 BrakeManifoldValve 1223
0060 Accumulator 1600
0070 TreadleValve 1225 Rev1
0090 DirectionalControlValve 1226
0100 MonoblockBrakeValve 1227 Rev2
0110 PressureReducingValve(Optional) 1820
0130 RetarderControlValve 1601Rev1
0140 Shuttle Valve 1229
260 OPERATORSCOMPARTMENT
0010 CabandMounting 1602 Rev1
0090 DriverSeatandMounting 1901
0110 PassengerSeat andMounting -Pre January2000 Production 1603
0110 PassengerSeatandMounting-FromJanuary2000Production 1902
0130 AirConditioningandMounting 1620 Rev1
270 BODY
0010 BodyandMounting 1604
300 MISCELLANEOUS
0020 LubricationSystem 1605Rev 1
0070 Service Tools 1237Rev 1
0080 StandardBolt and NutTorqueSpecifications 1238
0090 UnitStorage 1239

Section 000-0000
1
SM 1566 12-98
GENERAL INFORMATION -TR60 Off-Highway Truck
SM - 1957
ENGINE
Make/Model .................................... Cummins QSK19-C650
Type .................... 4 Cycle, Turbocharged/Low Temperature
Aftercooled. Electronic Management
Gross Power 1 500 through 2 100 rev/min............... 485 kW
(650 hp, 659 PS)
Net Power 1 500 through 2 100 rev/min .................. 462 kW
(620 hp, 628 PS)
Note: Power ratings to SAE J1995 Jun 95. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
EU NRMM (non-road mobile machinery directive).
Maximum Torque .............................. 3 084 Nm (2 275 lbf ft)
at 1 300 through 1 500 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 ............................. 2 350 rev/min
Idle Speed....................................................... Self Adjusting
Safe Operating Angle .................................. 30°/60% Grade
TRANSMISSION
Make/Model .............................................. Allison M6600AR
automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral TC 682 torque
converter and planetary gearing. Six speeds forward, two
reverse. Automatic converter lockup action in all speed
ranges. With body up, gear range is limited to 1st forward
only. Downshift inhibitor. Intregal hydraulic retarder.
Fig. 1 - Machine Dimensions
Dimensions in mm (ft-in)
2 360 (7-9) 4 170 (13-8) 2 600 (8-6)
9 130 (29-11)
580 (1-11)
15˚ 3 680
(12-1)
8 050
(26-5)
5 050
(16-7)
6 000
(19-8)
7 750
(25-5)
58˚
3 970
(13-0)
500
(1-8)
Vehicle Clearance Diameter (SAE) 21 m (68-10)
3 950
(12-11)
4 270
(14-0)
4 470
(14-8)
Max
Body
Depth1 425
(4-8)
1 380
(4-6)
950
(3-1) 600
(2-0)
2 900 (9-6)
4 450 (14-7)
Optional
Spillguard
4 980 (16-4)
4 630 (15-2)
4 820
(15-10)
4 440
(14-7)
660
(2-2)
2 580 (8-5)
3 320 (10-11)
4 060 (13-4)
Speeds With 24.00 R 35 Tyres
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 9.5 14.2 18.9 28.2 38.1 57.0
mile/h 5.9 8.8 11.8 17.5 23.7 35.5
Reverse
Gear 1 2
Ratio 5.12 3.46
km/h 7.4 11.0
mile/h 4.6 6.8

Section 000-0000
General Information - TR60 Off HighwayTruck
SM 1566 12-98
2
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios:
Differential................................................................... 3.73:1
Planetary..................................................................... 5.80:1
Total Reduction......................................................... 21.63:1
SUSPENSION
Front: 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.
Maximum Strut Stroke
Front ......................................................... 251 mm (9.9 in)
Rear .......................................................... 182 mm (7.2 in)
Maximum Rear Axle Oscillation..................... ± 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 17 in
Standard Tyres (Front & Rear) ..............24.00 R 35** 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
compensating pump provides hydraulic pressure for brakes
and steering. Independent circuits front and rear. Each
circuit incorporates a nitrogen accumulator which stores
energy to provide consistent braking response.
Front Brake Circuit Pressure ............. 159 bar (2 300 lbf/in²)
Rear Brake Circuit Pressure ....................52 bar (750 lbf/in²)
Accumulators:
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Front:
Type..............................Dry Disc with 1 calliper per wheel
Disc Diameter ............................................710 mm (28 in)
Pad Area, Total.................................... 1 395 cm²(216 in²)
Rear:
Type...............................Oil cooled, multiple friction discs,
completely sealed from dirt and water.
Braking Surface, Total ....................47 151 cm² (7 308 in²)
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. 510 kW (685 hp)
continuous.
Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes. Automatically applies when engine is switched off.
Parking brake applies should system pressure fall below a
predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
STEERING SYSTEM
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 meets 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 (3.70 US gal)
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Steering Angle (Left and Right) .......................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min....... 1.4 litres/s (22 US gal/min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the 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................................................ 16 Seconds
Body Lower Time ............................................... 14 Seconds
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

Section 000-0000
3
SM 1566 12-98
General Information - TR60 Off-HighwayTruck
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body is exhaust heated and rests on
resilient impact absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasion resistant steel. Yield strength of plates 1 000 MPa
(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)............................................... 26 m³ (34 yd³)
Heaped 2:1 (SAE) ...................................... 35 m³ (46 yd³)
SERVICE CAPACITIES
Engine Crankcase and Filters............ 66 litres (17.5 US gal)
Transmission and Filters.................... 85 litres (22.5 US gal)
Cooling System ................................ 157 litres (41.5 US gal)
Fuel Tank .......................................... 606 litres (160 US gal)
Steering Hydraulic Tank ....................... 61 litres (16 US gal)
Steering System.................................... 72 litres (19 US gal)
Body and Brake Cooling Tank ............ 216 litres (57 US gal)
Body and Brake Cooling System ........ 258 litres (68 US gal)
Planetaries (Total) ............................. 43 litres (11.4 US gal)
Differential.......................................... 52 litres (13.7 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)............................................ 79 dbA
*Exterior Sound Rating (SAE J88 JUN 86)................ 89 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 30 600 67 460
Body, standard 10 650 23 480
Net Weight 41 250 90 940
PAYLOAD, maximum 54 430 120 000
Maximum Gross Weight* 95 680 210 940
FOR UNIT EQIPPED WITH OPTIONAL HARD ROCK
BODY:
Chassis, with hoists 30 600 67 460
Body, with wear plates 13 200 29 100
Net Weight 43 800 96 560
PAYLOAD, maximum 51 880 114 380
Maximum Gross Weight* 95 680 210 940
* Maximum permissable gross vehicle weight with options,
attachments, full 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 personalinjury 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 personalinjury 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

Chassis - Chassis, Hood and Fenders
Section100-0010
2SM 1570 12-98
SM-1958MAINTENANCE
Inspection
Inspect the frame and attached parts at intervals not
exceeding250 hours for crackedorbroken welds and
bending/twisting of the frame. Any defects found
shouldberepairedbeforetheyprogressintomajor
failures.Contactyourdealerforrecommendedweld
andrepairinstructions.
Welding
Note: It is important that the electrical connections are
disconnectedinthefollowingordertoprevent damage
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
metalsproduceodourless fumeswhichare
toxic.Recommendedindustrialhygiene
practiceforprotectionof the weldingoperator
from the cadmium fumes and metallic oxides
requiresenclosureventilationspecifically
designedforthe weldingprocess.A respiratory
protectivedevicesuchasthe M.S.A. 'Gasfoe'
respirator with G.M.A. cartridge will provide
protectionagainstcadmium, fumesand
metallicoxides.The'Gasfoe'respiratorhas
been approved by the U.S. Bureau of Mines:
Approvalnumber
23B-10,andis designed toprotectagainst
gases,vapours, and/ormetal fumes.
Electric arc welding is recommended for all chassis
welding. Since the nature and extent of damage to the
framecannotbepredetermined,nodefiniterepair
procedurecanbe established. Asageneral rule
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, heatingor dressing surfaces
previouslypaintedusingpolyurethanepaint
producesfumeswhich aretoxic.Surfaces must
be prepared using paint stripper prior to area
beingreworked.RecommendedIndustrial
Hygiene and Safety Rules should be be
followedfor protectionof thewelding 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
paintingofabrasions and otherexposedmetal areas on
theframeis 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

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 -MirrorWide Angle
24 - Nut
25 - Washer
26 - Bolt
27 - Bolt
28 - Bolt
29 -Mudguard
30 -Mudguard
31 - Bolt
32 - Bolt
33 - FenderExtensionRH
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

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

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 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

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.
* * * *