KING PIN KIT T KING PIN KIT. Contents

Size: px

Start display at page:

Download "KING PIN KIT T KING PIN KIT. Contents"

Loraine Owens
5 years ago
Views:

1 Contents Important Information 1 Contents 3 Installation Guide 4 Torque Table CPS 8 Torque Table CPS Terex Warranty System 12 T Issue 1 - FEB 2011

2 Important: Familiarise yourself with the instructions prior to fitting the kit. Refer to the Operators Manual and Maintenance Manual for safety procedures and general working practices. Ensure that only qualified engineers/operators install this kit. Failure to do so could result in physical injury or death. NOTE: When instructed, torque metric threaded fasteners according to CPS 8 (Page ). When instructed, torque hydraulic fittings in according to CPS 807 (Page 11). Page 1

3 King Pin Kit - T Page 2

4 Ref. Part No Description Quantity 1 Swivel Housing 2 Screws 3 Upper King Pin 4 Belleville Washer 5 Bush 6 Axle housing 7 Belleville Washer 8 Lower King Pin 9 Seal Upper King Pin (Kit) 11 Grease Nipple (Kit) 12 Shims (Kit) 13 Belleville Washwer(Kit) 14 Sperical bearing (Kit) 15 Sperical bearing Bush (Kit) 16 Spacer (Kit) Page 3

5 Installation Warning: To drain and fill the oil and to check the oil level, the axle must be placed horizontal. 1. Drain the axle oil, by removing the level plug (A) and drain plug (B). 2. Clean the level plug (A) and drain plug (B) and tighten to 60 Nm (44.3 Ib.ft). Warning: Before removing the upper king pin (3) and lower king pin (8), secure the swivel housing (1) with a belt or a rope to a hoist or any other supporting device. Warning: Observe all current safety regulations to guarantee operator s safety. 3. Undo and remove the retaining screws (2) from upper and lower king pins. 4. Remove the upper king pin (3) and lower king pin (8). NOTE: The king pin (3) needs to be replaced with king pin () from the recovery kit. Page 4

6 5. Support and remove the wheel end and half-shaft group from the axle. 6. Recover the belleville washer (7). Remove and replace the belleville washer (4) with the belleville washer (13) (from the recovery kit). Note: The bush (5) must be replaced with the bearing cup (15) (from the recovery kit). 7. Using a suitable extractor, remove the bush (5) from the king pin housing. Page 5

7 8. Install the spacer (16) (from the recovery kit) into the upper king pin seat. 9. Using the special tool CA and a hammer, install the bearing cup (15) (from the recovery kit) into the upper king pin seat.. Fill the upper and lower king pin housings with excess grease (POLIMER 400). Warning: Secure the wheel end group with a belt or a rope to a hoist or any other supporting device. Warning: Observe all current safety regulations to guarantee operator s safety. Warning: Be careful not to damage the seal ring (9). 11. Install the Belleville washer (13) (from the recovery kit) on the upper king pin seat. 12. Install the Belleville washer (7) on the lower king pin seat. Page 6

8 13. Support and install the wheel end/halfshaft group to the axle. Note: Make sure that the bellivelle washers (7) and (13) are in their respective positions. 14. Install the lower king pin (8) and secure it with retaining screws (2). Tighten the retaining screws (2) to 190 Nm (140.1 Ib.ft). 15. Install the shim of thickness "U" between the Upper king pin () from the recovery kit) and the swivel housing (1) to obtain a minimum backlash value "Z" to be measured with a comparator. 16. Install the upper king pin () ( from the recovery kit), and the shims of thickness U. Screw-in the retaining screws (2) without tightening them to allow the adjustment operations. Page 7

9 17. Position the magnetic base comparator (C) with the base resting on the axle and with the feeler on the surface of the upper king pin (). 18. Insert a lever (D) between the axle beam and the swivel housing (1) and move the lever (D) alternately in vertical direction and read the value of the backlash "Z" measure on the comparator. 19. Unscrew the retaining screws (2) and remove the upper king pin (). Note: Make sure the Belleville washer (13) remains on the king pin seat. 20. Based on the measured backlash value Z, calculate the shim thickness "W" to be installed between the upper king pin () and the swivel housing (1) by using the following formula: Shim thickness, W = [U-Z-(0.1 to 0.2)] mm Where: 0.1 to 0.2 = Bearings preload. U = Shim thickness installed during backlash measurement. Z = Backlash measured. Page 8

10 21. Select the shims (12) of appropriate thickness 'W' from the range of available shims. Refer to the Table 1. Table 1: Shim Thickness SHIMS RANGE Thickness - mm Quantity Install the shim/ shims (12) of the calculated thickness 'W' between the upper king pin () and the swivel housing (1). 23. Install the retaining screws (2) and tighten to 190 Nm (140.1 Ib.ft). 24. Install the upper king pin retaining screws (2) and tighten to 190 Nm (140.1 Ib.ft). 25. Install the grease nipple (11) ( from recovery kit) on upper king pin () and tighten to 8 Nm (5.9 Ib.ft). Warning: To drain and fill the oil and to check the oil level the axle must be placed horizontal. 26. Remove the level plug (A). Fill the axle with API GL4 oil, until the oil level reaches the bottom of the level plug hole. 27. Wait to allow the oil flow through the axle and check the oil level. If necessary fill to the specified level. 28. Install the level plug (A) and tighten to 60 Nm (44.3 Ib.ft). Page 9

11 TORQUE VALUES FOR METRIC FASTENERS CPS A B TV0488 Nominal Size M3 STRENGTH CLASS ISO 4.6 (SAE 1, BS B) Min Tensile Stress Rm = 400 MPa STRENGTH CLASS ISO 8.8 (SAE 1, BS S) Min Tensile Stress Rm = 830 MPa STRENGTH CLASS ISO.9 (SAE 1, BS V) Min Tensile Stress Rm = 40 MPa Torque Nm Torque Nm Torque Nm Nom Max Min Nom Max Min Nom Max Min M M M M M M M M M M M Page

12 INSTALLATION TORQUE FOR STRAIGHT STEEL FITTINGS, CPS 807 Nominal Tube O/D mm 4 Nominal Tube O/D in 1/8 Thread Size Thread Size Torque lbf.ft mm in Nom Max Min M8 x 1.0 5/16-24 UNF /16 M x 1.0 3/8-24 UNF /4 M12 x 1.5 7/16-20 UNF /16 M14 x 1.5 1/2-20 UNF /8 M16 x 1.5 9/16-18 UNF /2 M18 x 1.5 3/4-16 UNF /8 M22 x 1.5 7/8-14 UNF /4 M27 x /16-12 UN M33 x /16-12 UN /4 M42 x /16-12 UN /2 M50 x /8-12 UN M60 x /2-12 UN INSTALLATION TORQUE FOR DRYSEAL PIPE (NPTF OR EQUIVALENT) STEEL FITTINGS, CPS 807 Nominal Pipe Size Nm Torque Lbf.ft In Nom Max Min* Nom Max Min* 1/ / / / / / Page 11

13 Terex Waranty System: Enter machine serial in search box and select the serial # button Page 12

14 Select with the mouse anywhere on this line to open the machine detail screen Page 13

15 Open the machine file Page 14

16 Check the front axle serial number is correct; if not take a photo of the serial plate and tcewarranty@terex.com and we will correct the record. Page 15

17 Select warranty registration and complete details as per normal process then select the next button. Page 16

18 Add text to the dealer notes page stating the Front Axle accessory kit has been fitted and the date of fitting. Then select the submit button. Page 17

Basics of Service DROP BOX DROP BOX FT 60, 70 & INTRODUCTION

Basics of Service DROP BOX DROP BOX FT 60, 70 & INTRODUCTION DROP BOX FT 60, 70 & 80 1. INTRODUCTION Purpose of this drop box is to transmit the power from gear box to four wheel drive. It can be called Transfer box also and it takes drive from the drive pinion