technologies orporation - TUG Technologies Corp.

TECHNOLOGIES
ORPORATION
SERVICE BULLETIN 660-592K
INSTRUCTIONS:
REPLACE INDIRECT HAND THROTTLE ACTUATION SYSTEM
WITH DIRECT PUSH-PULL CABLE SYSTEM ON PERKINS
EQUIPPED 660
EFFECTIVITY:
MODEL 660-23 EQUIPPED WITH PERKINS ENGINE AND
VERNIER HAND THROTTLE OPTION
CONTENTS
PAGE
PURPOSE..................................................................................................... 2
PARTS LIST ................................................................................................ 2
SCOPE OF WORK ..................................................................................... 3
INSTRUCTIONS .................................................................................... 3-16
Sean Davis,
January, 2012
1
Purpose: Instructions on changing 660-23 hand operated throttle to
direct throttle actuation. Original configuration actuated the throttle
indirectly through the accelerator pedal, which placed excessive stress
on the cable and Vernier adjustment mechanism.
Labor requirements: 1.5 Hour
Parts List:
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Number
TP-10541
TP-10542
TP-10537
TP-10565
TP-10538
TP-10564
TP-10563
TP-10562
12871041
T6-9011-928
A8006-838C
A8006-619C
TP-10566
-----------
Description
Bracket, Throttle Extension
Bracket, Cable
Bracket, Accel Throttle
Bracket, Return Spring
Bracket, Hand Throttle
Hardware, Washer, Shim, PTFE
Hardware, Jet Nut, 10-32
Return Spring, 2 in, .625 Dia
Pin, Cotter, 1/16 X 0.5
Accelerator Pin
Bolt, Hex Head, M8 X 1.25 X 25 HHCS
Washer, Lock, M8 LW
Cable,Vernier/Bulkhead 120 inch length
P-Clamps, for 0.25 OD cable
Quantity
1
1
1
1
1
8
3
1
2
2
2
2
1
6
See Figure 1 for exploded view showing parts, used for modification. Throttle body lever
(A) and pivot ball (B) are already present on 660
Figure 1.
2
Scope of Work:
A.
B.
C.
D.
Preparation: Safety Procedures
Unit Parking
Instructions
Preparation for use
WARNING: READ AND UNDERSTAND ALL INSTRUCTIONS
BEFORE BEGINNING PROCEDURE!
INSTRUCTIONS:
A. Preparation: Safety Procedures:
1. Observe all safety requirements for tool usage and OSHA facility
guidelines.
B. Unit Parking:
1. Park the 660 on level ground. Turn the ignition key off, apply
parking brake, and chock tires.
2. Disconnect the battery.
C. Instructions:
Vernier Throttle Cable Removal Instructions
1. Remove the four nuts, bolts, and washers securing the gold colored
pedal mount (See Fig. 2) to the pedal mount bracket. Save the
washers, spacers, and bolts as they will be reused. The nuts can be
discarded.
REMOVE THESE
BOLTS AND NUTS
TO REMOVE THE
CONTROL CABLE
Figure 1. Throttle pedal bracket assembly
3
2. Remove the two nuts and bolts securing the cable to the pedal
mount as shown in Figure 2. Remove the spring clip securing the
cable pin to the pedal arm as shown in Figure 3. The cable should
now be free from the accelerator pedal.
SPRING CLIP
CABLE PIN
Figure 2. Throttle pedal spring assembly
3. Reinstall the accelerator pedal using the original bolts, washers, and
spacers as they were installed previously. Use the supplied new hex
head nuts to secure them.
4. Now that the control cable is free from the accelerator pedal it
needs to be freed all the way back to the Vernier control handle.
This will mean cutting several cable ties and carefully working the
cable out of the inner fenders. Once the control cable is all the way
out, be sure to install new ties over the harnesses/hoses where they
were cut.
Vernier Adjuster Removal
The Vernier throttle adjuster is located on the left rear of the
vehicle, adjacent to the conveyor.
1. Remove the adjuster knob by depressing the button on
the knob and completely removing the adjusting shaft
as shown in Figures 4 and 5.
4
Release Button
Figure 3.
Vernier
Control Shaft
Figure 4. Vernier control shaft extracted from head unit.
2. Once the adjuster knob/shaft has been extracted, the junction
between the adjuster and cable will be revealed. This junction is
shown in Figure 6 below.
Take note of how this arrangement is attached and set
the adjuster knob aside on a clean work bench.
Inspect the coupling on the adjusting knob for
excessive wear. A loose fit where the adjusting knob
couples with the cable will lead to failure.
Additionally, if the adjusting knob is loose on the new
cable, premature wear on the new cable will result.
5
Plastic Cover
Cable Coupling
Figure 5. Cable-Control handle coupling
3. Remove the black plastic cover that says “RELEASE HOLD” by
unscrewing it in a counter clockwise direction. This will reveal the
rubber grommet bulkhead jam nut shown in Figure 7.
4. Remove the grommet and jam nut (See Figure 7), and place the
hardware on a clean workbench.
Bulkhead Jam
Nut
Grommet
Figure 6. Vernier head unit.
6
5. Now that the bulkhead jam nut has been removed, the remainder of
the Vernier adjuster mechanism and the attached cable may be
extracted from the vehicle. Remove the nut from chasis as shown in
Figure 8. The Vernier adjuster will now be completely free as
shown in Figure 9. Set it aside on the clean workbench.
Cable
Attachment
Nut
Figure 7. Vernier head unit.
Figure 8.
7
Cable Installation
1. Starting from the left rear wheel well, feed the new control cable
(Part Number TP-10566) past the right side of the rubber mud flap
as shown in Figure 10.
Mud Flap
Control Cable
Figure 9. Cable routed behind rubber mud flap adjacent to inner left rear wheel well.
2. Route the control cable through the large frame hole just in front of
the left rear rubber mud flap as shown in Figures 11 and 12.
Control Cable
Chassis Hole
Mud Flap
Figure 10. Control cable passing through large chassis hole.
8
Control Cable
Chassis Hole
Figure 11. Inboard view of control cable passing through large chassis hole
3. Secure the end of the cable near the engine in preparation for
control bracket assembly (covered in detail later in the report).
4. Prepare the Vernier adjuster assembly for re-installation by cleaning
with solvent. Clean and grease the shaft of the control knob.
5. The replacement cable is of a push-pull variety and has limited
travel. Therefore the re-installation of the Vernier control head will
be slightly different than the removal process.
6. Install one bulkhead jam nut onto the Vernier control head.
7. Replace the rubber grommet and black plastic knob onto the
Vernier control head. Do not tighten the plastic knob at this point.
8. Install the Control knob/shaft into the Vernier head by pressing the
control knob button and inserting the control knob shaft into the
bore of the Vernier unit. Insert the shaft until it is fully seated in the
Vernier mechanism. You should be able to see the cable coupling
protruding from the Vernier control head unit.
9. Install the Vernier control head onto the vehicle in its original
location on the left rear of the vehicle.
10. Reinstall and tighten the remaining bulkhead jam nut and locking
washer onto the other side of the Vernier control head from the
fender well side of the body of the vehicle.
11. Apply some grease to the cable coupling on the Vernier control
head.
12. Attach the cable to the cable coupling, and tighten the nut as shown
in Figure 13.
9
Figure 12. Cable attachment to Vernier head unit.
13. Now that the Vernier control head has been reinstalled, the control
cable may now be secured to the chassis of the vehicle. Utilize zip
ties and/or p-clamps where possible to secure the cable to the
chassis.
Follow these guidelines to properly secure the cable to the
chassis of the vehicle.
•
As a general rule, route the cable as straight as
possible. The fewer bends in the cable there are,
the smoother the cable operation will be.
•
If a turn in the routing is necessary, ensure that
the turn is as gradual as possible. Do not allow a
bend radius of less than 8 inches.
•
Secure the cable at regular intervals with supplied
p clamps and/or zip ties (See Fig. 14).
•
Avoid allowing the cable to contact sharp metal
parts (e.g. Bolt heads, hose clamps, sharp metal
transitions in the vehicle frame, etc.)
10
Attach Cable with Zip Ties
Figure 13. Cable routing.
Throttle assembly removal
1. Refer to Figure 15. Loosen the lock nuts securing the pivot ball cable
attachments to the existing control cables.
2. Loosen the bulkhead lock nuts
3. Remove the existing throttle bracket. Keep attachment hardware, as
it will be reused.
4. Remove the pivot ball cable attachments from the pivot balls.
5. Remove pivot balls by loosening the pivot ball nuts. Retain pivot
balls for later use.
6. Remove the pivot ball cable attachment from the accelerator cable.
Leave the pivot ball cable attachment in place on the transmission
modulator cable.
Figure 14. Original accelerator cable and transmission modulator cable arrangement.
11
Throttle assembly replacement
Figure 15. Exploded view of new throttle bracket assembly.
1. Refer to Figure 16. Attach throttle lever extension (Part Number
TP-10541) to throttle body lever using the preexisting pivot ball and
the supplied accelerator pin (Part Number T6-9011-928) for
fastening. Use supplied 10-32 jet nuts (Part Number TP-10563) to
secure the pivot ball and accelerator pin.
Note that jet nuts are considered an interference
fit fastener. Be careful to avoid cross-threading the
fasteners. Once the jet nut has been started, use a
wrench to fully tighten the nut.
2. Attach the second accelerator pin to the end of the throttle extension
bracket, again using a supplied jet nut.
3. Attach the assist spring (Part Number TP-10562) to the spring
bracket (Part Number TP-10565), and then attach the other end of
the spring to the throttle extension bracket using the pre-drilled
hole.
12
4. Using the supplied M8 cap screws (Part Number A8006-838C) and
lock washers (Part Number A8006-619C), attach the return spring
bracket to the cylinder head in the location indicated in Figure 17.
Spring Bracket
Throttle Extension Bracket
Accel. Yoke
Hand Throttle Yoke
Cable Bracket
Figure 16. Assembled view of new cable bracket assembly.
5. Now that the throttle extension arm and return spring/brackets are
installed, it is time to attach the control cables and various
remaining brackets. Loosen the cable lock nuts to ease installation
of the cable bracket later on.
6. Install the pivot ball cable attachment on the transmission
modulator cable onto the pivot ball on the throttle body lever.
7. Using 10-32 jam nuts, lock washer (one side only), and flat
washers, loosely install the accelerator yoke (Part Number TP10537) onto the accelerator control cable, approximately in the
middle of the threaded adjustment range.
8. Refer to Figure 18 below. Typically, three PTFE shim washers (Part
Number TP-10564) are required for each yoke. Install one shim
washer in between the accelerator pin and the accelerator yoke.
Install two additional shim washers onto the accelerator pin, and
insert a 1/16” X 0.5” zinc plated cotter pin (Part Number 12871041)
to secure the washer and yoke to the accelerator pin. Note the play
between the accelerator yoke and the shim washers. There should
be sufficient clearance to allow ease of movement without
13
excessive play. Excessive play will lead to premature wear of the
shim washers and possible binding.
9. Using a feeler gage, Ensure that clearance is between 0.01” and
0.05”. If clearance is in excess of 0.05”, use additional shims to
tighten the clearance.
10. Install cable bracket (Part Number TP-10542). While installing the
bracket, guide the accelerator and transmission modulator cables
into their respective locations on the bracket and hand tighten the
bulkhead jam nuts.
Be careful not to damage the plastic fuel lines that
run in close-proximity to the bulkhead jam nuts.
11. Re-use pre-existing ¼-20 hardware (three screws) to attach the
bracket to the engine.
Note that here may have been a stack of washers in between the
old bracket and where it mounted on the engine. Do not re-use
these washers.
.
Cotter Key
PTFE Shims
Figure 17. View of shim stack on new throttle yokes.
12. Using 11/16” pump wrenches, tighten the bulkhead jam nuts to
secure the accelerator and transmission modulator cable to the cable
bracket.
13. Adjust the accelerator yoke such that there is minimal slack
between the accelerator pin and the yoke when the throttle is fully
closed. Secure the jam nuts using two 3/8” open end wrenches.
14
14. Similarly adjust the transmission modulator cable so that there is
little or no slack in the cable when the throttle is closed. If
adjustment is required, it may be done by loosening/tightening the
pivot pin attachment on the cable.
15. Using two 10-32 jam nuts, two flat washers, and one lock washer,
loosely attach the hand throttle yoke (shown in Figure 19) onto the
end of the Vernier control cable.
16. Attach the Vernier control cable (Part number TP-10566) onto the
cable bracket, and hand-tighten the bulkhead jam nuts.
17. Follow the same procedure outlined in steps 8 and 9 above to install
the hand throttle yoke (Part number TP-10538) onto its associated
accelerator pin.
18. With the hand throttle yoke installed onto the accelerator pin, adjust
the bulkhead jam nuts on the control cable such that there is some
slack between the yoke and accelerator pin.
19. Adjust the accelerator yoke such that there is minimal slack
between the accelerator pin and the yoke when the throttle is fully
closed. Secure the jam nuts using two 3/8” open end wrenches
.
Figure 18. Assembly view of hand throttle bracket arrangement.
20. Installation of the Vernier control cable and associated brackets and
hardware is now complete. With the assistance of a helper, observe
the motion of the throttle linkage and ensure that there is no binding
when the accelerator is fully or partially depressed. Repeat for the
Vernier hand throttle.
15
21. All control cables should be adjusted so that there is 0.050-0.100
inches of play at the yokes when the controls (both accelerator
pedal and hand throttle) are fully closed.
D. Preparation for use:
1. Re-connect the battery.
2. Start the unit and let the unit reach proper operating temperatures.
3. Fully actuate both the accelerator and Vernier hand throttles. Ensure
that throttle does not bind, and that throttle lever on the engine
returns to the idle position when both throttles are released.
4. Check that shifter is locked when either accelerator pedal or hand
throttle are actuated and engine is more than 100 rpm above idle.
5. If steps 3 and 4 above are successful, return the tractor to service.
6. If problems persist, contact Tug Warranty
E-Mail: [email protected]
Phone: 1-800-989-8499
16