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TUG M3 Operation And Service Manual

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Summary of Contents for TUG M3

  • Page 1 Overhaul...

  • Page 2: Table Of Contents

    CHAPTER 3 TABLE OF CONTENTS CHAPTER/SECTION PAGE OVERHAUL RECOMMENDED OVERHAUL PERIODS 3 - 1 GENERAL ............................. 1 HYDRAULIC PUMP ........................1 DISC BRAKE CALIPERS......................1 BRAKE BOOSTER PUMP ......................1 MASTER CYLINDER ........................1 PLANETARY REDUCTION HUBS ....................1 STEER AXLE 3 - 2 DISCUSSION ..........................
  • Page 3 MASTER CYLINDER DISASSEMBLY AND ASSEMBLY 3 - 4 BLEEDING THE MASTER CYLINDER ..................3 MASTER CYLINDER INSTALLATION ..................3 FOUR WHEEL DISC BRAKES 3 - 5 BRAKE PAD REPLACEMENT ...................... 1 Preparation: .......................... 1 Rear Caliper Removal ......................1 Brake Pad Removal ......................2 Cleaning and inspection: ......................

  • Page 4: Recommended Overhaul Periods

    Recommended Overhaul Periods GENERAL The following overhaul periods are approximate and can vary greatly due to different operating conditions. Units operating in extreme conditions such as high or low temperatures, long periods of sustained operation, continued operation in sand or dust or continued exposure to sea air or moisture require careful, regular inspections.
  • Page 5 (This Page Intentionally Left Blank) Chapter 3: Overhaul Sept. 1995 Section 3-1 p. 2...

  • Page 6: Steer Axle

    STEER AXLE DISCUSSION If tractor has been properly lubricated and maintained and has not experienced damage to the steering system, the steering components will provide many hours of service without an over- haul. Should overhaul be required, follow the procedure below: WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED IN THE SAFETY SEC- TION OF THIS MANUAL! INSPECTION AND OVERHAUL...
  • Page 7 Note that bushings are located at the tips of the U-shape. The span between the U- tips must be bridged so that arms are not bent during pressing. Rig a secure steel bridge between the arms, or contact Tug Manufacturing regarding special tooling. Reassemble a-arm(s) but do not tighten pivot bolts.
  • Page 8 Disconnect the rod ends from the spindle arms, removing the cotter pins and retainer nuts. Remove the connecting rod and remove the rod end retainer clamps. Screw the new rod ends approximately 1/4 inch into each end of the rod. Install the connecting rod to the spindle arms, securing the connecting rod ends to the spindle arms with the two (2) retainer nuts and cotter pins.
  • Page 9 (This Page Intentionally Left Blank) Chapter 3: Overhaul Sept. 1995 Section 3-2 p. 4...

  • Page 10: Hydraulic Pump

    III. HYDRAULIC PUMP DISCUSSION Hydraulic pump should be overhauled after 5000 hours or when internal or external leakage is evident. The hydraulic pump assembly can be divided into three main components. (Refer to figure on page 2). Reservoir, pump section & motor. Disassemble and replace all worn or damaged parts.
  • Page 11 Chapter 3: Overhaul Sept. 1995 Section 3-3 p. 2...
  • Page 12 Ref. Part Description Req'd 03142 PUMP ASSEMBLY, Gear Code 62 02625 PUMP ASSEMBLY, Gear Code 51 02650 PUMP ASSEMBlY, Gear Code 43 02624 PUMP ASSEMBlY, Gear Code 42 02629 PUMP ASSEMBLY, Gear Code 05 02659 PUMP ASSEMBLY, Gear Code 03 02352 O-RING, Industrial (3-5/8 x 3-7/8 x 1/8) 00075...
  • Page 13 (This Page Intentionally Left Blank) Chapter 3: Overhaul Sept. 1995 Section 3-3 p. 4...

  • Page 14: Master Cylinder Disassembly And Assembly

    MASTER CYLINDER DISASSEMBLY AND ASSEMBLY MASTER CYLINDER REMOVAL Open Console door. Remove brake lines from cylinder body. Plug brake line ports or drain brake fluid into appropriate container. Remove (2) mounting bolts and nuts. Slide master cylinder off of push rod. When it is necessary to repair the master cylinder during the warranty period, replace the cylinder as a unit instead of overhauling the cylinder with a service repair kit.

  • Page 15: Inspection And Repair

    MASTER CYLINDER DISASSEMBLY AND ASSEMBLY DISASSEMBLY(CONT) Remove the push rod boot (if equipped), from the groove at the rear of the master cylinder, and slide the boot away from the rear of the master cylinder. Remove the snap ring holding the pistons in the cylinder body. Remove the push rod (if equipped), and primary piston assembly from the master cylinder.

  • Page 16: Bleeding The Master Cylinder

    Install the primary piston assembly in the master cylinder. Push the primary piston inward and tighten the secondary piston stop bolt to hold the secondary piston in the bore. Position the stop plate and snap ring on the primary piston. Depress the primary piston and install the snap ring in the cylinder body.
  • Page 17 (This Page Intentionally Left Blank) Chapter 3: Overhaul Sept. 1995 Section 3-4 p. 4...

  • Page 18: Four Wheel Disc Brakes

    M3 rear disk brakes. In general, the following procedures can be applied to the rear brakes as well. For specific rear brake information, refer to section E at the end of this section.

  • Page 19: Brake Pad Removal

    FOUR WHEEL DISC BRAKES BRAKE PAD REPLACEMENT Caliper Removal (cont.): NOTE: If only brake pads and linings are being replaced, omit step (d). Disconnect brake line from caliper and plug openings in caliper and line to prevent fluid loss and to keep out contamination. (See Figure 2.) Figure 2 Inspect mounting bolts for corrosion.
  • Page 20 Figure 3: Chapter 3: Overhaul Sept. 1995 Section 3-5 p. 3...

  • Page 21: Brake Pad Installation

    FOUR WHEEL DISC BRAKES BRAKE PAD REPLACEMENT (CONT.): Brake Pad Installation Using Delco Silicone Lube No. 179-651, lubricate new sleeves, new rubber bushings, and bushing grooves. Install rubber bushings in all four caliper ears. Note: It is essential that the new sleeves and rubber bushings which are included in each Delco pad kit be used, and that lubrication instructions be followed to insure proper functioning of the sliding caliper design.

  • Page 22: Check-Out

    Lubricate both ends of the mounting bolts with Delco Silicone Lube No. 179-651. Start the bolts through the sleeves in the inboard caliper ears and mounting bracket, making sure that the ends of the bolts pass under the retaining ears of the inboard pad.

  • Page 23: Caliper Overhaul

    FOUR WHEEL DISC BRAKES CALIPER OVERHAUL General Layout; Front Figure 6 Removal Chapter 3: Overhaul Sept. 1995 Section 3-5 p. 6...

  • Page 24: Disassembly

    See Pad Replacement Section. Removal of the caliper for overhaul is the same as for Pad replacement except that it will be necessary to disconnect the brake hose. Disassembly Move the caliper to a work bench for overhaul. Drain fluid from caliper. Remove pad and spring clip from end of piston.

  • Page 25: Cleaning And Inspection

    FOUR WHEEL DISC BRAKES CALIPER OVERHAUL (CONT.): Figure 8 Cleaning and Inspection Thoroughly clean all parts not in repair kit with denatured alcohol. Inspect caliper bore for scoring, nicks, corrosion or wear. Use crocus cloth to polish out any light corrosion.

  • Page 26: Installation

    Press piston assembly into caliper bore using C-clamp (See figure 9). Be careful not to unseat the seal. Position outside diameter of boot in caliper counterbore and seat with Delco tool no. J-22904. Figure 9 Installation Install caliper following instructions given in Pad and Lining Replacement Section. Bleed system.

  • Page 27: Cleaning

    FOUR WHEEL DISC BRAKES FRONT ROTOR Slide the wheel hub and rotor off the axle. Press rotor from hub. Cleaning WARNING: NO SMOKING, FIRE OR OPEN FLAME IS PERMITTED IN AREAS WHERE ALCOHOL IS BEING USED. AVOID INHALATION OF FUMES. Clean rotor with alcohol.

  • Page 28: Bleeding The Disc Brake System

    Check brake pedal for sponginess or hard pedal. Drive belt loader slowly and make several slow speed stops. Check all brake fluid line fittings and caliper areas for fluid leakage. Correct any discrepancies before returning vehicle to normal service. BLEEDING THE DISC BRAKE SYSTEM General If the caliper was removed for overhaul, or if the brake hose or steel line was disconnected for any other reason, it will be necessary to bleed all air from the...

  • Page 29: Check-Out

    FOUR WHEEL DISC BRAKES BLEEDING THE DISC BRAKE SYSTEM Pressure Bleeding (cont.): the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system. Install the special bleeding adapter to the master cylinder. Make sure that the pressure tank is at least 1/3 full of fluid. Position the tank so that its hose will easily reach the adapter on master cylinder of the vehicle being serviced, then make the air pressure connection to the tank (20 to 25 psi).

  • Page 30: Rear Caliper Assembly

    Rear Caliper Assembly See Figure 10 (below). Figure 10: Rear Caliper Exploded Assembly Chapter 3: Overhaul Sept. 1995 Section 3-5 p. 13...
  • Page 31 (This Page Intentionally Left Blank) Chapter 3: Overhaul Sept. 1995 Section 3-5 p. 14...

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