36630-89E02 Suzuki REMOCON WIRE HARNESS

Introduction to Torque
"Torque" is measured in terms of force and distance. Force is the amount of pushing or pulling applied at the end of the lever. Distance is the length of the lever that is being used. Torque values are given in the following units: NEWTON meters (N m), pound inches (lb in), and pound feet (lb ft)This manual is intended to provide the operator with a reference. This manual will provide the standard torque settings for the following: bolts, nuts, plugs, fittings, and clamps.Exceptions to these torques are given in the Service Manual, if necessary.Be sure to use a torque wrench that has the proper range. Torque wrenches must be used properly in order to ensure that the correct torque is applied. Always use a smooth pull for torque wrenches. Do not jerk a torque wrench. Do not use adapters that change the length of the torque wrench. For the correct use of your torque wrench, refer to the instructions that were packaged with your torque wrench. For more information on the correct use of torque wrenches, refer to Special Publication, SEBV0516, "An Introduction to Torque". This publication is available on the Caterpillar Media Information Center (CMIC) and through the normal literature distribution system at your local Cat ® dealer.Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean reused fasteners with a noncorrosive cleaner. Lightly lubricate the threads of reused fasteners. Lightly lubricate the mating surface of the head of reused fasteners. Other applications for lubricating fasteners may also be specified in the Service Manual. The Service Manual may also specify the use of sealants and compounds.Note: Do not use sealants that are not specified in the Service Manual. Do not use compounds that are not specified in the Service Manual. Clean old compound from the bolt and from the hole before installation.Torque-Turn
The torque-turn method is used when precise control over clamping force is required. There is an initial torque and an additional turn. The initial torque is required to bring all parts of the joint into contact. The additional turn provides the desired clamping force. Ensure that all fasteners have been torqued before you perform the additional turns. Turn the fastener according to the specified amount. The specified amount will normally be equal to or greater than 90°. The specified amount will normally be in 30° increments. Turns of 120° or 180° are preferred. Turns of 120° or 180° are easily measured by the points of the hex head of the fastener. Lubrication may be specified in order to reduce the effort that is required for the final turn. The use of the torque-turn method will allow the following:
Increase the life of the fastener.
Maximize the potential clamping force of a fastener.Typical applications are the following:
Track bolts
Sprocket bolts
Connecting rod bolts
Engine Cylinder Heads
Drive Shaft boltsNote: Too much tension on the bolt will cause the bolt to be stretched beyond the point of yield. The bolt will be permanently stretched. The bolt will loosen the grip on the parts that are being fastened. If the bolt is tightened again, the bolt will break. Do not reuse bolts that have been permanently stretched.Torque Sequence
Unless the bolt tightening sequence is specified by the Service Manual, the fasteners should be tightened in a cross pattern. Use Step 1 through Step 5 unless the tightening sequence is specified:
Hand tighten all fasteners. Larger fasteners may require the use of a small hand wrench.
Torque all fasteners to 40% of full torque.
Torque all fasteners to 70% of full torque.
Torque all fasteners to full torque by using a cross pattern. Large flanges may require additional passes.
Apply at least one final full torque to all fasteners in a clockwise direction until all torque is uniform. Large flanges may require additional passes.Note: Final torque may be a turn.Torque Marking (Best Practices)
Basic Process
Torque all bolts in the joint to a low torque or a snug torque.
Illustration 1 g06223465
Mark bolt head corner to abutment.
Tighten bolt to specified torque.
Illustration 2 g06223468
Verify that the lines are broken.Circular Process
Torque all bolts in the joint to a low torque or a snug torque.
Illustration 3 g06223470
Mark bolt heads in a circular pattern.
Tighten bolt to specified torque.
Illustration 4 g06223472
Verify that the lines are no longer in a circular pattern.Torque-Turn
Torque-Turn applies to fasteners that need turned to a set angle after the initial torque is applied.
Torque the fastener to the initial torque.
Illustration 5 g06241021
Example of 120° torque angle
Mark a line on the fastener and on the abutment.
Mark another line in a different color at the required angle on the abutment.
Turn the fastener to the appropriate torque angle.Note: Marking the socket and aligning the mark on the socket with the original starting mark can aide in turning the fastener to the correct angle.
Illustration 6 g06241028
Example of 120° torque angle
Verify the mark on the fastener is in-line with the torque angle mark.