CAT Telehandler TH514 TH417 TH514C TH417C Axle Axle Disassembly/Assembly Manual

Disassembly/Assembly Manual Axle

Models TH514, TH417, TH514C, TH417C S/N TBW00100 & After S/N TBT00100 & After S/N MWC00150 & After S/N KKW00150 & After S/N RRJ00150 & After S/N RRW00150 & After 31200455 UENR6253-03 Revised July 15, 2014

EFFECTIVITY PAGE August 8, 2008 - A - Original Issue Of Manual November 5, 2012 - B - Update 2.7.2, page 2-8 January 22, 2014 - C - Update Front Cover to include TH514C & TH417C. July 15, 2014 - D - Revised Front Cover.

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a

EFFECTIVITY PAGE

b

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SECTION CONTENTS Section

Subject

Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Page

1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-1 1-1 1-2 1-2 1-3

Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommendations for Repair Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening Torques and Sealants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-3 2-3 2-4 2-5 2-7 2-11

Section 3 Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.1 3.2 3.3 3.4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change and Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grease in Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-5 3-8 3-9

Section 4 Disassembly/Assembly/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14

Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Epicyclic reduction gear group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Hub Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flange Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trunnions Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Beam Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Support Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Group Limited Slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Group - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pinion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Toe-in/steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing After Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-4 4-7 4-14 4-20 4-22 4-25 4-31 4-35 4-43 4-46 4-49 4-57 4-61

Section 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5.1 31200455

Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 i

Section

ii

Subject

Page

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Section 1 Safety Practices 1.1

INTRODUCTION

This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local Caterpillar dealer.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

Supplementary information is available from the manufacturer in the form of Service Bulletins, Service Campaigns, Service Training Schools, the service website, other literature, and through updates to the manual itself.

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1.2

DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication.

The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3

OPERATION & MAINTENANCE MANUAL

The mechanic must not operate the machine until the Operation & Maintenance Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Maintenance Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Maintenance Manual is missing, consult your local Caterpillar dealer before proceeding.

1.4

DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1-1

Safety Practices

1.5

SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.6

Following are general safety statements to consider before performing maintenance procedures on the telehandler.

Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before proceeding.

1.6.1 1.5.1

Safety Alert System and Signal Words

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

1-2

SAFETY INSTRUCTIONS

Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2

Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

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Safety Practices 1.6.3

General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

appropriate container and dispose of in accordance with prevailing environmental regulations.

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely.

Failure to follow the safety practices could result in death or serious injury.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4

Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings.

Always use matched sets according to machine specifications.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot.

Hot components and fluids can cause severe burns.

Allow systems to cool before proceeding.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection.

NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an 31200455

1.7

SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Maintenance Manual supplied with machine for information.

1-3

Safety Practices

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1-4

31200455

Section 2 General Information and Specifications 2.1

GENERAL

The machine should be checked and/or repaired only by qualified technicians, acquainted with its features and well aware of all safety instructions.

Before performing any operation, it is advisable to carry out unit cleaning accurately by removing oil/ grease encrustations and accumulation.

All disassembled mechanical parts must be cleaned accurately with suitable products to avoid possible damage. Parts should be replaced if damaged, worn out, cracked, seized, etc. as they could affect proper working.

Rotating parts (bearings, gears, shafts) and that of hardware/fasteners (O-Ring, oil seals) should be examined carefully since they are subject to major stress, wearing and ageing.

We highly advise to replace tightening parts during every teardown or repair.

If one part of the bevel gear set is replaced, the other part should be replaced also.

Use appropriate spare parts, nuts and bolts to avoid any problems. Also, use metric tools for metric nuts and bolts and Imperial tools for the others.

Some operations are destructive for removed components.

Careful reading of and a thorough understanding of these instructions will avoid damage to other components.

2.2

RECOMMENDATIONS FOR REPAIR OPERATIONS

• Do not damage the seals while assembling the shaft.

O-rings • Lubricate adequately before inserting them at the right place and avoid o-ring rolling while inserting the shaft.

Adjusting shims • Use appropriate adjusting shims and measure each one separately.

• Complete group measurement or stampings on the shims are not always a reliable: check.

Bearings • Its advisable to heat up bearings to 80°C - 90°C before assembling them onto their respective shafts or to cool them (dry ice) before inserting them into corresponding bore.

• Always use suitable extractors to remove the bearings. Before reassembling the bearings, clean, check and lubricate them.

Split pins • Before assembling elastic pins, make sure the notch is oriented towards the stressing force.

• Spiral elastic pins do not need orientation.

Sealing • Use sealing as advised by specifications. Ensure that parts to be sealed are clean, dry and completely grease free.

Oil drain

Before starting any disassembly and assembly operations, read carefully the following recommendations.

Shafts seals Respect the following recommendations during shaft seal assembly: • Clean shaft very carefully and ensure that the part in contact with the shaft seal is not damaged, cut or out of roundness.

• Assemble the seals so the lip is fitted towards the oil side.

• Lubricate seal lips (use oil) and fill 3/4 of seal cavity with grease.

• Before disassembly, oil should be drained out.

Cleaning • Wash all moving parts (gears, bearings, etc.) carefully with diesel fuel or kerosene.

• Avoid gasoline and watery alkaline solutions. Do not wash with steam or hot water, since it is difficult to eliminate surface humidity.

• Dry all parts with a rag or air jet to avoid scratching from abrasive residuals.

• All surfaces should be covered with lubricant to protect them from future oxidation.

• Use appropriate drivers. Do not use a hammer directly on the seals.

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2-1

General Information and Specifications Checks • Examine accurately all bearings, external rings which may be still stuck in their position and pivot pins on which rolls rotate. Replace those which are worn out or damaged.

2.2.1

Symbols used in disassembly/ assembly/adjustment procedures

• Gears should not be spoiled and teething should not be excessively worn out. Teeth smoothing should not be deteriorated.

• Check all grooves: assure that they are not worn out or damaged.

• Replace spoiled parts with original spare parts.

• Replace seals on rotating shafts, before reassembly.

Ends of flanges and tools • Be careful when hammering tool or flange ends, in order to avoid jeopardizing functionality and integrity of either the tools or the components on which you are operating.

Lubricant Use • In order to lubricate the manufacturer axles correctly and to reach the exact operation temperature, it is important to use the recommended lubricants (see 2.8), keeping their level constant as indicated in this manual.

2-2

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General Information and Specifications

2.3

PRODUCT IDENTIFICATION

Axle Tag

2.4

MEASUREMENTS

This manual indicates all measurements in the International System (SI). Use the conversion table shown below to convert Imperial Measurement.

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2-3

General Information and Specifications

2.5

GENERAL DESCRIPTION

The axles described in this manual consist mainly of the groups shown above.

• WHEEL HUB: wheel support parts containing the epicyclic gears

• DIFFERENTIAL SUPPORT: differential housing with ring bevel gear for adjusting system

• EPICYCLIC REDUCTION GEAR: planetary carrier with reduction/transmission parts

• DIFFERENTIAL: differential parts with ring bevel gear

• AXLE BEAM TRUMPET: load-bearing shell structure of the axle

• PINION: pinion with adjusting and supporting parts

• BRAKE: brake parts and brake shell structure, including the parking brake parts and brake support structure • STEERING CYLINDER: steering cylinder parts with adjusting system components

2-4

• PARKING BRAKE: parking brake parts and brake support structure • TRUNNIONS: trunnion parts to secure axle to the vehicle.

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General Information and Specifications

2.6

TECHNICAL FEATURES

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2-5

General Information and Specifications

2-6

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General Information and Specifications

2.7

COMPONENT SPECIFICATIONS

2.7.1

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Sensor Specifications

2-7

General Information and Specifications 2.7.2

Brake Disks Typical Data

2.7.3

Limited Slip Differential Disks Specifications

2-8

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General Information and Specifications 2.7.4

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Front Axle Main Dimensions (mm)

2-9

General Information and Specifications 2.7.5

2-10

Rear Axle Main Dimensions (mm)

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General Information and Specifications

2.8

TIGHTENING TORQUES AND SEALANTS

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2-11

General Information and Specifications

2-12

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General Information and Specifications

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2-13

General Information and Specifications

2-14

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General Information and Specifications

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2-15

General Information and Specifications

This Page Intentionally Left Blank

2-16

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Section 3 Troubleshooting and Maintenance 3.1

TROUBLESHOOTING The axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

This section provides an easy reference guide covering the most common problems that may occur during operation.

Note: Contact your Local Caterpillar Dealer if internal axle repair is required during the warranty period.

Problems

Possible Causes 1

2

3

•

•

•

•

•

•

•

•

•

•

Uneven wear of tire.

•

•

Friction noise.

•

Vibration during forward drive,

•

Wheel vibration; front tire resistance;

4

5

6

7

8

9

10

11

•

•

halfshaft breakage.

Steering is difficult; vehicle goes

•

•

straight while turning.

No differential action; jamming while

•

•

•

•

•

•

•

•

•

•

•

steering.

Extreme loud noise from the

•

•

•

transmission.

•

•

•

•

• •

•

•

•

• •

intermittent noise.

1. Incorrect installation/defective axle - Correct installation or repair or replace the differential in case it does not survive one of the test phases.

2. Overloading/incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.

3. Different rotation radius of the tires - If one tire has a smaller radius, it will cause partial wheel slipping when force is applied. The other tire with bigger radius will have to support all the work.

Replace the tire or adjust pressure to have same radius on both tires.

4. Broken halfshaft - It is not advisable to operate the vehicle with a broken halfshaft. It is acceptable to move the vehicle (engine off, unloaded) a few meters away only.

6. Blocked differential - Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all components.

Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.

7. Incorrect wheel adjustment - Verify group integrity and wheel side bearings. Adjusting accordingly.

8. Spoiled or worn out axle parts - Check the condition of ring gear, pinion gear, bearings etc.

Replace when ever necessary.

9. Contamination in the axle box or incorrect assembly parts - Look for foreign particles. Check assembly of the various parts of the axle.

5. Bent halfshaft - Replace halfshaft.

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3-1

Troubleshooting and Maintenance 10. Incorrect adjustment of bevel gear set: Parts of the transmission worn out - Replace or adjust as required.

Problem Ring gear tooth broken on the outer side.

11. Incorrect use of the product - Refer to the Operation and Maintenance Manual for proper use.

Cause

Action

1. Excessive gear load compared to the one foreseen.

Replace bevel gear set. Follow carefully the recommended operations for the adjustment of bevel gear set backlash.

2. Incorrect gear adjustment (excessive backlash).

3. Pinion nut loose.

Ring gear tooth broken on the inner side.

1. Load bump 2. Incorrect gear adjustment (insufficient backlash).

3. Pinion nut loose.

Pinion or ring gear teeth worn.

1. Insufficient lubrication 2. Contaminated oil.

3. Incorrect lubrication or depleted additives.

4. Worn out pinion bearings that cause an incorrect pinion axlebacklash and wrong contact between pinion and ring.

Overheated ring and pinion teeth.

See if gear teeth have faded.

1. Prolonged functioning at high temperatures.

2. Incorrect lubrication.

3. Low oil level.

Replace bevel gear set. Follow carefully the recommended operations for the adjustment of bevel gear set backlash.

Replace bevel gear set. Follow carefully the recommended operations for the adjustment of bevel gear set backlash. Use correct lubricants, fill up to the right levels and replace according to the recommended intervals.

Replace bevel gear set. Use proper lubrication, fill up to the right level and replace at recommended intervals.

4. Contaminated oil.

Pinion teeth pitting.

Axle beam body bent

1. Excessive use.

2. Insufficient lubrication.

Replace bevel gear set. Use proper lubrication, fill up to the right level and replace at recommended intervals.

1. Vehicle overloaded.

Replace axle beam body.

2. Vehicle accident.

3. Load bump.

Worn out or pitted bearings.

1. Insufficient lubrication.

2. Contaminated oil.

3. Excessive use.

Replace bearings. Use proper lubrication, fill up to the right level and replace at recommended intervals.

4. Normal wear out.

5. Pinion nut loose.

3-2

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Troubleshooting and Maintenance

Problem Oil leakage from gaskets and seals.

Cause 1. Prolonged functioning at high temperature of the oil.

2. Oil gasket assembled incorrectly.

Action Replace the gasket or seal and matching surface if damaged. Use proper lubrication and replace at recommended intervals.

3. Seal lip damaged.

4. Contaminated oil.

Excessive wearing out of input flange spline.

1. Exhaustive use.

3. Pinion axle backlash.

Replace the flange. Check that the pinion spline is not excessively worn out. Replace bevel gear set if required.

Fatigue failure of pinion teeth. See if the fracture line is well defined (wave lines, beach lines).

1. Exhaustive use.

Replace bevel gear set.

Pinion and ring teeth breakage.

1. Crash load of differential components.

Check and/or replace other differential components.

Side gear spline worn out. Replace all scratched washers (excessive backlash).

1. Excessive use.

Replace differential gear group.

Replace halfshaft if required.

Thrust washer surface worn out or scratched.

1. Insufficient lubrication.

Use proper lubrication and fill up to the right level. Replace at recommended intervals. Replace all scratched washers and those with 0,1 mm thickness lower than the new ones.

2. Pinion nut loose.

2. Continuous overload.

2. Incorrect lubrication.

3. Contaminated oil.

Inner diameter of tapered roller bearing worn out.

1. Excessive use.

2. Excessive pinion and axial backlash.

3. Insufficient lubrication.

Replace bearing. Check pinion axial backlash. Use proper lubrication, fill up to the right level and replace at recommended intervals.

4. Contaminated oil.

Bent or broken halfshaft.

1. Vehicle intensively operated or overloaded.

Replace

Halfshaft broken at wheel side.

1. Wheel support loose.

Replace. Check that wheel support is not worn out or wrongly adjusted.

2. Beam body bent.

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3-3

Troubleshooting and Maintenance

Problem Noise while driving.

Noise while driving in neutral.

Cause 1. Excessive backlash between pinion and ring gear.

1. Adjust

2. Worn out pinion and gear ring.

2. Replace

3. Worn out pinion bearings.

3. Replace

4. Pinion bearings loose.

4. Adjust

5. Excessive axial pinion backlash

5. Adjust

6. Worn out differential bearings.

6. Replace

7. Differential bearing loose.

7. Adjust

8. Ring gear out of roundness.

8. Replace

9. Low lubricant level.

9. Oil level

10. Poor or wrong lubricant.

10. Replace

11. Bent halfshaft.

11. Replace

1. Noise coming from axles is usually heard when vehicle moves in neutral gear but are not loud.

1. Replace or adjust (see above)

2.Incorrect backlash between pinion and ring (sound heard while decelerating disappears while increasing speed).

Intermittent noise.

Constant noise.

Noise while steering.

2. Replace

3. Pinion or input flange worn out.

3. Adjust

1. Ring gear damaged.

1.Replace bevel gear set

2. Differential box bolts loose.

2. Tighten to proper torque

1. Ring gear teeth or pinion damaged.

1. Replace bevel gear set.

2. Worn out bearings.

2. Replace

3. Pinion spline worn out.

3. Replace

4. Bent halfshaft.

4. Replace

1. Worn out differential gears.

1. Replace

2. Worn out differential box or spider.

2. Replace

3. Differential thrust washers worn out.

3. Replace

4. Half shaft spline worn out.

3-4

Action

4. Replace

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Troubleshooting and Maintenance

3.2

OIL CHANGE AND SERVICE CHECKS

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3-5

Troubleshooting and Maintenance

Note: To drain and fill the oil and check the oil level, the axle must be horizontal.

Danger: There is a risk of violent oil ejection, carefully follow all the safety procedures provided in this manual and the Operation and maintenance manual provided with the machine.

4. Unscrew the oil fill plug (1) and fill to the bottom of the level plug hole with the specified oil. Wait to allow the oil to flow through the axle. Check oil level and fill to the specified level if necessary. Screw the plug (1) to the prescribed torque. See “Tightening Torques and Sealants” on page 2.12.

1. Clean the breather (3) and the surrounding area.

2. To drain the oil, remove the level plug (1) and the drain plug (2).

3. Drain all oil.Clean the plug (2) and tighten it to the prescribed torque. See “Tightening Torques and Sealants” on page 2.12.

3-6

5. Before draining the oil from wheel end, rotate the wheel end so that the plug (4) is at the highest position (pos.A) and partially unscrew to release possible pressure. Rotate the wheel end so that the plug (4) is toward the ground (pos.B). Remove the plug and drain the oil.

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Troubleshooting and Maintenance

6. Rotate the wheel end so the hole (4) is in the position shown in the graphic above. Fill to the bottom, of the fill plug hole with specified oil. See “Technical Features” on page 2.5. Tighten plug to the prescribed torque. See “Tightening Torques and Sealants” on page 2.12.

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3-7

Troubleshooting and Maintenance

3.3

SERVICE SCHEDULE

Specified maintenance intervals are for standard-duty use. Severe operating conditions may require shorter intervals.

Note: Maintenance intervals shown in the table below.

This operation must be performed only by personnel authorized by the Caterpillar dealer.

This operation must be performed only by trained personnel.

(1) Which of both conditions comes first.

(2) 50 hours for severe operating condition.

(3) At the season end if you have not reached the indicated work hours.

3.3.1

3-8

Lubricants Application Range

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Troubleshooting and Maintenance

3.4

GREASE IN ASSEMBLY

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3-9

Troubleshooting and Maintenance

This Page Intentionally Left Blank

3-10

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Section 4 Disassembly/Assembly/Adjustment 4.1

STEERING CYLINDER

4.1.1

General Drawing

4.1.2

Disassembly

Note: Some of the graphics in the Disassembly/ Assembly/Adjustment section of this manual may not show your axle; however, indicated procedures are correct and may be utilized.

Note: If necessary use a hammer.

Important: Do not damage the threaded pin ends.

During the assembly replace the nuts (2 and 15).

1. Disconnect the steering sensor connector (16).

Remove the nuts (2 and 15) then extract the tie rods (4 and 13) from the swivel housing (3 and 14).

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4-1

Disassembly/Assembly/Adjustment 4.1.3

2. Remove the tie rods (4) and (13) from the cylinder rods by loosening the nuts (5), then checking their conditions. Unscrew the ball joints (6) and (11).

Remove the fastening bolts (7) and (10). Extract the bushing (8) using an extractor with a M18 screw.

Assembly

1. Assemble new seals and O-Rings (19) on the cylinder heads (1) and (17), on the piston (20) and the cylinder body (18). Insert the rod (20) into the cylinder (18) then assemble the cylinder heads (1) and (17).

3. Remove the cylinder (9) from the axle.

Danger: Wear safety gloves.

2. Assemble the steering cylinder (9) to the axle. Cool the bushing (8) to a temperature lower than -100°C with liquid nitrogen. Assemble the bushing (8) with a punch and hammer.

4. Detach the cylinder heads (1 and 17) from the cylinder case (18) and remove it from the rod (20).

Remove the rod (20) from the cylinder case (18).

Remove all the seals and O-Rings (19) from the cylinder head (1 and 17) and piston (20).

4-2

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Disassembly/Assembly/Adjustment Note: It’s important to unscrew the nut (5) to carry out this operation. Repeat the mentioned operations on the other side.

5. Align the swivel housing (3) with the axle. Screw the tie rod (4) so that its ball joint can be inserted into the swivel housing (3) arm.

3. Apply the specified sealant on the thread (Sec. 2.8) and tighten the fastening screws (10) and (7) to the prescribed torque (Sec. 2.8). Screw the ball joints (6) and (11) to the ends of the rod (20) to the requested torque (Sec. 2.8).

6. Insert the ball joint of the tie rod (13) into its housing on the swivel housing (14).

Assemble and tighten the lock nut (15) to the requested torque (Sec. 2.8).

Assemble the cotter pin (16).

Repeat the mentioned operations at the other side of the swivel housing.

Note: Screw the nuts (5) and (12) of the tie rods (4) and (13) only when the toe-in adjustment has been carried out. See: Section 4.13.

4. Assemble the nuts(5) and (12) then the tie rods (4) and (13) to the ball joints (6) and (11).

7. Screw the nuts (5 and 12) of the tie rods (4 and 13) only when the toe-in adjustment has been completed.

See: Section 4.13

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4-3

Disassembly/Assembly/Adjustment

4.2

EPICYCLIC REDUCTION GEAR GROUP

4.2.1

General Drawing

4.2.2

Disassembly

4-4

1. Unscrew the plug (1) and drain the oil completely from the epicyclic reduction gear.

See: section 3.2.

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Disassembly/Assembly/Adjustment 4. If required, replace the planetary gears (8) as follows: - remove the fastening bolts from every pin; - remove the washer; - remove the planetary gears from the pins; - collect the needle bearings and washer; - collect the thrust washer.

4.2.3

Assembly

2. Unscrew and remove the two fastening bolts (3) of the planetary carrier (2) with a wrench.

1. Position the planetary carrier (2) on a workbench.

Insert the thrust washer (5) on every pin.

3. Remove the planetary carrier (2) from the wheel hub (14) and collect the relative O-Ring (13). Position the planetary carrier (2) on a workbench and check its wear conditions.

2. Position the planetary carrier (2) on a workbench.

Note: grease the needle bearings well (see section 3.4).Insert the needle bearings in the planetary gears. Fit the planetary gears to the planetary carrier pins. Insert the thrust washer and the snap rings to the planetary carrier pins.

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4-5

Disassembly/Assembly/Adjustment

3. Fit the thrust washer (10) to the pins (4). Assemble the fastening bolts (11) and tighten to the prescribed torque (Sec. 2.8).

5. Fit the epicyclic reduction gear group to the wheel hub (13). Assemble the fastening screws (3) and tighten them to the prescribed torque (Sec. 2.8).

Note: The pin on thrust washers (7) must be fitted into the hole of the pins (4).

4. Assemble a new lubricated O-ring (13) on the wheel hub (14).

4-6

6. Top up the oil on the wheel hub (See: Sec.3.2). Fit the oil plug (2) on the planetary carrier (1) and tighten to the prescribed torque (Sec. 2.8).

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Disassembly/Assembly/Adjustment

4.3

WHEEL HUB GROUP

4.3.1

General Drawing

4.3.2

Disassembly

Note: Remove the epicyclic reduction gear group before disassembling wheel hub group.

Important: Do not damage the double U-Joint while completing the following procedure.

1. Insert a lever between the swivel housing (14) and the axle beam and fit it into the double U-Joint.

With the lever, push the double U-Joint in the direction of the wheel hub to allow lock ring (1) removal.

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4-7

Disassembly/Assembly/Adjustment 4. To extract the wheel carrier, screw two of the just removed bolts (5) in the threaded holes.

Remove the wheel carrier (7) with the epicyclic ring gear (4).

2. Remove the lock ring (1) from the double U-Joint shaft. Collect the double U-Joint shaft washers (2) and (3).

5. Remove the steel lock ring (8) and the wheel carrier (7) from the epicyclic ring gear (4).

Only if necessary, remove the centering bushes (6) from the wheel carrier with a hammer and the special tool (Sec. 5).

3. Unscrew and remove the fastening bolts (5) from the wheel carrier (7).

6. Remove the wheel hub (11) using levers and a hammer to facilitate the operation.

Note: Collect the bearing cone (9).

4-8

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Disassembly/Assembly/Adjustment

Note: The following is a destructive operation for the seal ring (13).

9. Remove the swivel housing (14) from the axle beam and from the short shaft of the double U-Joint.

Collect the belleville washers (26) and (27).

7. Position the wheel hub (11) on a flat surface and remove the seal ring (13).

Remove the bearing cones (9 and 12) using a hammer and a suitable drift.

Remove the bearing cone (12) from the swivel housing end (14) using a suitable extractor.

10. Position the swivel housing (14) on a flat surface and take the seal ring (25) out with an extractor.

8. Unscrew and remove the fastening screws (15) and (21) from the upper (17) and lower (19) king pins.

Danger: before removing the king pins (17) and (19), secure the swivel housing (14) with a belt or a rope to a hoist or any other supporting device, observe all current safety regulations to guarantee operator’s safety.

Remove the king pins (17) and (19).

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Note: This is a destructive operation for the seal ring.

Turn the swivel housing and take the bush (24) out, using a suitable drift and hammer.

4-9

Disassembly/Assembly/Adjustment 4.3.3

Assembly

1. If it has been previously removed, reassemble the steering stop composed by the spacer (29), the screw (23) and the nut (22).

Note: do not tighten the nut (22) until the steering angle adjustment has been completed.

See: section 4.13.

2. Force the bush (24) into the swivel housing (14) with the special tool (Sec. 5) and a hammer or a press.

Assemble the seal ring (25) on the swivel housing (14) with the special tool (Sec. 5) and a hammer.

Carefully grease the seal ring (25).

See: section 3.4.

4-10

3. If the cone (18) of the spherical joint has been previously removed, reassemble it to the lower king pin (19) using the special tool (Sec. 5) under a press.

Carefully grease the king pin (17) and (19) housings with specific grease. See: section 3.4.

Position the belleville washers (26) and (27) on the king pin (17) and (19) housings.

Important: secure the swivel housing (14) with a belt or a rope to a hoist or any other supporting device.

4. Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring (25).

Assemble the swivel housing (14) on the axle beam and after assembly, remove the adhesive tape completely.

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Disassembly/Assembly/Adjustment

5. Assemble the king pins, the lower (19) and the upper (17), and tighten the retaining screws (21) and (16) to the requested torque (Sec. 2.8).

Note: Make sure that the belleville washers (26) and (27) are in the correct position.

6. The special operation "Set Right" of the bearings (9 and 12) does not require preload or backlash adjustment. However, before assembling new components check the indicated dimensions.

7. Force both bearing cups (9 and 12) to their wheel hub (11) housings using the special tool (Sec. 5) under a press or with a hammer. Insert the seal ring (13) into the wheel hub (11) with the special tool (Sec. 5) and a hammer.

Note: Do not lubricate the seal ring (13).

8. Assemble the bearing cone (12) on the swivel housing (14) end. Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing cone (9).

A = 27.590 ÷ 27.640 mm B = 81.775 ÷ 81.825 mm C = 27.000 ÷ 27.100 mm

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4-11

Disassembly/Assembly/Adjustment

9. Position the wheel carrier (7) on a workbench and force the bushes (6) to the carrier surface level with the special tool (Sec. 5). At least two bushes (diametrically-opposed) should be set slightly higher that the carrier surface level to be used as dowel pins.

10. Preassemble the wheel carrier (7) and the epicyclic ring gear (4) with the special locking ring (8) shown in the illustration above.

4-12

11. Assemble the wheel carrier group on the wheel hub using the two projecting bushes as dowel pins and screw the relative screws (5) in order to attach the ring bevel gear with the wheel hub.

12. Force all the hub dowel bushes (6) completely with the special tool (Sec. 5) and a hammer.

Assemble the wheel carrier (7) fastening bolts (5) and tighten to the requested torque (Sec. 2.8).

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Disassembly/Assembly/Adjustment

13. Insert a lever between the swivel housing (14) and the axle beam and fit it into the double U-Joint. With the lever, push the double U-Joint in the direction of the wheel hub to make the lock ring (1) insertion easier.

14. Slide the thrust washers (3) and (2) onto the double U-Joint shaft end (24).

Insert the lock ring (1) at the end of the splined hub and push it into its housing.

Note: Check that the lock ring (1) is correctly fitted in its seat. Push the double U-Joint thoroughly.

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4-13

Disassembly/Assembly/Adjustment

4.4

PARKING BRAKE GROUP

4.4.1

General Drawing

4.4.2

Disassembly

Important: proceed with care to avoid damage to the brake pads (14).

1. Loosen the two nuts (13).

4-14

2. Unscrew the two screws (11).

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Disassembly/Assembly/Adjustment 5. Unscrew and remove the fastening screws (6) from the brake caliper support (7).Remove the brake caliper support (7) from the central body.

3. Remove the brake caliper (12).

6. Remove the seal (3) from the central housing (9) with a puller.

Remove the snap ring (16) and the bearing (15) from the central housing (9).

Note: This is a destructive operation for the seal.

4.4.3

Assembly

4. Remove the snap ring (1) and the input flange (2).

Note: Collect the O-ring (4) and the spacer (5)

1. Insert the bearing (15) into the central body using the special tool (Sec. 5). Insert the snap ring (16).

Insert a new seal (3) into the central body using the special tool (Sec. 5).

Note: Lubricate the seal lip (3) (see 3.4).

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4-15

Disassembly/Assembly/Adjustment

2. Insert the dowel pin (10) and the brake caliper support (7) on the central body (9).

Tighten the fastening screws (6) to the specified torque (see 2.8).

3. Grease the O-Ring (4) (see 3.4).

Insert the washer (5) on the splined pinion end, a new O-Ring (4), the input flange (2) and the lock ring (1).

4-16

Important: proceed with care to avoid damaging the brake pads (14).

4. Position the brake caliper (12) on the flange disc (2).

Important: after tightening nuts, make sure that a 1 ± 0.5 mm space is left between the nuts (13) and the spacers shown in the graphic above.

5. Screw in the bolts (11) and tighten the nuts (13) to the specified torque (see 2.8).

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Disassembly/Assembly/Adjustment 4.4.4

Parking Brake Caliper

Some of the following graphics may not show your axle, but indicated procedures are correct.

6. Note in the illustration above that the brake caliper of the 314-8934 axle is positioned downward.

1. The parking brake assembly is a ball and cam, sliding caliper brake designed for use primarily as a parking brake, with some service brake capability.

The brake (shown in the photos above and the exploded graphic on the following page) has an open caliper design to facilitate changing linings, along with a retraction spring to reduce drag from the brake pads and the disc.

Note: The brake assembly should not be subject to high pressure wash.

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4-17

Disassembly/Assembly/Adjustment 2. PARTS

b.

3. MOUNTING PROCEDURE ...

a. insert mounting bolts through sleeves (9) and thread brake mounting locking nuts as far as possible on mounting bolts.

This is not required if brake assembly comes with the sleeve/bolt sub-assy (9). Position the brake over disc align with mounting holes in mounting bracket. b. Thread mounting bolts (9) into mounting bracket, adjusting bolts until a 0,5 ÷ 1,5 mm exists between the Sleeves and Locking Nuts. Tighten the Locking Nuts to 115 Nm of torque against the bracket. c. Refer to Adjustment Procedure to set backlash of installed brake assembly.

4. ADJUSTMENT PROCEDURE a. Loosen two Adjustment Locking Nuts (12 and 13).

4-18

Tighten inner Adjustment Nut (12) until firm contact is made with the disc by the linings.

Torque to 13-14 Nm (115-125 lb. in). Make certain lever is in proper operating position for application. c. Back of inner Adjustment nut (12) 4 to 6 flats (1/ 2 ÷1 turn) and check that disc is free to move. d. Tighten outer Locking Nut (13) against inner Adjustment Nut (12) to lock Adjustment Bolt (2) in place. Torque to 61÷74Nm (45÷55 lb. ft).

5. BALL AND CAM REPLACEMENT a. Remove both Adjustment Locking Nuts (12 and 13), Thrust, stainless steel and Hardened Washer (11, 16, 17), Lever (1), and Boot (3) from Adjustment Bolt (2). b. Remove outer cam (4) and Ball Assembly (8) from Adjustment Bolt (2). c. Use a screwdriver, or similar tool, to gently pry inner Cam (4) protrusions on back of cam, loose from Torque Plate (5), and remove the Adjustment Bolt (2). Remove seal (15) from Adjustment Bolt (2).

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Disassembly/Assembly/Adjustment d. Install new Seal (15) on Adjusting Bolt (2), inserting through inner Cam (4) until Seal (15) bottoms out on Torque plate.

Note: Prior to installation of the cams (4), it is recommended to apply anti-seize and lubricating compound to ramp areas of cams. e. Install new Cam (4) on Adjustment Bolt (2), taking care to orient protrusions into Holes in Torque Plates (5) f. Install Ball Assembly (8) onto Adjusting Bolt (2), orienting balls into pockets of Inner Cam (4).

Install outer Cam (4) onto Adjustment Bolt (2) orienting pockets onto Balls of Ball Assembly (8).

Install boot (3) over cam assembly. g. Install lever (1), using protrusions on back of outer Cam (4) and holes in Lever (1) to orient lever to proper operating position. h. Install remaining washer and nuts and follow procedure in Paragraph 5.

Note: Make sure to orient coated face of thrust washer (11) toward stainless steel washer (17).

6. LINING REPLACEMENT a. Loosen two adjustment Locking Nuts (12 and 13) enough to remove each Torque Plate (5 and 7) away from disc far enough to provide backlash to remove old carrier and lining assemblies and install new ones. (It may be necessary to remove one or both nuts).

7. SLEEVE SEAL REPLACEMENT L

a. Loosen the two locking nuts on the mounting bolts and remove the mounting bolt/sleeve assembly (9) from the brake. b. Insert sleeve seals (18) between the torque plates (5 and 7) and align with the sleeve bores.

Note: Prior to installation of the mounting bolt and sleeve assembly, it is recommended that grease (anti-seize and lubricating compound) be applied to the sleeve and bores of the torque plates. c. Insert mounting bolt and sleeve assembly through the front torque plate (5) and sleeve seal (18), and back torque plate (7). d. Mount per paragraph 3b and adjust per paragraph 4.

8. BRACKET CABLE RETENTION REPLACEMENT a. Remove the screws (19) of the bracket (20) from the front torque plate (5). Remove the bracket (20). b. Position the bracket (20) in correspondence with the threaded holes of the pad support of the torque plate(5). c. Fix the bracket (20) to the front torque plate (5) with the appropriate screws (19).

Tighten the screws to 63 Nm.

b. Collapse the two Lining retraction Springs (10) and remove them from brake Head Assembly. c. Remove Torque Plates (5 and 7) away from disc, move Carrier and Lining Assemblies (6) out of pockets, and remove from the Brake Head Assembly from the side.

Note: Prior to installation of the new linings, it is recommended that a coating of anti-seize and lubricating compound be applied to the interface of the sleeve (9) and the torque plates (5 and 7).

After grease has been applied, move torque plates back and forth on sleeve as far as possible to insure that the grease has been introduced into the bores of the torque plates. d. Install new Carrier and Lining Assemblies (6) in each Torque Plate (5 and 7). e. Install the two Lining Retention springs (10) into Brake Head Assembly. Be sure spring’s feet are positioned properly in holes in both Lining Carrier Assemblies (6). Adjust brake per Paragraph 3.

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4-19

Disassembly/Assembly/Adjustment

4.5

FLANGE GROUP

4.5.1

General Drawing

4.5.2

Disassembly

2. Remove seal ring (3), spacer (5), O-rings (4) and (6) and the washer (7).

1. Remove lock ring (1) and flange (2).

4-20

Note: The preceding is a destructive operation for the seal rings.

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Disassembly/Assembly/Adjustment 4.5.3

Assembly

1. Attach the washer (7) and a new O-ring (6) to the pinion end. Put the new O-ring (4) on the spacer (5).

Attach the new seal ring (3) to the differential support with the special tool (Sec. 5) and hammer.

2. Assemble the flange (2).

Attach the lock ring (1) to the pinion end.

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4-21

Disassembly/Assembly/Adjustment

4.6

TRUNNIONS GROUP

4.6.1

General Drawing

4.6.2

Disassembly

1. Remove the front (3) and rear support (14).

2. If necessary, remove the bushings (7) and (11) and the thrust washers (8) and (10) using a punch.

Note: This procedure is a destructive operation for the components.

4-22

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Disassembly/Assembly/Adjustment 4.6.3

3. Remove the fastening bolt (13).

Remove the bushing (12) from the rear support.

Assembly

1. Position the front and rear supports on a work bench and assemble their respective thrust bushings (6) and (2).

Insert the lock screws (2) and (13) and tighten them to the specified torque (see 2.8).

Insert a new O-ring (5) in the thrust bushing of the rear support.

4. Loosen the lock screw (2) with the grease nipple and remove the bushing (6) from the support.

If necessary, replace the O-Ring (5).

Note: Apply sealant (ref. sec. 2.8) to the contact surfaces before replacing bushings.

2. If necessary, replace and insert the bushings (4) and (15) using a drive and hammer.

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4-23

Disassembly/Assembly/Adjustment

3. Insert the washers (8) and (10).

Heat the bushings (7) and (11) at 110-120°C for about four minutes, then attach to the axle housing (9).

Note: If necessary, assemble bush (7)and (11) with a pad and a hammer.

4. Insert the rear and front supports on the axle beam.

Important: Do not damage the O-ring during this process!

4-24

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Disassembly/Assembly/Adjustment

4.7

BRAKE GROUP

4.7.1

General Drawing

4.7.2

Disassembly

1. Remove the beam trumpet assembly from the brake flange (1). Refer to Section 4.8, Axle Beam Group, disassembly.

2. Remove the brake counter plates (6) and (9), brake plates (7) and (10), and the brake disk carrier gear (8) from the brake flange (1).

Note: Remember the position of the brake disk carrier gear (8), it must be reassembled in the same position.

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4-25

Disassembly/Assembly/Adjustment 4.7.3

Assembly

Note: Assemble the differential support group (see section 4.9) before assembling the brake group.

3. Remove the self-adjust kit’s (5) screw and collect all the components.

Remove the positive brake piston (4).

1. Collect the brake piston (4).

With the special tool (Sec. 5) and a hammer, push the bushings into the self-adjust housing until they are aligned with the piston supporting inner surface.

4. Remove the O-Rings (2) and (3) from the brake piston (4).

2. The bushings must be aligned with the piston supporting inner surface.

4-26

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Disassembly/Assembly/Adjustment

3. Assemble new O-Rings (2) and (3) to the brake piston (4). Lubricate the O-rings.

4. Insert the piston (4) into the brake cylinder (1) and position the special tool (Sec. 5) on the piston.

Note: Position the positive brake piston (4) with a slot aligned with the hydraulic connection or with the inspection hole on the brake cylinder (1).

5. With a lever anchored to an eyebolt, apply just enough pressure to insert the piston into the brake flange.

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6. Assemble the self-adjust kit (5) and tighten the screws to the prescribed torque (see 2.8).

Note: Assembly of the self-adjust kit (5).

7. Check that the brake plate (7) and (10) and the brake drive plate (6) and (9) (see graphic at top of next page) do not show any sign of burning. If they do, replace them.

Furthermore, check brake plate wear and if necessary, replace it.

Note: See the following section 4.7.4, Brake disks replacement.

4-27

Disassembly/Assembly/Adjustment Important: Place the brake disk carrier (8) as shown in the next graphic. Assemble brake disks with holes aligned.

9. This is the correct position of the step on the external diameter of the brake disk carrier (8).

Important: The brake piston must be pushed in the original position if worn brakes are replaced by new disks.

Note: See the following section 4.7.4, Brake disks replacement,

10. Assemble the beam trumpet group to the brake flange (1).

See: section 4.8, Axle Beam Group

8. Reassemble all the components of the brake group as shown in the graphic above: brake counter plate (6), brake plate (7), brake disk carrier (8), brake counter plate (9) and brake plate (10).

4-28

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Disassembly/Assembly/Adjustment 4.7.4

Brake Disk Replacement

1. Remove the beam trumpet group from the brake flange (1).

See: section 4.8.2, disassembly

3. To replace worn brake disks with new disks the brake piston must be pushed in the original position.

Remove straight threads, bleeds or plugs from the service brake oil port.

Danger: risk of ejection of oil from the axle.

2. Remove from the brake flange (1) the brake counter plate (9) and brake plate (10), the brake disk carrier gear (8) the brake plate (7) and the brake counter plate (6).

Note: Remember the position of the brake disk carrier, it must be reassembled in the same position.

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4. Push the brake piston (4) at the end of stroke using the special tool (Sec. 5) and the handle (Sec. 5) with a hammer.

Note: Position the pad with accuracy to avoid damage to the brake piston.

4-29

Disassembly/Assembly/Adjustment

5. Reassemble all the components of the brake group as shown in the graphic above: brake counter plate (6), brake plate (7), brake disk carrier (8), brake counter plate (9) and brake plate (10).

7. Assemble the beam trumpet group to the brake flange (1).

See: section 4.8.3, assembly

Important: Place the brake carrier (8) as shown in the next graphic.

6. This is the correct position of the step on the external diameter of the brake disk carrier.

4-30

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Disassembly/Assembly/Adjustment

4.8

AXLE BEAM GROUP

4.8.1

General Drawing

4.8.2

Disassembly

See: previous sections before disassembling this group.

1. Put alignment marks on the central body, brake cylinders and beam trumpets in order to identify the parts on right side and left side.

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2. Remove double U-Joint (9) from axle beam trumpet (3).

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Disassembly/Assembly/Adjustment

Important: Position the axle on supports fitted to hold either the central body or the beam trumpets, following their separation or secure every group to a lifting device with ropes or belts.

6. Remove the bushing (7) only if the wear conditions require this.

3. Unscrew and remove the fastening bolts.

4. Remove the axle beam trumpet (3).

Remove the O-Ring (2).

7. Remove the upper king pin bushing (5) and the ball bearing cup (6) from the king pin seats using a suitable extractor only if the wear conditions require this.

Important: Be careful not to damage the housing for the bushing during the following procedure. See graphic at top of next column to identify parts.

5. Remove the seal rings (8) from the axle beam (3) with an extractor.

Note: The preceding is a destructive operation for the seal rings.

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Disassembly/Assembly/Adjustment 4.8.3

Assembly

Important: Wear safety gloves.

1. Cool the upper king pin bushing (5) and the ball bearing cup (6) at a temperature lower than -100°C with liquid nitrogen.

Assemble the bushing (5) on the upper king pin seat with the special tool (Sec. 5) and a hammer.

Assemble the ball bearing cup (6) on the lower king pin seat with the special tool (Sec. 5) and a hammer.

3. Assemble the seal ring (8) with the special tool (Sec. 5) and a hammer.

Important: Assemble the seal ring (8) as shown in graphic above.

Note: Carefully grease the seal rings (see section 3.4).

4. Lubricate the new O-Ring (2).

Assemble the new O-Ring on the axle beam trumpet (3).

2. Insert the bushing (7) into the axle beam (3) with the special tool (Sec. 5) and a hammer.

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Disassembly/Assembly/Adjustment

5. Insert the double U-Joint (9) inside the axle beam trumpet (3).

Important: Do not damage the seal ring (8).

Important: Support the groups properly as already pointed out for disassembly.Do not damage the O-Ring (2) during the procedure.

7. Assemble the fastening bolts (4).

Tighten fastening bolts (4) to the requested torque (see 2.8) according to the sequence shown in step 8.

8. Tighten fastening bolts (4) according to sequence shown in graphic.

6. Assemble the beam trumpet (3) to the central body (1) on the correct side following the reference marks applied prior to disassembly.

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4.9

DIFFERENTIAL SUPPORT GROUP

4.9.1

General Drawing

4.9.2

Disassembly

2. Secure the brake cylinder (6) to a hoist with ropes or safety belts. Remove the fastening screw (7).

1. Measure the starting total preloading T0 of the bearings (pinion-crown gear system), using a dynamometer whose cord is wound on the pinion splined end. Note the value T0 that is necessary in the bearings reassembly.

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Disassembly/Assembly/Adjustment

6. Remove the O-Ring (2) from the central body (1).

3. Remove the brake cylinder.

Important: Ensure the differential box is free.

4. Remove the O-Ring (5) from the brake cylinder (6).

7. Loosen and remove screw (10) and ring nut retainer (9) from brake cylinder (6).

5. Remove the differential housing (3).

8. Unscrew and remove the adjuster ring nut (8) from the brake cylinder (6) with the special tool (Sec.5).

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9. Use a driver and a hammer to remove the bearing cup (4) from the brake cylinder (6).

2. Lubricate and assemble new O-Ring (2) on every side of the central body (1).

Important: Do not invert the bearing cups if the bearings are not replaced

4.9.3

Assembly

3. Position the brake cylinder (6) on a flat surface and force the bearing cup (4) using the special tool (Sec. 5).

Important: Do not invert bearing cups if the bearings are not replaced.

1. Assemble the pinion group before assembling the differential support group.

See: section 4.12.3, assembly

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Disassembly/Assembly/Adjustment

4. Measure the external diameter C of the bevel crown assembled to the differential housing.

Calculate the value: R=C/2 mm Note: This value is necessary to measure the backlash between the pinion and crown.

7. Assemble the fastening screw (7) at the position shown in the graphic above. Tighten the fastening screw to the requested torque (see 2.8).

Assemble in the shown position an axle beam trumpet fastening screw M16x2x160 (part #4 in section 4.8) to a torque of 80 Nm on both sides with suitable shim.

.

5. Assemble a new well lubricated O-Ring (5) on the brake cylinder (6) housing.

First assemble the left brake cylinder (Lh) to the central body (1). Insert the differential group into the central body (1).

8. Fastening screws M16x2x160 (part #4 in 4.8) with suitable shim. Tighten bolt to the torque of 80 Nm (on both sides).

Important: The bevel gear must be placed on the right side (Rh).

6. Assemble the right brake cylinder (Rh).

Note: Check that the reference marks made prior to disassembly between the brake cylinders and the central body coincide.

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9. Screw both adjuster ring nuts (8) using the special tool (Sec. 5) till the backlash is eliminated and the differential bearings are slightly loaded.

11. Move the bracket of the special tool (Sec. 5) installed on the differential housing hole alternately by hand.

Measure backlash between pinion and crown.

Check if the backlash is within the prescribed range: 0.15÷0.30 mm Set the backlash by turning the adjusting ring nuts (8) using the special tool (Sec. 5).

10. Assemble the special tool (Sec. 5) on the differential housing hole. Position a comparator with the feeler in contact with and at a 90° with respect to the surface of the special tool bracket, in correspondence with the reference R value.

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12. Adjust the ring nuts (8), remembering that: - if the measured backlash is less than the given tolerance range, screw the ring nut from the side opposite to the ring gear and unscrew the opposite one of the same measure (A); - if the measured backlash is greater than the given tolerance range, screw the ring nut from the side of the ring gear and unscrew the opposite one of the same measure (B).

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Disassembly/Assembly/Adjustment

13. Once the adjustment of the pinion-bevel gear backlash had been carried out, check to ensure there is minimum preloading on the differential housing bearings.

Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached.

14. Once the pinion-ring gear backlash has been established, measure the total preloading Tm of the bearings (pinion-crown bevel gear system), using a dynamometer whose cord is wound on the pinion splined end.

Note: Do not use this method with new bearings, if the bearings have been replaced see next step.

The measured value should be the starting value (see section 4.9):

Important: All the preloads should be measured without the seal rings.

15. If the bearings have been replaced, measure the total preloading T of the bearings with a dynamometer whose cord is wound on the special tool (Sec. 5) inserted on the end of the pinion shaft.

16. The total preloading Tm is measured on the special tool (Sec. 5) (gauge diameter Dm = 104.4 mm).

The measured value should be within the following range: Tm = (Pm+7.9) ÷ (Pm+11.9) N (314 - 8936) Tm = (Pm+7.9) ÷ (Pm+11.29) N (314 - 8937) Where Pm is the effective preloading measured on the special tool (Sec. 5) (gauge diameter Dm = 104.4 mm). See: section 4.12, assembly

Tm = T0 Important: all the preloads should be measured without the seal rings.

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17. Once the pinion-ring gear backlash has been established, measure the total rolling torque (TT) of the bearings (pinion-crown bevel gear system) with a torque meter and the special tool (Sec. 5).

See: section 2.8 Important: All the preloads must be measured without the seal installed.

18. The total rolling torque TT must be within the following range (see C.4): TT= (TP+0.41)÷(TP+0.62) Nm where TP is the pinion bearing preloading.

Note: See procedure described in 4.12.

19. If the measurement is not within the requested range, check the assembly of each component and operate on the adjuster ring nuts (8) of the differential support: - if the total preloading is less than the given range, screw in both adjuster ring nuts by the same measure, keeping the pinion-ring gear backlash value unchanged (A); - if the total preloading is greater than the given range, unscrew both adjuster ring nuts by the same measure, keeping the pinion-ring gear backlash value unchanged (B)

20. Once all the adjustment operations are completed, fit the adjuster ring nut retainers (9) and their respective screws (10), tightening them to their requested torque (see 2.8).

Important: Turn the adjuster ring nuts (8) slightly in order to allow the assembly.

21. Remove the M16x2x160 fastening screws on both sides.

See step 8 of this assembly procedure.

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Disassembly/Assembly/Adjustment 4.9.4

Bevel gear marking test.

1. To test the marks of the bevel gear teeth, paint the ring gear with red lead paint.

The marking test should always be carried out on the ring bevel gear teeth and on both sides.

3. Movements to correct excessive contact on the tooth tip and at the tooth base.

1) move the pinion away from the bevel gear for type X contact adjustment.

2) Move the pinion toward the bevel gear for type Z contact adjustment.

2. OK Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular.

Z Excessive contact on tooth tip: Approach the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the backlash (see step 3) X Excessive contact at the tooth base: Move the pinion away from the ring bevel gear and then move the ring bevel gear to the pinion in order to adjust the backlash (see step 3).

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Disassembly/Assembly/Adjustment

4.10

DIFFERENTIAL GROUP LIMITED SLIP

4.10.1

General Drawing

4.10.2

Disassembly

See: section 4.9 before disassembling the differential group./

Important: this procedure will free both differential half boxes (4) and (12), take care not to drop the internal components.

1. Lock the differential with a clamp.

Unscrew the fastening screws (1) and remove the bevel crown gear (2).

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Disassembly/Assembly/Adjustment 4.10.3

Note: Mark the two half boxes before separating them in order to reassemble them in the same position as they were before disassembly.

2. Disassemble the differential box in two half boxes (4) and (12) complete with relative components.

Disassemble the components.

Check the operating and wear condition of the components.

Assembly

4. Assemble the bearing cones (3) and (13) on the half housings (4) and (12), using the special tool (Sec. 5) and a hammer.

Note: The first disk (7) must be assembled with friction material on the disk’s side and the flat surface of the sun gear (8) side.

3. Remove the bearing cones (3) and (13) from the half boxes (4) and (12), using two levers or a three-hold extractor.

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5. Position a half housing (4) or (12) on a workbench and assemble all inner components: locking differential counterdisks (6), locking differential disks (5) and (7), sun gears (8), spider gears (10), and thrust washers (11) as shown in the general drawing at the beginning of this section. See: Differential disks specifications in section 2.7.3.

Join the two half boxes, aligning the reference marks that were made on them prior to disassembly.

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Disassembly/Assembly/Adjustment

6. Before matching surfaces, make sure they are perfectly clean. Degrease and clean them with appropriate detergents.

Position the bevel crown gear (2) on the half box (14).

Note: Check the dowel pin (4) position.

7. Apply the specified sealant on the thread (see 2.8) and tighten the bolts (1) to the requested torque (see 2.8).

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Disassembly/Assembly/Adjustment

4.11

DIFFERENTIAL GROUP - OPEN

4.11.1

General Drawing

4.11.2

Disassembly Important: The following will free both differential half boxes (4) and (12). Take care not to drop the internal components.

1. Lock the differential with a clamp.

Unscrew the fastening bolts (1) and remove the bevel gear crown (2).

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Disassembly/Assembly/Adjustment 4.11.3

2. Make alignment marks on the two half boxes before splitting them.

Disassemble the differential box into two half boxes (4) and (12) complete with relative components.

Disassemble all the components.

Check the operating and wear condition of the components.

3. Remove the bearing cones (3) and (13) of the half boxes (4) and (12) using two levers or a three-hold extractor.

Assembly

1. Assemble the bearing cones (3) and (13) on the half housings (4) and (12) using the special tool (Sec. 5) and a hammer.

2. Position a half housing (4) or (12) on a workbench and assemble all inner components: thrust washers (5) and (11), sun gears (6) and (10), spider gears (8), and thrust washers as shown in the graphic above.

3. Join the two half boxes, aligning the reference marks made prior to disassembly.

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Disassembly/Assembly/Adjustment

4. Position the bevel crown gear (2) on the half box (4).

Note: clean the matching surfaces carefully.

Apply the specified sealant on the thread (see 2.8) and tighten the screws (1) to the requested torque (see 2.8).

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4.12

PINION GROUP

4.12.1

General Drawing

4.12.2

Disassembly 1. Remove the differential group (See section 4.9.2, disassembly).

Measure the starting preloading P0 of the pinion bearings using a dynamometer whose cord is wound on the pinion splined end.

Note that the value P0 is necessary during the bearings reassembly.

See section 4.9.3, assembly.

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Disassembly/Assembly/Adjustment

2. Unscrew the locking ring nut (10) using the special tools (Sec. 5).

Note: This operation will damage the locking ring nut; the nut (10) must be replaced when assembling the group.

3. Tap the end shaft with a soft hammer to remove the bevel pinion (1).

Collect the washer (9) and the bearing (8).

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4. Once the bevel pinion (1) has been removed, collect the washer (6), the collapsible spacer (5) and the washer (4).

Note: The collapsible spacer (5) must be replaced when assembling the group.

5. Check the bearing cups wear condition.

If bearing replacement is necessary, remove bearing cups from central body with a drift punch and hammer.

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Disassembly/Assembly/Adjustment 4.12.3

6. Remove the bearing cone (3) from the bevel pinion (1) with a standard bearing extractor.

Collect the shim (2).

7. Check all pinion components for wear.

Remember, the locking ring nut (10) and the collapsible spacer (5) must be replaced when reassembling the unit.

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Assembly

1. Place the central body (6) on a workbench.

Fit the bearing cups into their seats using the special tools kit (Sec. 5).

2. Use the special tools false pinion (Sec. 5). and false differential box (Sec. 5) to measure the conic distance.

Insert the bearing cones and false pinion into the seats.

Tighten the locking ring nut (10) to eliminate the backlash.

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Disassembly/Assembly/Adjustment

3. Check the correct position of the right and left brake cylinder and differential housing supports, using the reference marks placed on them and on the central body (6).

Assemble the two brake cylinders with their fastening bolts.

4. Insert the false differential box (Sec. 5) into the central body (6). Make sure the false differential box is inserted in both differential support housings.

5. To adjust bevel gear/pinion measure the distance "A" with a depth gauge.

Calculate the value "X" as follows: X=(A+C)-B mm where "B" and "C" are known.

6. "From the value "X" deduct the value "V" (stamped on the pinion head) to get the value "S".

S=X-V mm

.

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Disassembly/Assembly/Adjustment

7. Choose the shim (2) with thickness value (S) in mm and the number needed from among the following available shims range: 2.5 - 2.6 - 2.7 - 2.8 - 2.9 - 3.0 - 3.1 - 3.2 - 3.3 - 3.4

9. Insert the chosen shim (2) with the chamfer against the gear on the pinion shaft (1).

Force the bearing (3) on the pinion shaft (1) with the special tool (Sec. 5) under a press, making sure that it is well set.

Assemble the shim (4), a new collapsible spacer (5) and the shim (6) to the pinion shaft.

Note: Always use a new collapsible spacer (5).

8. Loosen and remove the locking ring nut (10).

Remove the false pinion (Sec. 5) and the bearing cones from the central body (7).

Disassemble the false differential box (Sec. 5) from the brake cylinders, then unscrew the screws to remove the brake cylinders.

10. Insert the bevel pinion (1) unit into the central body (7) and the bearing (8) into the pinion shaft, as shown in the graphic above.

Force the bearing (8) in position with the special tool (Sec. 5) and a hammer.

Note: Push the pinion against the central body to perform this operation.

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Disassembly/Assembly/Adjustment

11. Insert the ring nut washer (9) and screw a new locking ring nut (10) on the pinion end.

Screw the locking ring nut (10) in, using the special tools (Sec. 5).

Important: The torque setting is given by the preloading measurement on bearings (3) and (8); tighten the locking ring nut (10) gradually.

Note: If the tightening is excessive, the collapsible spacer (5) will be damaged and must be replaced and the procedure repeated.

13. To measure the preloading PM of the pinion taper roller bearings (3) and (8), use a dynamometer whose cord is wound on the end of the pinion shaft (1).

Note: Do not use this method with new bearings, if the bearings have been replaced, see next step.

The measured value must be the starting value (see 4.12.2) PM = PO See: step 17 of this procedure.

12. When you check the preloading, it is advisable to slightly beat both pinion ends (1) with a soft hammer to help set the bearings (3) and (8).

Important: All preloadings must be measured without the seal rings.

14. If the pinion taper roller bearings (3) and (8) are new, measure the preloading P of the bearings. Use a dynamometer whose cord is wound on the special tool (Sec. 5) inserted on the end of the pinion shaft.

The adjustment is carried out by increasing the ring nut torque gradually, being careful not to exceed the specified torque value.

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Disassembly/Assembly/Adjustment

15. The effectively preloaded PM is measured on the special tool (Sec. 5) (gauge diameter DM = 104.4 mm).

The measured value should be within the following range:

16. The measured value TP must be within the following range: TP= 1.6÷2.4 Nm

PM= 30.6÷45.8 N Important: The measured value is for new bearings.

17. Once the requested preloading is achieved, stake the locking ring nut (10) using a hammer and chisel.

Note: In addition to using steps 14 and 15 to measure preloading of the bearings, the pinion shaft bearings rolling torque TP may also be measured with a torque meter and the special tool (Sec. 5).

Important: Remember that all the preloads must be measured without the seal ring.

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Disassembly/Assembly/Adjustment

18. Assemble the differential.

See: section 4.9.3.

19. Assemble the flange group.

See: section 4.5.3.

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Disassembly/Assembly/Adjustment

4.13

TOE-IN/STEERING ANGLE

4.13.1

General Drawing

4.13.2

Toe-in adjustment

1. Put two equal one-meter-long linear bars on the wheel sides and lock them with two nuts on the wheel hub stud bolt.

Important: The two bars must be fixed on their middle so they are perpendicular to the supporting surface and parallel to the pinion shaft axis; align the two bars.

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Disassembly/Assembly/Adjustment external diameter of the wheel hubs flange, therefore the measured value (M) at the bars ends must be related to the ratio between length of the bar and flange diameter. nominal toe-in (sec. 2.6) = A±1 ---> measured toe-in = M±3

2. Measure the distance M (measured value) in mm between the bars end with a tapeline.

Note: Keep the minimum value, swinging the measurement point.

4. 314-8936 Check that the difference of the measurements between the wheel hubs diameter ends is within the requested tolerance range.

See: "Toe-in" in Sec. 2.6.

The nominal toe-in value (A) is referred to the external diameter of the wheel hubs flange, therefore the measured value (M) at the bars ends must be related to the ratio between length of the bar and flange diameter. nominal toe-in (sec. 2.6) = A0-2 ---> measured toe-in = M0-5

3. 314-8937 Check that the difference of the measurements between the wheel hubs diameter ends is within the requested tolerance range.

See: "Toe-in" in Sec. 2.6.

The nominal toe-in value (A) is referred to the 4-58

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Disassembly/Assembly/Adjustment 4.13.3

5. If toe-in is incorrect, use two wrenches on the guide rods (1) to screw the two joint tie rods (3) in and out equally until the toe-in is within the specified tolerance (see 2.8).

6. After adjusting the toe-in, screw in the lock nuts (2) of the guide rods (1) to the specified tightening torque (see 2.8).

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Steering angle adjustment

1. Use the same bars that were attached for the toe-in adjustment and a long bar perfectly leaned over the machined part of the central body (pinion side), so the two bars form an acute angle at the maximum steering.

2. Set a protractor to the specified angle (Sec. 2.6) and position it on the long bar.

Move a wheel side until it forms, with the two bars, the angle fixed by the protractor.

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Disassembly/Assembly/Adjustment

3. Adjust the mechanical steering stop by screwing the stop bolt (4) in or out, locking it with the locknut (5) to the specified tightening torque (see 2.8).

Important: Check the position of the stops on the opposite side, both screws must touch the steering stop pads at the same time.

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4. Steer completely towards the other side and repeat the same adjustments for the mechanical steering stop that were done in step 3.

Important: Check the position of the stops on the opposite side, both screws must touch the steering pads at the same time.

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Disassembly/Assembly/Adjustment

4.14

TESTING AFTER ASSEMBLY

4.14.1

Testing methods

1. With the engine off, lift the axle so the tires are off of the ground.

2. Engage the gear so the pinion becomes locked.

3. With the help of another person standing on the opposite side, begin testing the assembly by rotating both wheels forward as much as possible. (Both wheels should be blocked after a while.)

4. Keeping the pinion locked, free the right wheel and rotate the left wheel in the line of march. Rotate the right wheels in the opposite direction.

The wheel (left one) will move freely without difficulty and the right wheel will move in the opposite direction if the assembly has been carried out correctly.

5. Repeat the same test procedure in the opposite direction (reverse gear).

Note: IF ONE WHEEL DOES NOT ROTATE FREELY IN BOTH DIRECTIONS, check all assembly procedures step-by-step.

Check to ensure the brakes are adjusted correctly and functioning properly.

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This Page Intentionally Left Blank

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Section 5 Special Tools 5.1

TOOL USAGE

The special drift/pad used to assemble the seals, bearings, and bushings should always be used with the interchangeable handle, and the safety handle in order to protect the hands.

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5-1

Special Tools

5-2

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Special Tools

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5-3

Special Tools

5-4

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