Case 8845DHP 865VHP 865AWD 885 885AWD Tier 3 Grader Repair Manual 71114197 - PDF DOWNLOAD

REPAIR MANUAL

GRADER 845DHP 865VHP/865AWD 885/885AWD TIER 3

71114197 NA

Issued 01July 08

6007-5

CONSTRUCTION

FRONT DRIVE AXLE ASSEMBLY STEP 3

STEP 1

Special Tool “AA”

2 3 2 26

3

photo 2 Locate the camber joint (2) and (3) qty 01 on an assembly stand to install the external ring of angular joint GE45-SX assembly (26) qty 04. x Put the external ring from angular joint GE45-SX assembly item (26) qty 04 in nitrogen reservoir per 5 minutes. x Then install the four (4) external ring from joint assembly item (26) in each side from camber joint LH and RH items (2) and o(3) Note: To install is needed the special tool, as drawing “AA” page of 6007- 4.

Make this tool in your shop. x

figure1 Separate the camber joint LH and RH items (2) and (3) qty 01.

STEP 2

STEP 4

photo 1 Lift the camber joint LH and RH items (2) and (3), qty 01 Use a lifting equipment.

photo 3 Put the camber joint LH and RH items (2) and (3) qty 01 in the stand extremity.

Contagem, MG Brazil 6-46760 July,2008

CONSTRUCTION

6007-6

STEP 5

STEP 9 The flange bumper RH and LH must be in the correct position in yellow for low

A shown in the figure 2, after installed the flange LH and RH items (4) and (5) to the camber joint LH and RH items (2) and (3), install the internal ring of the angular joint GE50-SX item (25) qty 04 to the each pins item (12) qty 04.

STEP 10 As shown in the figure 2, install the external ring of the angular joint GE50-SX item (25) qty 04 to the pins item (12) qty 04 and complete the installation of this item.

STEP 11 As shown in the figure 2, install the bushing item (13) qty 04 to the pins item (12) qty 04 with the external ring of assembly item (25) qty 04, using the washer item (36) qty 04 and bolts M12x40 mm, item (35) qty 04.

Note: Tighten the bolts item (36) qty 04 at 100 Nm / (74 pound-feet) torque.

figure 2 As shown in the figure 2, separately install the rings item (22) qty. 02 for each pins item (12) qty 02.

STEP 12

STEP 6 As shown in the figure 2, put the bearing item (25) qty. 02 and also the assembly pins item (12) qty 02 already with rings item (22) qty 04 assembled in the step 5 in the nitrogen reservoir per 5 minutes.

STEP 7 As shown in the figure 2, locate the flanges items (4) and (5) to the camber joint LH and RH items (2) and (3) for assembly of pins.

Note: The bumper must be in the position for low. Refer to figure 2 for the correct control points in yellow.

Install the cover item (11) using the bolts and washer items (32) and (34).

Tighten the bolts item (32) qty 08 at 28.8 Nm (21 pound-feet) torque. photo 4

STEP 8 As shown in the figure 2, install the pins item (12) to the camber joint LH and RH items (2) and (3) already together with the flanges LH and RH items (4) and (5).

Note: Mount both pins (bottom and low) of the flange.

As shown in the figure 2 and photo 4, install the cover item (11) qty 02, one to the each camber joint LH and RH items (2) and (3) (bottom terminal), using the bolts item (32) qty 08 and washer item (34) qty 08 for each side (camber joint LH and RH).

Note: Tighten the bolts item (32) qty 08 at 28.8 Nm (21 pound-feet) torque.

Contagem, MG Brazil 6-46760 July,2008

CONSTRUCTION

6007-7

STEP 13

STEP 15 As shown in the figure 2 and 3, install the grease fitting item (31) qty 04 to the camber joint LH and RH items (2) and (3) (use two grease fitting for each camber joint in the bottom and low terminal)

STEP 16

figure 3

photo 6 As shown in the photo 6, locate the shaft item (1) qty 01 on stand.

STEP 17

photo 5 As shown in the figure 3 and photo 5, install the cover item (14) qty 02 one to the each camber joint LH and RH items (2) and (3) (low terminal) Note: First tighten the cover item (14) at 200 Nm (148 pound-feet) torque, then loose and tighten again at 60 Nm (44 pound-feet) final torque.

STEP 14 As shown in the figure 3 and photo 5, install the plate item (15) qty 02, one for each camber joint LH and RH items (2) and (3) (low terminal), using the bolts M8 x 16 mm tem (33) and washer item (34) qty 04 (each side)

figure 4 As shown in the figure 4, separate and put the pin item (16) qty 02 in the nitrogen reservoir per 5 minutes.

Contagem, MG Brazil 6-46760 July,2008

CONSTRUCTION

6007-8

STEP 18

STEP 24

As shown in the figure 4, install the angular joint GE45-SX item (26) qty 02 to the camber joint assembly RH item (3).

As shown in the figure 4, install the grease fitting item (31) qty 02 to the pin item (16) qty 02.

STEP 19

STEP 25

As shown in the figure 4, Put, locate the flange and camber joint RH items (3 and 5) assembled to the shaft item (1) qty 01.

STEP 20 As shown in the figure 4, Put, locate the seal item (17) qty 01 and ring item (24) qty 01 in the point “A” Note: To put and fasten, is needed the special tool as drawing “BB” of page 6007- 4.

Make this tool in your shop.

STEP 21 As shown in the figure 4, Put, locate the seal item (17) qty 01 and ring item (24) qty 01 in the point “B” and then install (introduce) the pin item (16) qty 01. figure 5 As shown in the figure 5, separate and put the pins item (18) qty 02 and item (21) qty 01 in the nitrogen reservoir per 5 minutes.

STEP 26

STEP 22 photo 7 As shown in the figure 4 and photo 7, fasten the pin (16) qty 01, using the washer item (28) qty 01, special nut item (29) qty 01 and pin item (30) qty 01.

Note: Manually locate the castle nut until the end of all thread and install the pin (30) Not use pneumatic impact wrench to tighten.

photo 8 As shown in the figure 5 and photo 8, install the hydraulic cylinder assembly item (10) qty 01 to the shaft item (1) qty 01, using the pin item (21) qty 01, bolt M10 x 80 mm item (40) qty 01 and nut item (41) qty 01.

STEP 23 As shown in the figure 4 and photo 7 repeat the process (step 17 to 22) for the other axle side.

Contagem, MG Brazil 6-46760 July,2008

CONSTRUCTION 6009-5

FRONT AXLE ASSEMBLY STEP 3

STEP 1

Special Tools “AA”

2 3

2

26

3

photo 2 Locate the camber joint (2) and (3) qty 01 on an assembly stand to install the external ring of angular joint GE45-SX assembly (26) qty 04. x Put the external ring from angular joint GE45-SX assembly item (26) qty 04 in nitrogen reservoir per 5 minutes. x Then install the four (4) external ring from joint assembly item (26) in each side from camber joint LH and RH items (2) and o(3) Note: To install is needed the special tool, as drawing “AA” of page 6009- 4.

Make this tool in your shop.

x

figure1 Separate the camber joint LH and RH items (2) and (3) qty 01.

STEP 2

STEP 4

photo 1 Lift the camber joint LH and RH items (2) and (3), qty 01 Use a lifting equipment.

photo 3 Put the camber joint LH and RH items (2) and (3) qty 01 in the stand extremity.

Contagem, MG Brazil 6-46780 July,2008

CONSTRUCTION 6009-6

STEP 9

STEP 5 The flange bumper RH and LH must be in the correct position in yellow for low

A shown in the figure 2, after installed the flange LH and RH items (4) and (5) to the camber joint LH and RH items (2) and (3), install the internal ring of the angular joint GE50-SX item (25) qty 04 to the each pins item (12) qty 04.

STEP 10 As shown in the figure 2, install the external ring of the angular joint GE50-SX item (25) qty 04 to the pins item (12) qty 04 and complete the installation of this item.

STEP 11 As shown in the figure 2, install the bushing item (13) qty 04 to the pins item (12) qty 04 with the external ring of assembly item (25) qty 04, using the washer item (36) qty 04 and bolts M12x40 mm, item (35) qty 04.

Note: Tighten the bolts item (36) qty 04 at 100 Nm / (74 pound-feet) torque.

figure 2 As shown in the figure 2, separately install the rings item (22) qty. 02 for each pins item (12) qty 02.

STEP 12

STEP 6 As shown in the figure 2, put the bearing item (25) qty. 02 and also the assembly pins item (12) qty 02 already with rings item (22) qty 04 assembled in the step 5 in the nitrogen reservoir per 5 minutes.

STEP 7 As shown in the figure 2, locate the flanges items (4) and (5) to the camber joint LH and RH items (2) and (3) for assembly of pins.

Note: The bumper must be in the position for low. Refer to figure 2 for the correct control points in yellow.

STEP 8 As shown in the figure 2, install the pins item (12) to the camber joint LH and RH items (2) and (3) already together with the flanges LH and RH items (4) and (5).

Note: Mount both pins (bottom and low) of the flange.

Install the cover item (11) using the bolts and washer items (32) and (34).

Tighten the bolts item (32) qty 08 at 28.8 Nm (21 pound-feet) torque photo 4 As shown in the figure 2 and photo 4, install the cover item (11) qty 02, one to the each camber joint LH and RH items (2) and (3) (bottom terminal), using the bolts item (32) qty 08 and washer item (34) qty 08 for each side (camber joint LH and RH).

Note: Tighten the bolts item (32) qty 08 at 28.8 Nm (21 pound-feet) torque.

Contagem, MG Brazil 6-46780 July,2008

CONSTRUCTION 6009-7

STEP 13

STEP 15 As shown in the figure 2 and 3, install the grease fitting item (31) qty 04 to the camber joint LH and RH items (2) and (3) (use two grease fitting for each camber joint in the bottom and low terminal)

STEP 16 photo 6

figure 3

As shown in the photo 6, locate the shaft item (1) qty 01 on stand.

STEP 17

photo 5 As shown in the figure 3 and photo 5, install the cover item (14) qty 02 one to the each camber joint LH and RH items (2) and (3) (low terminal) Note: First tighten the cover item (14) at 200 Nm (148 pound-feet) torque, then loose and tighten again at 60 Nm (44 pound-feet) final torque.

STEP 14 As shown in the figure 3 and photo 5, install the plate item (15) qty 02, one for each camber joint LH and RH items (2) and (3) (low terminal), using the bolts M8 x 16 mm tem (33) and washer item (34) qty 04 (each side)

figure 4 As shown in the figure 4, separate and put the pin item (16) qty 02 in the nitrogen reservoir per 5 minutes.

Contagem, MG Brazil 6-46780 July,2008

CONSTRUCTION 6009-8

STEP 18

STEP 24

As shown in the figure 4, install the angular joint GE45-SX item (26) qty 02 to the camber joint assembly RH item (3).

As shown in the figure 4, install the grease fitting item (31) qty 02 to the pin item (16) qty 02.

STEP 19

STEP 25

As shown in the figure 4, Put, locate the flange and camber joint RH items (3 and 5) assembled to the shaft item (1) qty 01.

STEP 20 As shown in the figure 4, Put, locate the seal item (17) qty 01 and ring item (24) qty 01 in the point “A” Note: To put and fasten, is needed the special tool as drawing “BB” of page 6009- 4.

Make this tool in your shop.

STEP 21 As shown in the figure 4, Put, locate the seal item (17) qty 01 and ring item (24) qty 01 in the point “B” and then install (introduce) the pin item (16) qty 01.

STEP 22 figure 5 As shown in the figure 5, separate and put the pins item (18) qty 02 and item (21) qty 01 in the nitrogen reservoir per 5 minutes.

STEP 26

photo 7 As shown in the figure 4 and photo 7, fasten the pin (16) qty 01, using the washer item (28) qty 01, special nut item (29) qty 01 and pin item (30) qty 01.

Note: Manually locate the castle nut until the end of all thread and install the pin (30) Not use pneumatic impact wrench to tighten.

STEP 23 As shown in the figure 4 and photo 7 repeat the process (step 17 to 22) for the other axle side.

photo 8 As shown in the figure 5 and photo 8, install the hydraulic cylinder assembly item (10) qty 01 to the shaft item (1) qty 01, using the pin item (21) qty 01, bolt M10 x 80 mm item (40) qty 01 and nut item (41) qty 01.

Contagem, MG Brazil 6-46780 July,2008

6010 -7

PRODUCT (PARTS IDENTIFICATION) WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46781 July,2008

6010 -8

CONSTRUCTION

WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Shelter Spring Cap Spring Threaded pin Sprocket on wheel Locking plate Out-put Shaft assembly Retaining washer Brake piston Brake disk assembly Steel Plate Brake disk drum Support brake Body Brake Adjusting Shim Tapered Roller Bearing Tapered Roller Bearing Lip Seal Screw Snap Ring Seal Seal Snap Ring Snap Ring O-ring Seal Interlocking Pin

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -9

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46781 July,2008

6010 -10

CONSTRUCTION

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sprocket Adjusting Shim Check Washer Locking Plate Axle Shaft Snap Ring Gear Reducer Gear Reducer Support Tapered Roller Bearing Piastrina Per Semiasse Thrust Washer Planetary Gear Spacer Needle Rollers Pin Adjusting Shim Lip Seal Tapered Roller Bearing Reducer Hub

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -11

AXLE DIFFERENTIAL SECTION COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46781 July,2008

6010 -12

CONSTRUCTION

AXLE DIFFERENTIAL SECTION COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Drive Flange Nut Washer Seal Tapered Roller Bearing Adjustment Spacer Spacer Adjustment Spacer Tapered Roller Bearing Screw Differential Support Tapered Roller Bearing Adjusting Nut Elastic Pin Differential Case Crown Screw Adjusting Nut Seal Piston Reaction Plate O-ring Seal Thrust Sleeve Shoulder Ring Axial Roller Bearing Spring Lockring O-ring Seal Oil Passage Dowel Tapered Roller Bearing Pinion Crown Guard Screw Piston Counter Plate Friction Plate Thrust Washer Thrust Washer Pinion Gear Thrust Washer Cross Planetary Gear Pinion Gear

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -13

REAR AXLE SERVICE SPECIFICATIONS x

SERVICE INTERVAL

Oil Level check interval............................... Every 500 hours of operation, with axle on horizontal position.

Oil Change interval ....................After the first 100 hours then every 2000 hours of operation.

x

OIL SPECIFICATIONS

Central Axle Oil specification………………… AKCELA AXLEPOWER SAE 80W-90 API GL5 Limited Slip Tandem Box (see section 6013) Oil specification : ……………………………………AKCELA TRANSAXLE FLUID SAE 20W- 40

x

OIL CAPACITY

Central Axle……………………………………………………………………44.0 litres (11.6 gal.)

Tandem box (see section 6013) .…………………………………………..60.0 litres (15.8 gal.)

x

LUBRICATION (GREASE)

Grease type………………CASE Molydisulfide Grease (AKCELA MOLYGREASE 1070173) Lubricate (grease) ……………………………………………………each 100 hours of operation

Axle Oil Level Remove level/ filler plug (2). Add oil as necessary to bring oil level to bottom of plug hole.

Install plug and be sure it is properly tightened.

Rear Axle Oil Change REAR AXLE HOUSING COMPARTMENT Change the axle oil every 2000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Clean the oil level and drain plugs.

3. Make sure the oil in the rear axle is near normal operating temperature.

4. Remove drain plug (1) and filler plug (2) to help oil drain more rapidly.

5. After draining, reinstall the drain plug and fill the housing to the level of the filler hole with the specified oil. Allow sufficient time for oil to fill all axle compartments. Wait 15 minutes and top off. Install and tighten filler plug.

IMPORTANT: ANY KIND OF WARRANTY EXPIRES IF THE END USER DOES NOT PERFORM NORMAL MAINTENANCE AND IF NOT APPROVED OIL IS USED.

Contagem, MG Brazil 6-46781 July,2008

6010 -14

CONSTRUCTION

PERIODIC SERVICING Oil replacement procedure

Keep adequate containers corresponding to drain plugs.

Axle case • Remove oil filling and level checking plug (1).

• Remove drain plug (2) and fully drain the exhausted oil.

• Refit the drain plug (2).

IMPORTANT: Dispose of used oil in accordance with applicable local rules.

• Fill until oil flows from level hole (1).

• Refit the oil filling and level checking plug (1).

NOTE: DO NOT use an alternate oil in the axles.

The brake components in the axles could be damaged as a result of using an alternate oil.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -15

REAR AXLE DISASSEMBLING OVERHAULING AND RE-ASSEMBLING GENERAL INSTRUCTIONS Before starting the dismantling or assembling procedures of the Axle, bear in mind the following points: 1) When working on the axle observe high standards of cleanliness. All parts must be cleaned thoroughly prior to assembly.

2) The area where the procedure will be carried out must be fully dust-free and clean.

3) Make sure that all the required tools are available, particularly those identified in this manual. Parts fitted incorrectly can cause serious damages, as well as metal chips or foreign objects.

4) During the axle overhaul, it is recommended to replace the following components with new parts: sealing rings, gaskets, retaining rings and any parts damaged during dismantling.

5) In case of breakages inside the gearbox, all lines, casings must be cleaned thoroughly to prevent damage caused by residues left inside the system.

SHIMS During any adjustment, select the shims and measure them one by one with a micrometer gauge, then sum up all the values measured; do not trust in an incorrect measurement of a full pack or in the nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS Proceed as follows for correct fitting of oil seals on revolving shafts: x before assembly, seals should be soaked, for at least half an hour, in the same oil to be sealed; x

clean thoroughly shaft and make sure that working surface is not damaged; put the sealing lip against the fluid to be sealed. In case of hydrodynamic lip, the lines should be oriented in a way that, considering the direction of the revolving shaft, they lead fluid inside the seal.

x

smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space between sealing lip and dust shield lip, if using double sealing lip type seals;

x

press seal in relevant position or use a proper fitter with flat contact surface; never use hammer or mallet to fit seal;

x

when press fitting seal, make sure that it is correctly driven into relevant position, i.e. square with respect to its position; when fitting is completed make sure, if required, that seal itself is in contact with relevant shoulder;

x

to prevent damage of seal lip when inserting shaft, cautiously protect components during assembly.

Contagem, MG Brazil 6-46781 July,2008

6010 -16

CONSTRUCTION O-RING SEALS Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS For matching surfaces identified by X use LOCTITE 510 compound or a similar one.

Clean matching surfaces as follows before applying the sealing compound: x remove old deposits using a metal brush; x remove accurately any grease from the surfaces.

BEARINGS When installing the bearings, it is recommended to proceed as follows: x heat them at 80 to 90 °C before fitting on relevant shafts; x cool them before inserting into relevant external position.

SPRING PINS When using spring pins be sure that the lengthwise slot is in position toward the stress on the pin.

Coil pins do not require any specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

STORAGE AND SERVICE INSTRUCTION In order to assure the right condition, handling and utilization of the equipment, comply with the following instructions: x

During handling of the equipment, avoid any shock in order not to damage the external and the internal components.

x

In case of long inactivity of the equipment, before installing or starting it, be sure that the equipment has not suffered any damage.

x

Do not energize the electrical components with incompatible voltage.

x

Never use petrol, solvents or other inflammable fluids, use only approved commercial solvents that are both not flammable no toxic.

x

In case of stopping and before leaving the vehicle, make sure the parking brake is engaged.

Non compliance with these instructions or an incorrect use of the equipment, may result in injuries to persons and damage to the equipment.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -17

REAR AXLE IDENTIFICATION PLATE The axle is identified by two numbers punched into the rear part of the axle housing:

A - Identification number for axle type: B - Manufacturer’s serial number.

Put the axel case on a suitable support.

Drain oil from the axle central section, refer to “Periodic Servicing” Section.

Contagem, MG Brazil 6-46781 July,2008

6010 -18

CONSTRUCTION

Wheel assembly with Brake dismantling procedure

Install the tool, 4A94740, unscrew the screw (10) and remove wheel assembly (11).

Flatten locking plates (13) and unscrew the screw (12).

• Remove the locking plates (13).

• Remove the sprockets retaining plate (14).

• Remove the adjustment shim (15).

• Remove the sprockets (16).

Remove brake support (17), the cage with conical rollers bearing (18) end O-ring seal (19) from the support.

• Inspect the roller bearing outer race (18). If worn, remove it with a suitable puller, during mounting use a buffer.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -19

Remove the snap ring (20), remove brake disk drum (21).

• Remove the brake disks (22) and steel plates (23).

Remove the interlocking pin (27).

• Install the 4A95444 tool then screw the tool nuts until the snap rings (24) are removed.

• Remove the 4A95444 tool.

• Remove and retain the spring caps (25) and the springs (26).

Remove the brake piston (28)

Contagem, MG Brazil 6-46781 July,2008

6010 -20

CONSTRUCTION

Press and remove the output shaft (29) from the brake body (30).

Use a suitable press, press out the bearing race (31) from the brake body (30).

• Remove the seals (32) and (33).

Use a suitable extractor tool and remove the roller race of the bearing (35) from the output shaft.

• Remove the lip seal (34) and the shelter (36).

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -21

Visually inspect studs (37) for damages or deformations on threads.

Replace, if required, using a press for removal; fit new studs, taking care not to damage threads. .

Wheel Assy Maintenance and Overhaul: In order to carry out a visual inspection of the components, it is recommended to wash thoroughly all the metallic parts using a solvent, biodegradable if possible, then blow them with compressed air. x

Pay special attention to the internal lubrication channels, which must be spotlessly clean.

x

Check that the supports and the covers show no indentations and that the seats are intact, without scoring or ridging. If this is the case, they must be replaced immediately.

x

Make sure that the threading and the grooving on the shafts are in good condition.

Contagem, MG Brazil 6-46781 July,2008

6010 -22

CONSTRUCTION

Wheel assembly with Brake re-assebling

Apply “LOCTITE 601” sealant or similar on shelter (36) and install on output shaft.

Fit the race of bearing (31) on brake body.

• Lubricate the new seal quadrings (32) and (33) with “AKCELA MOLYGREASE” type or similar then insert them on brake body.

• Install the rollers race of bearing (35) on brake body.

• Use the tool 4A95443 and fit the lip seal (34) on brake body

Install the output shaft (29) on brake body (30).

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -23

Insert the brake piston (28).

• Install the springs (26) and caps (25) on pins.

• Install the tool 4A95444, then screw the nuts of the tool to compress the springs in order to fit the snap rings.

Put the snap ring in position on the appropriate bevel tool (drawing 4904506); • Put the tool in upright position with the snap ring (27) on the pin and press.

Repeat this procedure on the remaining two snap rings.

• Remove the tool 4A95444.

• Apply “LOCTITE 270” or similar on the threading of the interlocking pin (27) and install.

Install brake disk drum (21) on output shaft and insert snap ring (20).

Contagem, MG Brazil 6-46781 July,2008

6010 -24

CONSTRUCTION Insert first a steel plate (23), a brake disk (22) and alternate steel plate and brake disk.

IMPORTANT: In case of inverting disks positions, brake disks gets damaged.

Apply sealant on the contact surface of the brake body (30).

• Insert the a new O-ring (19) on the brake support (17).

IMPORTANT: Install the brake support (17) as shown in Fig. 19a. The slots (a) must be to the left of the oil inlet on the right front and left rear brake; and they must be to the right of the oil inlet on the left front and on the right rear brake.

• Install the roller race (18) of the bearing.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION 6010 -25

Install the sprocket (16) on output shaft.

Measure the distance (s) between the sprocket plane and the output shaft.

• Subtract 0.05 mm from the distance measured, this is the thickness of the adjustment shim (15).

Contagem, MG Brazil 6-46781 July,2008

6010 -26

CONSTRUCTION Install the adjustment shim (15) already calculated.

• Install the sprocket retaining washer (14), the locking plates (13), the screws (12) and torque them to 120 thru 130 Nm. • Check the rolling torque, it must be 15 thru 30 Nm without axial play.

• Bend the locking plates (13).

Install the tool 4A94740 on wheel assy (11).

• Clean and degrease the contact surfaces of the tandem housing and the wheel assy.

• Apply a uniform and continuous strip of LOCTITE 510 on the inner part of the tandem housing contact surface, circling the holes.

• Assemble the wheel assembly (11).

• Smear locking compound on fixing screws (10) and, tighten with a torque of 190 Nm ± 5%.

• Remove the tool 4A94740 from wheel assy.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -27

Axle overhauling: dismantling

Flatten locking plates (b) for caps crew (a) removal.

• Remove locking plates caps crew (b).

• Remove the sprockets retaining plate (c).

• Remove the adjustment shim (d).

• Remove the drive sprockets (e) from the drive shaft.

Position axle assembly vertically, with adequate support to avoid accidents.

• Remove the eight nuts (1).

• Remove the ten screws (1a).

• Remove the axle support (2).

Disassembly axle support with planetary spider: • Remove reduction support with proper lifting device.

• Remove the bearing cone from the hub (4).

Contagem, MG Brazil 6-46781 July,2008

6010 -28

CONSTRUCTION Remove the ring gear (5).

• If necessary, replace the inner bearing (6) with universal puller. Reassemble heating the bearing (80 - 90 C°).

Remove the elastic pin (7).

• Remove the gear pin (8).

• Remove the planetary gear (9).

• Make the same procedure for the other two planetary gear.

Check needle bearings (10), thrust washer (13), pins (8), planetary gear (9) and if worn replace.

Contagem, MG Brazil 6-46781 July,2008

6010 -29

If the removal of the hub from the support is necessary, remove the six screws.

At reassembly tighten screws with a torque of 470 Nm.

Re-assembly axle support with planetary spider: Apply grease to needle bearings (10) total 62.

IMPORTANT: In case of replacement, use the same class of bearing.

• Place the pin (8) on a flat surface; • insert a thrust washer (13) and apply grease to the pin (8); x

mount the first needle rollers (10);

• mount the spacer (12); • mount needle bearing rollers (10).

• position the planetary gear (9) and the second thrust washer (10), hold the two thrust washers and install the pin.

Contagem, MG Brazil 6-46781 July,2008

6010 -30

CONSTRUCTION Install the planetary gear assembly (9).

Position the pin (8), from the hole side, so that it is aligned with hole of the planetary spider hub.

• Align with a punch then install the elastic pin (7) and notch.

IMPORTANT: The elastic pin must not be longer than the diameter of the pin (fig. 33a).

• Make sure of free pin rotation and check the axial play.

• Repeat this procedure for the remaining two planetary gears.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -31

Put in position and install again the ring gear (5).

Inspect the bearings, axle support side, for wear and, if necessary, remove the outer races (14) and (16) using a punch.

• Install a new lip seal (15) at 6 mm from the stop plate of the outer bearing (Fig. 35a).

• Use a suitable sleeve having a diameter that will fit inside the cage I.D. and press in seal.

• Install with force the outer races (14) and (16) using a punch.

Contagem, MG Brazil 6-46781 July,2008

6010 -32

CONSTRUCTION Position the reduction hub on a base (a) of 150 mm, the studs must not touch the surface.

• Mount the reduction unit on axle support, the lip seal (15) spring must not extend from seat.

Install the bearing cone after heating to 90 to 100°C (4).

Remove half-shaft assembly (17).

• Inspect components of half-shaft assembly for wear and if necessary replace.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -33

Determination of shims between half-shaft and reduction hub Remove the half shaft thrust washer (18) and save shim pack (19).

Make a plate with same dimension of the thrust washer differing only thickness which should be 13 mm.

• Install this plate stop which will be dimension “E”.

• Install axle support assembly with halfshaft and measure GAP with feeler gauge at three points and average, dimension F”.

E - F = G i.e.: 13 - 0.5 = 12.5 mm Subtract dimension of plate stop 13mm “E” from dimension “F” (GAP) to obtain dimension “G”.

Determine shim pack thickness “X” by subtracting 11mm, original thurst washer thickness 10.5 mm add 0.5mm shaft end play, from dimension “G”.

X = 12.5 - 11 = 1.5 mm, this is the shim requested between thrust plate and reduction support assembly.

Contagem, MG Brazil 6-46781 July,2008

6010 -34

CONSTRUCTION Install shims “X” already calculated, apply Loctite 270 to original thurst washer (18) and Install in reduction support assembly.

Clean with care each contact surfaces, smear sealing compound to mating surface of central housing.

Install axle support housing (2) on central housing, make sure of correct position reduction hub gears with input shaft.

• Apply loctite 242 on the thread of nuts (1), install washers and nuts then torque to 290 ± 5% Nm. • Screw in fixing screws (1a) and lock a torque of 300 ± 5% Nm. • Make sure of correct rotation of reduction hub . .

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -35

Reinstall the drive sprockets (e) on the drive shaft, adjusting shim (d), sprockets retaining plate (c), locking plates (b), the screws (a) and torque them to 114 to 126 Nm. • Bend the locking plates (b).

Contagem, MG Brazil 6-46781 July,2008

6010 -36

CONSTRUCTION

Overhauling of differential unit dismantling Before the differential unit dismantling, dismantle the axle supports and remove the two half shafts as described before “Axle overhauling”.

Unlock and undo screws (1) retaining differential group (2), then remove it from axle case.

• Place on proper support and lock the differential. Straighten notches on pinion nut (3), then position reaction tool on P.T.O. flange (4) and unlock nut; release pinion nut.

• Remove the washer (4) and drive flange (5) from pinion shank.

• Unscrew the three screws (6) and remove crow guard (7).

• Should bevel gear set be renewed, unlock the screws (8) of bevel gear to differential case (9).

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -37

Dismantling of differential from support

Specific tooling for differential dismantling and re-assembling.

Insert the thread rod (a) with flange (b) and nut (c) assembled. Position on the opposite side the flange (d) and screw the nut (e).

• Screw the nut (c) until the spring lock ring has been removed (16).

• Unscrew the nut (e) and remove tooling.

Contagem, MG Brazil 6-46781 July,2008

6010 -38

CONSTRUCTION

Rotate drive head back through 90° to lie in as the position shown in the illustration.

• Remove the piston back plate (17) from the differential lock housing.

• Remove and discard O-rings (18) and (19).

• Remove piston (20). Remove O-ring (21) and discard.

• Remove compression spring (22) thrust sleeve (23), axial roller bearing (24) and plate (25).

• Unlock and remove caps fixing screws (26).

• Remove the roll pin (27). Unscrew the anti-rotation screw (28), remove caps (29) and (30), and adjusting nuts (31) and (32).

• Remove the oil passage dowel (33).

• Remove and discard O-rings (34).

• Remove the differential assembly (35);

Lift up differential by a lifting tool with proper capacity.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -39

Drive out bevel pinion (36) from differential support (2) hammering by a proper remover on shank, don't damage thread.

• Pry off seal (37) from PTO flange.

• Remove the taper roller bearing (38) and the adjustment spacer (39).

• Remove outer races of pinion shank (40) and under head bearings (41), save adjustment spacer (42) for axial position of pinion and the spacer (43).

• Remove the taper roller bearing (44) from the bevel pinion (36)

Contagem, MG Brazil 6-46781 July,2008

6010 -40

CONSTRUCTION

Differential disassembling, overhauling and re-assembling

Dismantling • Remove the bolts (1) and separate the differential lock case (2) from the rest of the assembly.

• Remove actuating sleeve (3).

• Remove seven counter plate (4) and six friction plates (5) from the differential pinion gear (6).

• Remove the differential half case (7).

• Remove the pinion gear (6) the cross (8), the four bevel gear (9) and thrust washer (10) the pinion gear (11) and thrust washer (12) and (13) from both half case.

• Should bevel gears set be renewed release fixing screws (14) and remove crown (15) from the differential case (16).

Important: The differential crown is supplied as a spare part together with the pinion (crown and pinion): the two components must always be replaced together.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -41

Differential Component Maintenance and Overhaul: Have visual and dimensional check of wear on sun and side gear, relevant thrust washers and spider.

• Clean thoroughly every differential component.

• Lubricate bearings and make turn freely the rollers carrying cage; rotation must be regular and without obstructions.

• Check support surfaces of ring gear and seat surface of half-case in order to have perfect ring gear adherence; deformation of those surfaces would cause vibration of fixing screw ring gear, thus compromising group good working.

• Replace ring gear fixing screws (14), in case of disassembly.

• Clean thoroughly all thread to obtain correct adjusting and exact torques.

• If necessary, replace the bearings (17) and (18) assembling with an heating equipment at 90 -110 °C or with proper installer.

Contagem, MG Brazil 6-46781 July,2008

6010 -42

CONSTRUCTION

Assembly • Assemble the pinion gear (11) and thrust washer (12), the cross (8), the four bevel gear (9) and thrust washer (10) the pinion gear (6)and thrust washer (13) into differential case half (16).

• Position the differential case half (7) aligning the match mark letters.

• Fit seven counter plates (4) and six friction plates (5), starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

• Position the actuating sleeve (3) on top of the last counter plate. Position the differential lock case (2) over the counter and friction plates and align the bolt holes with those of differential case half (7).

• Check free rotation of the gears in the horizontal position (if held vertically the friction and counter plates would prevent rotation).

• Screw in fixing screws and lock a torque of 115 - 130 Nm. • Check free rotation of the gears in the horizontal position.

• Assemble differential crown (15) and lock screws (14).

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -43

Differential unit re-assembling Prior re-assembling of bevel pinion on differential support it is necessary to record some dimensions to compute thickness of spacer to be interposed between pinion under head bearing and shoulder on relevant differential seat. Record dimension from ring gear axis to seating surface of pinion under head bearing, it will be identified as A, to this end a plate is to be positioned center on caps, then probe the exact available space.

Contagem, MG Brazil 6-46781 July,2008

6010 -44

CONSTRUCTION Each bevel pinion head face is marked with a number having (±) sign.

Said number, expressed in millimeter tenth, shows displacement from the theoretical dimension from pinion under head to ring gear axis. e.g.: -2 = - 0.20 mm therefore, the true dimension, identified as B, will be: B = 208 ± displacement in our case: B = 208 - 0.20 = 207,8 mm.

• Furthermore, measure pinion head height from bearing seating face to outer edge and mark as H. • Measure and record dimension relevant to width of pinion under head bearing as D. • Determine shim S thickness for correct axial position of bevel pinion: S = A - B – D • Add 0.05 mm to theoretical computed thickness to compensate the following bearing pre-load. Round up or down to the nearest tenth of millimeter the computed thickness.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -45

• Fit in pinion shank inner race (44) of under head bearing, heat or press-in part by installer.

• Insert adjustment shim (42) for axial position of pinion. Its value was computed previously; also, fit outer races of pinion under head (41) and shank bearings (40).

• Insert spacer (43) • Insert bevel pinion (36) in its seat on differential support.

• Fit bearing pre-load shims (39) (e.g., a shim of 1.5 mm); fit inner race (38) of pinion shank bearing.

• To simplify determination of pre-load, it is advisable to fit as many shims as required to warrant a pinion end play and with a preload (perhaps excessive) of bearings.

• Mount drive flange (5) on pinion, the washer (4) and screw the nut (3), place proper reaction tool and lock the nut (3) with a torque of 665 - 735 Nm.

Contagem, MG Brazil 6-46781 July,2008

6010 -46

CONSTRUCTION Check, by mean of a dial gauge end, play of pinion (for example, if play is 0.20 mm, decrease 0.25 mm from an adjusting shim); then disassemble and change adjustment shims (39) to eliminate all end play up to reach a pre-load.

• Reassemble components and check correct bearing pre-load, it should correspond to a rotating torque (no seal fitted) of: for new bearings: 2 - 4 Nm for running bearings: 1 - 2 Nm.

As bearing pre-load has been determined, remove drive flange and fit lip seal (37) in relevant seat, taking care to follow the assembling dimension indicated in figure 25, to apply the grease on inner diameter surface.

• Reassemble flange (5), the washer (4) and nut (3) and lock up definitively with a torque of 665 - 735 Nm. • Perform the two securing notches on pinion nut.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -47

Assemble differential assembly (34) on support.

Lift up differential by a lifting tool with proper capacity.

• Replace O-ring (34) and fit the oil passage dowel (33).

• Install caps (29) and (30), and lock screws fixing to differential support with a torque of 32 ÷ 35 Nm. • Check by a dial gauge end play of differential unit.

• Screw in a threaded ring (31) so to have a notch aligned against spring lock pin (a) and actuate the opposite ring (32) one up to eliminate end play.

• As such a condition has been reached go on with bearing pre-load by screwing in ring nut (32) further one more notch.

Contagem, MG Brazil 6-46781 July,2008

6010 -48

CONSTRUCTION

Position a dial gauge perpendicular than the ring gear tooth and check, with pinion steady, backlash that has to be 0.20 -0.28mm.

Otherwise rotate both threaded rings (31) and (32), by displacing them of the same number of notches and nearing ring gear to pinion, if backlash is excessive, by moving away on the contrary.

• Fit the roll pin (27) and screw the anti-rotation screw (28).

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -49

It is a good rule to check the contact impression of the pinion’s toothing on the bevel gear.

• Apply marker to the crown and make the bevel gear and pinion do some revolutions.

• Check that the impression on the bevel gear is centered with respect of the tooth side, is both on the drive side and on the coast one (see Fig. 58).

If this is not the case, adjust the spacer thickness to obtain an optimal bevel gear and pinion positioning (see Fig. 59), making sure the prescribed backlash and pre-load conditions are maintained.

Contagem, MG Brazil 6-46781 July,2008

6010 -50

CONSTRUCTION

Insert compression spring (22) thrust sleeve (23), axial roller bearing (24) and plate (25).

• Fit new O-ring (21) to piston (20).

• Fit the piston (20) and position the slit to align it with the anti-rotation screw (28).

• Fit new O-rings (18) and (19) to piston back plate (17).

• Insert the piston (20) back plate (17).

• Fit the thread rod (a) with flange (b) and nut (c) assembled. Position on the opposite side the flange (d) and screw the nut (e).

• Screw the nut (c) until the spring locking has been fit correctly (16).

• Unscrew the nut (e) and remove tooling.

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -51

Should bevel gear set be renewed and replaced, lock fixing screws (8) of bevel gear to differential case (9) with a torque of 450 - 480 Nm. • Assemble the crow guard (7), smear sealing compound and screw the three screws (6) with a torque of 50 - 60 Nm. • Clean with care each contact surfaces, smear sealing compound, then install differential unit (2) on central axle case; screw in fixing screws (1) and lock with a torque of 285 - 315 Nm. • Mount the two half-shafts and the axle supports as described before “Axle overhauling”.

• Refill with lubricant as specified in paragraph “AXLE PERIODIC SERVICING”.

Contagem, MG Brazil 6-46781 July,2008

6010 -52

CONSTRUCTION

REAR AXLE TROUBLESHOOTING FAULT

CAUSE

SOLUCTION

• Oil leakage from wheel assembly

• Incorrect screws torque.

O-Ring damaged

• Oil leakage from seals

• Incorrect installation Seals damaged

• Replace seals.

Replace seals

• Oil leakage from breather

• High oil level

• Check oil level

• Lubricant with excessive foam

• Incorrect lubricant

• Replace the oil.

• Incorrect lubricant

• Replace the oil

• Low oil level.

• Check oil level

• Incorrect bearing adjustment

• Verify and adjust the bearing setting

• Bearing damaged

• Verify and change the bearing

• Gears damaged

• Verify and replace the gears.

• Incorrect lubricant

• Replace the oil

• Incorrect backlash

• Verify and adjust

• Incorrect bearing preload

• Verify and adjust

• Incorrect bevel pinion position

• Verify the pinion position

• Side gears thrust washer damaged

• Verify and replace.

• Final drive noise

• Differential assembly noise

Contagem, MG Brazil 6-46781 July,2008

• Check the torque Replace O-Ring

CONSTRUCTION

6010 -53

SPECIAL TOOLS

Tool PN. 4904506/00 4A94740 4A95443 4A95444

description Tool to install the ring retaining cup Tool for lifting the wheel assy Tool for fitting the lip seal Tool for rings retaining spring cups assembly

(Make in your shop)

Contagem, MG Brazil 6-46781 July,2008

drawing / detail see pages 60010- 54 and 55 60010 - 56 60010 - 57 60010 - 58

6010 -54

CONSTRUCTION

Tools to install the ring retaining cup (Qty. 01) Assembly 4904506/00

Ref

Description

Qty

Material

1

Bevel Pin

01

88 Mn 8V KU

2

Pusher

01

88 Mn 8V KU

3

Hand

01

Elesa PS.50 - M16

Tratament Temp and Reven.

Temp and Reven.

-

Contagem, MG Brazil 6-46781 July,2008

Dimension HRC 60 HRC 60 -

obs see pg 6010 - 55 see pg 6010 - 55

CONSTRUCTION

6010 -55

Item 1 (Assembly 4904506/00) Bevel Pin (Material = 88 Mn 8V KU) - Qty.01

item 2 (Assembly 4904506/00) Pusher (Material = 88 Mn 8V KU) - Qty.01

Contagem, MG Brazil 6-46781 July,2008

6010 -56

CONSTRUCTION

Tools for lifting the wheel assembly (Qty.01) PN 4A94740

Material = FE 37 B Tratment = Norm. / Brun

Contagem, MG Brazil 6-46781 July,2008

CONSTRUCTION

6010 -57

Tool for fitting the lip seal (Qty. 01) PN 4A95443

Material = 18 NiCrMo5 Tratment = CMT. / TMP. Dimens. = HRc.60- 62

Contagem, MG Brazil 6-46781 July,2008

6010 -58

CONSTRUCTION

Tool for rings retaining spring cups assembly (Qty. 01) PN 4A95444

Ref 01 02 03/N

Description PLATE BAR NUT

Qty 01 03 03

Material C40 M10 M10

Tratament BRUN.

Contagem, MG Brazil 6-46781 July,2008

Dimensions

CONSTRUCTION

6010 -59

NOTES :

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This page was left blank intentionally.

6011

Section 6011 REAR AXLE ASSEMBLY (GRAZIANO MODEL)

885 885AWD

CNH Latin America Ltda 2237, General David Sarnoff Avenue Contagem - MG - Brasil

6-46790

Copyright © 2008 CNH Latin America Ltda All rights reserved Printed in Brazil Issued July, 2008

6011 -2

CONSTRUCTION

INTRODUCTION This section has been prepared to provide the maintenance personnel with information and instructions on the maintenance and repair of the rear axle.

In order to become familiar with the various parts of the axle, its principle of operation, troubleshooting and adjustments, it is important for the mechanic to read / study all the instructions in this section carefully and use it as a reference when performing maintenance and repair operations.

Whenever repair or replacement of component parts is required, only CNH approved spares as listed in the applicable spare parts catalog should be used.

Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment.

The CNH does not guarantee non approved repair or replacement parts; nor failures resulting from the use thereof, which are not supplied by or approved by CNH.

Important: Always furnish the Axle serial and model number when ordering parts.

SAFETY THIS REPAIR MANUAL MUST BE READ BY THE CUSTOMER COMPLETELY, AS SOON AS RECEIVED AND, THEN, BY ALL PERSONNEL THAT IS IN CHARGE OF CONTINUOUS OR OCCASIONAL OPERATING AND/OR CARRYING OUT INTERVENTION ON THE MACHINE. THIS REPAIR MANUAL OR AN INTEGRAL AND PERFECTLY READABLE COPY OF IT MUST BE ALWAYS AVAILABLE FOR REFERENCE THIS DOCUMENT SHALL BE KEPT IN AN EASILY VISIBLE POSITION AND PROTECTED BY AN ENVELOPE PREVENTING ITS DETERIORATION. THE MANUFACTURER DECLINES ALL RESPONSIBILITY IN CASE OF DAMAGES TO PEOPLE ANIMALS OR THINGS RESULTING FROM ALTERATIONS OF THE ORIGINAL CONTENT OF THIS INSTRUCTION MANUAL.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -3

TABLE OF CONTENTS INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6011 - 2 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6011 - 3 REAR AXLE (Graziano) Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 4 to 5 REAR AXLE (Graziano) Product specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 6 REAR AXLE (Graziano) Product identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 7 to 12 REAR AXLE (Graziano) Service specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 13 REAR AXLE (Graziano) Periodic servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 14 REAR AXLE (Graziano) Disassembling, overhauling and re-assembling . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 15 to 41 REAR AXLE (Graziano) Assembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 42 to 51 REAR AXLE (Graziano) Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 52 REAR AXLE (Graziano) Special Tools (make in your shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6011 - 53 to 58

Contagem, MG Brazil 6-46790 July,2008

6011 -4

CONSTRUCTION

This sign identify important messages devoted to your safety.

Read carefully safety rules reported here and follow with the greatest care all recommended suggestion to avoid potential dangers and protect your health and personal safety.

AVOID CAUSALITIES Most of all injuries and accidents that are encountered in workshops are caused by disregarding some simple and basic caution and safety rule.

For this reason most of these events can be avoided. To anticipate possible causes will suffice and acting accordingly with proper care and caution.

Each kind of operating machine, even if correctly planned and assembled, cannot be absolutely safe.

A cautious and careful operator is the best warrant against injuries.

To comply carefully with safety rules will be sufficient to prevent many dangerous injuries.

SAFETY RULES GENERAL x

Follow strictly directions reported for servicing and repair operations.

x

Don’t wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves, unbuttoned jackets or overall with open zipper that could be entangled in moving parts.

x

It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes, gloves, goggles helmets, etc.

x

Don’t start any servicing operation on machine with anyone on driver seat, except for authorized operator that cooperate for the work to be done.

x

Don’t operate machine or use relevant equipment from position other than driver’s seat.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -5

x

Don’t service machine with engine running, if not specified by repair instructions.

x

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers, valves, etc.

x

All servicing operations must be performed with best attention and care.

x

Disconnect batteries and mark all controls to point out that servicing operations are on course. Lock machine, all equipment must be lifted up and mechanically secured accordingly, with the appropriate device.

x

Brakes are inoperative when released for servicing operations: in such a condition machine control should be provided by proper blocks or similar equipment.

x

Should heavy components be displaced or moved, use proper hoist or similar equipment.

x

Care for people near operation areas.

x

Never pour gasoline or diesel fuel into open, large and low containers.

x

Never use gasoline, diesel fuel or other flammable fluids as cleaning agents. Use only commercially available not toxic, not flammable cleaning agents.

x

When using compressed air for cleaning purposes wear goggles with side shields.

x

Pressure must be limited to 2.1 bar max., according current local or national safety rules.

x

Never use free flame for illumination when operations are devoted to repair or locate leaks.

x

Move carefully when repairs are carried out working under the vehicle, wear the safety equipment prescribed: helmets, goggles and safety shoes.

x

The area where servicing operations are carried out must be always kept CLEAN and DRY. Clean and dry immediately any oil or water puddle.

Contagem, MG Brazil 6-46790 July,2008

6011 -6

CONSTRUCTION

!PRODUCT SPECIFICATIONS

Technical Features Maximum brake torque at 65 bar : 67116 Nm Oil type and quantity: see page 6011-13

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -7

PRODUCT (PARTS IDENTIFICATION) WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46790 July,2008

6011 -8

CONSTRUCTION

WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Shelter Spring Cap Spring Threaded pin Sprocket on wheel Locking Plate Out-put Shaft assembly Retaining washer Brake piston Brake disk assembly Steel Plate Brake disk drum Support brake Body Brake Adjusting Shim Tapered Roller Bearing Tapered Roller Bearing Lip Seal Screw Snap Ring Seal Seal Snap Ring Snap Ring O-ring Seal Interlocking Pin

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -9

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46790 July,2008

6011 -10

CONSTRUCTION

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Sprocket Adjusting Shim Check Washer Locking Plate Axle Shaft Snap Ring Gear Reducer Gear Reducer Support Tapered Roller Bearing Piastrina Per Semiasse Thrust Washer Planetary Gear Spacer Needle Rollers Pin Adjusting Shim Lip Seal Tapered Roller Bearing Reducer Hub

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -11

AXLE DIFFERENTIAL SECTION COMPONENTS IDENTIFICATION

Contagem, MG Brazil 6-46790 July,2008

6011 -12

CONSTRUCTION

AXLE DIFFERENTIAL SECTION COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Drive Flange Nut Washer Seal Tapered Roller Bearing Adjustment Spacer Spacer Adjustment Spacer Tapered Roller Bearing Screw Differential Support Tapered Roller Bearing Adjusting Nut Elastic Pin Differential Case Crown Screw Adjusting Nut Seal Piston Reaction Plate O-ring Seal Thrust Sleeve Shoulder Ring Axial Roller Bearing Spring Lockring O-ring Seal Oil Passage Dowel Tapered Roller Bearing Pinion Crown Guard Screw Piston Counter Plate Friction Plate Thrust Washer Thrust Washer Pinion Gear Thrust Washer Cross Planetary Gear Pinion Gear

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -13

REAR AXLE SERVICE SPECIFICATIONS x

SERVICE INTERVAL

Oil Level check interval............................................Every 500 hours of operation, with axle on horizontal position.

Oil Change interval ....................After the first 100 hours then every 2000 hours of operation.

x

OIL SPECIFICATIONS

Central Axle Oil specification………………… AKCELA AXLEPOWER SAE 80W-90 API GL5 Limited Slip Tandem Box (see section 6013) Oil specification : ……………………………………AKCELA TRANSAXLE FLUID SAE 20W- 40

x

OIL CAPACITY

Central Axle……………………………………………………………………44.0 litres (11.6 gal.)

Tandem box (see section 6013)……………………………………………60.0 litres (15.8 gal.)

x

LUBRICATION (GREASE)

Grease type………………CASE Molydisulfide Grease (AKCELA MOLYGREASE 1070173) Lubricate (grease) ……………………………………………………each 100 hours of operation

Axle Oil Level Remove level/ filler plug (2). Add oil as necessary to bring oil level to bottom of plug hole.

Install plug and be sure it is properly tightened.

Rear Axle Oil Change REAR AXLE HOUSING COMPARTMENT Change the axle oil every 2000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Clean the oil level and drain plugs.

3. Make sure the oil in the rear axle is near normal operating temperature.

4. Remove drain plug (1) and filler plug (2) to help oil drain more rapidly.

5. After draining, reinstall the drain plug and fill the housing to the level of the filler hole with the specified oil. Allow sufficient time for oil to fill all axle compartments. Wait 15 minutes and top off. Install and tighten filler plug.

IMPORTANT: ANY KIND OF WARRANTY EXPIRES IF THE END USER DOES NOT PERFORM NORMAL MAINTENANCE AND IF NOT APPROVED OIL IS USED.

Contagem, MG Brazil 6-46790 July,2008

6011 -14

CONSTRUCTION

PERIODIC SERVICING Oil replacement procedure

Keep adequate containers corresponding to drain plugs.

Axle case • Remove oil filling and level checking plug (1).

• Remove drain plug (2) and fully drain the exhausted oil.

• Refit the drain plug (2).

IMPORTANT: Dispose of used oil in accordance with applicable local rules.

• Fill until oil flows from level hole (1).

• Refit the oil filling and level checking plug (1).

NOTE: DO NOT use an alternate oil in the axles.

The brake components in the axles could be damaged as a result of using an alternate oil.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -15

REAR AXLE DISASSEMBLING OVERHAULING AND RE-ASSEMBLING GENERAL INSTRUCTIONS Before starting the dismantling or assembling procedures of the Axle, bear in mind the following points: 1) When working on the axle observe high standards of cleanliness. All parts must be cleaned thoroughly prior to assembly.

2) The area where the procedure will be carried out must be fully dust-free and clean.

3) Make sure that all the required tools are available, particularly those identified in this manual. Parts fitted incorrectly can cause serious damages, as well as metal chips or foreign objects.

4) During the axle overhaul, it is recommended to replace the following components with new parts: sealing rings, gaskets, retaining rings and any parts damaged during dismantling.

5) In case of breakages inside the gearbox, all lines, casings must be cleaned thoroughly to prevent damage caused by residues left inside the system.

SHIMS During any adjustment, select the shims and measure them one by one with a micrometer gauge, then sum up all the values measured; do not trust in an incorrect measurement of a full pack or in the nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS Proceed as follows for correct fitting of oil seals on revolving shafts: x before assembly, seals should be soaked, for at least half an hour, in the same oil to be sealed; x

clean thoroughly shaft and make sure that working surface is not damaged; put the sealing lip against the fluid to be sealed. In case of hydrodynamic lip, the lines should be oriented in a way that, considering the direction of the revolving shaft, they lead fluid inside the seal.

x

smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space between sealing lip and dust shield lip, if using double sealing lip type seals;

x

press seal in relevant position or use a proper fitter with flat contact surface; never use hammer or mallet to fit seal;

x

when press fitting seal, make sure that it is correctly driven into relevant position, i.e. square with respect to its position; when fitting is completed make sure, if required, that seal itself is in contact with relevant shoulder;

x

to prevent damage of seal lip when inserting shaft, cautiously protect components during assembly.

Contagem, MG Brazil 6-46790 July,2008

6011 -16

CONSTRUCTION O-RING SEALS Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS For matching surfaces identified by X use LOCTITE 510 compound or a similar one.

Clean matching surfaces as follows before applying the sealing compound: x remove old deposits using a metal brush; x remove accurately any grease from the surfaces.

BEARINGS When installing the bearings, it is recommended to proceed as follows: x heat them at 80 to 90 °C before fitting on relevant shafts; x cool them before inserting into relevant external position.

SPRING PINS When using spring pins be sure that the lengthwise slot is in position toward the stress on the pin.

Coil pins do not require any specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

STORAGE AND SERVICE INSTRUCTION In order to assure the right condition, handling and utilization of the equipment, comply with the following instructions: x

During handling of the equipment, avoid any shock in order not to damage the external and the internal components.

x

In case of long inactivity of the equipment, before installing or starting it, be sure that the equipment has not suffered any damage.

x

Do not energize the electrical components with incompatible voltage.

x

Never use petrol, solvents or other inflammable fluids, use only approved commercial solvents that are both not flammable no toxic.

x

In case of stopping and before leaving the vehicle, make sure the parking brake is engaged.

Non compliance with these instructions or an incorrect use of the equipment, may result in injuries to persons and damage to the equipment.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -17

REAR AXLE IDENTIFICATION PLATE The axle is identified by two numbers punched into the rear part of the axle housing:

A - Identification number for axle type: B - Manufacturer’s serial number.

Put the axel case on a suitable support.

Drain oil from the axle central section refer to “Periodic Servicing” Section.

Contagem, MG Brazil 6-46790 July,2008

6011 -18

CONSTRUCTION

Wheel assembly with Brake dismantling procedure

Install the tool, 4A94740, unscrew the screw (1) and remove wheel assy (2).

Flatten locking plates (4) and unscrew the screw (3).

• Remove the locking plates (4).

• Remove the sprockets retaining plate (5).

• Remove the adjustement shim (6).

• Remove the sprockets (7).

Remove brake support (8), the cage with conical rollers bearing (9) end O-ring seal (10) from the support.

• Inspect the roller bearing outer race (9). If worn, remove it with a suitable puller, during assembly use a buffer.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -19

Remove the snap ring (11), remove brake disk drum (12).

• Remove the brake disks (13) and steel plates(14).

Remove the interlocking pin (18).

• Install the 4A95444 tool, then screw the tool nuts until the snap rings (15) are removed.

• Remove the 4A95444 tool.

• Remove and retain the spring caps (16) and the springs (17).

• Remove the brake piston (19)

Contagem, MG Brazil 6-46790 July,2008

6011 -20

CONSTRUCTION

Press and remove the output shaft (20) from the brake body (21).

Use a suitable press, press out the bearing race (22) from the brake body (21).

• Remove the seals quadring (23) and (24).

Use a suitable extractor tool and remove the roller race of the bearing (26) from the output shaft.

• Remove the lip seal (25) and the shelter (27).

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -21

Visually inspect studs (28) for damages or deformations on threads.

Replace, if required,using a press for removal; fit new studs, taking care not to damage threads.

Wheel Assy Maintenance and Overhaul: In order to carry out a visual inspection of the components, it is recommended to wash thoroughly all the metallic parts using a solvent, biodegradable if possible, then blow them with compressed air.

Pay special attention to the internal lubrication channels, which must be spotlessly clean.

Check that the supports and the covers show no indentations and that the seats are intact, without scoring or ridging. If this is the case, they must be replaced immediately.

Make sure that the threading and the grooving on the shafts are in good condition.

Contagem, MG Brazil 6-46790 July,2008

6011 -22

CONSTRUCTION

Wheel assembly with Brake re-assebling

Apply “LOCTITE 601” sealant or similar on shelter (27) and install on output shaft.

Fit the bearing race (22) on brake body.

• Lubricate the new seal quadrings (23) and (24) with “AKCELA MOLYGREASE” type grease or similar, then insert them on brake body.

• Install the rollers race of bearing (26) on brake body.

• Use the tool 4A95443 and fit the lip seal (25) on brake body.

Install the output shaft (20) on brake body(21)

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -23

Insert the brake piston (19).

• Install the springs (17) and caps (16) on pins .

• Install the tool 4A95444, then screw the nuts of the tool to compress the springs in order to fit the snap rings.

Put the snap ring in position on the appropriate bevel tool (dwg. 4904506); • Put the tool in upright position with the snap ring (15) on the pin and press.

Repeat this procedure on the remaining two snap rings.

• Remove the tool 4A95444.

• Apply “LOCTITE 270” or similar on the threading of the interlocking pin (18) and install.

Install brake disk drum (12) on output shaft and insert snap ring (11).

Contagem, MG Brazil 6-46790 July,2008

6011 -24

CONSTRUCTION Insert first a steel plate (14), a brake disk (13) and alternate steel plate and brake disk.

IMPORTANT: In case of inverting disks positions, brake disks gets damaged.

Apply sealant on the contact surface of the brake body (21).

• Insert the a new O-ring (10) on the brake support (8).

IMPORTANT: Install the brake support (8) asshown in Fig. 19a. The slots (a) must be to the left of the oil inlet on the right front and left rear brake; and they must be to the right of the oil inlet on the left front and on the right rear brake.

• Install the roller race (18) of the bearing.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -25

Install the sprocket (16) on output shaft.

Measure the distance (s) between the sprocket plane and the output shaft.

• Subtract 0.05 mm from the distance measured, this is the thickness of the adjustmet shim (6).

Contagem, MG Brazil 6-46790 July,2008

6011 -26

CONSTRUCTION

Install the adjustement shim (6) already calculated.

• Install the sprocket retaining washer (5), the locking plates (4), the screws (3) and torque them to 120 thru 130 Nm. • Check the rolling torque, it must be 15 thru 30 Nm without axial play.

• Bend the locking plates (4).

Install the tool 4A94740 on wheel assy (2).

• Clean and degrease the contact surfaces of the tandem housing and the wheel assy.

• Apply a uniform and continuous strip of LOCTITE 510 on the inner part of the tandem housing contact surface, circling the holes.

• Assemble the wheel assy (2).

• Smear locking compound on fixing screws (1) and, tighten with a torque of 190 Nm ± 5%.

• Remove the tool 4A94740 from wheel assy.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -27

Flatten locking plates (b) for caps crew (a) removal.

• Remove locking plates caps crew (b).

• Remove the sprockets retaining plate (c).

• Remove the adjustment shim (d).

• Remove the drive sprockets (e) from the drive shaft.

Position axle assembly vertically, with adequate support to avoid accidents.

• Remove the eight nuts (1).

• Remove the ten screws (1a).

• Remove the axle support (2).

Disassembly axle support with planetary spider: • Remove reduction support with proper lifting device .

• Remove the bearing cone from the hub (4).

Contagem, MG Brazil 6-46790 July,2008

6011 -28

CONSTRUCTION

Remove the ring gear (5).

• If necessary, replace the inner bearing (6) with universal puller. Reassemble heating the bearing (80 ÷ 90 C°).

Remove the elastic pin (7).

• Remove the gear pin (8).

•Remove the planetary gear (9).

• Make the same procedure for the other two planetary gear.

Check needle bearings (10),thrust washer (13), pins (8), planetary gear (9) and if worn replace.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -29

If the removal of the hub from the support is necessary, remove the six screws.

At reassembly tighten screws with a torque of 470 Nm.

Re-assembly axle support with planetary spider: Apply grease to needle bearings (10) total 62.

IMPORTANT: In case of replacement , use the same class of bearing.

Place the pin (8) on a flat surface; • insert a thrust washer (13) and apply grease to the pin (8); • mount the first needle rollers (10); • mount the spacer (12); • mount needle bearing rollers (10).

• position the planetary gear (9) and the second thrust washer (10), hold the two thrust washers and install the pin.

Contagem, MG Brazil 6-46790 July,2008

6011 -30

CONSTRUCTION

Install the planetary gear assembly (9).

Position the pin (8), from the hole side, so that it is aligned with hole of the planetary spider hub.

• Align with a punch then install the elastic pin (7) and notch.

IMPORTANT: The elastic pin must not be longer than the diameter of the pin (fig.33a). x

Make sure of free pin rotation and check the axial play.

• Repeat this procedure for the remaining two planetary gears.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -31

Put in position and install again the ring gear (5).

Inspect the bearings, axle support side, for wear and, if necessary, remove the outer races (14) and (16) using a punch.

• Install a new lip seal (15) at 6 mm from the stop plate of the outer bearing (Fig. 35a).

• Use a suitable sleeve having a diameter that will fit inside the cage I.D. and press in seal.

• Install with force the outer races (14) and (16) using a punch.

Contagem, MG Brazil 6-46790 July,2008

6011 -32

CONSTRUCTION

Position the reduction hub on a base (a) of ~ 150 mm, the studs must not touch the surface.

• Mount the reduction unit on axle support, the lip seal (15) spring must not extend from seat.

Install bearing cone after heating to 90 to 100°C (4).

Remove half-shaft assembly (17).

• Inspect components of half-shaft assembly for wear and if necessary replace.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -33

Determination of shims between half-shaft and reduction hub

Remove the half shaft thrust washer (18) and save shim pack (19).

Make a plate with same dimension of the thrust washer differing only thickness which should be 13 mm.

• Install this plate stop which will be dimension “E”.

• Install axle support assy with half- shaft and measure GAP with feeler gauge at three points and average, dimension “F”.

E - F = G i.e.: 13 - 0.5 = 12.5 mm Subtract dimension of plate stop 13mm “E” from dimension “F” (GAP) to obtain dimension “G”.

Determine shim pack thickness “X” by subtracting 11mm, original thurst washer thickness 10.5 mm add 0.5mm shaft end play, from dimension “G”.

X = 12.5 - 11 = 1.5 mm this is the shim requested between thrust plate and reduction support assembly

Contagem, MG Brazil 6-46790 July,2008

6011 -34

CONSTRUCTION

Install shims “X” already calculated, apply Loctite 270 to original thurst washer (18) and Install in reduction support assembly.

Clean with care each contact surfaces, smear sealing compound to mating surface of central housing

Install axle support housing (2) on central housing, make sure of correct position reduction hub gears with input shaft.

• Apply loctite 242 on the thread of nuts (1), install washers and nuts then torque to 290 ± 5% Nm. • Screw in fixing screws (1a) and lock a torque of 300 ± 5% Nm. • Make sure of correct rotation of reduction hub.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -35

Reinstall the drive sprockets (e) on the drive shaft, adjusting shim (d), sprockets retaining plate (c), locking plates (b), the screws (a) and torque them to 114 ÷ 126 Nm. • Bend the locking plates (b).

Contagem, MG Brazil 6-46790 July,2008

6011 -36

CONSTRUCTION

Overhauling of differential unit: dismantling Before the differential unit dismantlig, dismantle the axle supports and remove the two halfshafts as described before “Axle overhauling”.

Unlock and undo screws (1) retaining differential group (2), then remove it from axle case.

• Place on proper support and lock the differential. Straighten notches on pinion nut (3), then position reaction tool on P.T.O. flange (4) and unlock nut; release pinion nut.

• Remove the washer (4) and drive flange (5) from pinion shank.

• Unscrew the three screws (6) and remove crow guard (7).

• Should bevel gear set be renewed, unlock the screws (8) of bevel gear to differential case (9).

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -37

Differential Dismantling of support

Specific tooling for differential dismantling and re-assembling.

Insert the threaded rod (a) with flange (b) and nut (c) assembled. Position on the opposite side the flange (d) and screw the nut (e).

• Screw the nut (c) until the spring lockring has been removed (16).

• Unscrew the nut (e) and remove tooling.

Contagem, MG Brazil 6-46790 July,2008

6011 -38

CONSTRUCTION

Rotate drive head back through 90° to lie in as the position shown in the illustration.

• Remove the piston back plate (17) from the differential lock housing.

• Remove and discard O-rings (18) and (19).

• Remove piston (20). Remove O-ring (21) and discard.

• Remove compression spring (22) thrust sleeve (23), axial roller bearing (24) and plate (25).

• Unlock and remove caps fixing screws (26).

• Remove the roll pin (27). unscrew the anti rotation screw (28), remove caps (29), (30), and adjusting nuts (31) and (32) .

• Remove the oil passage dowel (33). x

Remove and discard O-rings (34)

• Remove the differential assembly (35);

ATTENTION: Lift up differential by a lifting tool with proper capacity.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -39

Drive out bevel pinion (36) from differential support (2) hammering by a proper remover on shank, don't damage thread.

• Pry off seal (37) from PTO flange.

• Remove the taper roller bearing (38) and the adjustment spacer (39).

• Remove outer races of pinion shank (40) and under head bearings (41); save adjustment spacer (42) for axial position of pinion and the spacer (43).

• Remove the taper roller bearing (44) from the bevel pinion (36).

Contagem, MG Brazil 6-46790 July,2008

6011 -40

CONSTRUCTION

Differential disassembling, overhauling and re-assembling

Dismantling • Remove the bolts (1) and separate the differential lock case (2) from the rest of the assembly.

• Remove actuating sleeve (3).

• Remove seven counter plate (4) and six friction plates (5) from the differential pinion gear (6).

• Remove the differential half case (7).

• Remove the pinion gear (6) the cross (8), the four bevel gear (9) and thrust washer (10) the pinion gear (11) and thrust washer (12) and (13) from both half case.

• Should bevel gears set be renewed, release fixing screws (14) and remove crown (15) from the differential case (16).

Important The differential crown is supplied as a spare part together with the pinion (crown and pinion): the two components must always be replaced together.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -41

Differential Component Maintenance and Overhaul: Have visual and dimensional check of wear on sun and side gear, relevant thrust washers and spider.

• Clean thoroughly every differential component.

• Lubricate bearings and make turn freely the rollers carrying cage; rotation must be regular and without obstructions.

• Check support surfaces of ring gear and seat surface of half-case in order to have perfect ring gear adherence; deformation of those surfaces would cause vibration of fixing screw ring gear, thus compromising group good working.

• Replace ring gear fixing screws (14), in case of disassembly.

• Clean thoroughly all thread to obtain correct adjusting and exact torques.

• If necessary, replace the bearings (17) and (18) assembling with an heating equipment at 90 ÷ 110 °C or with proper installer.

Contagem, MG Brazil 6-46790 July,2008

6011 -42

CONSTRUCTION

Assembling • Assemble the pinion gear (11) and thrust washer (12), the cross (8), the four bevel gear (9) and thrust washer (10) the pinion gear (6) and thrust washer (13) into differential case half (16).

• Position the differential case half (7) aligning the match mark letters.

• Fit seven counter plates (4) and six friction plates (5), starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

• Position the actuating sleeve (3) on top of the last counter plate. Position the differential lock case (2) over the counter and friction plates and align the bolt holes with those of differential case half (7).

• Check free rotation of the gears in the horizontal position (if held vertically the friction and counter plates would prevent rotation).

• Screw in fixing screws and lock a torque of 115 ÷ 130 Nm. • Check free rotation of the gears in the horizontal position.

• Assemble differential crown (15) and lock screws (14).

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -43

Differential Unit re-assembling Prior re-assembling of bevel pinion on differential support it is necessary to record some dimensions to compute thickness of spacer to be interposed between pinion under head bearing and shoulder on relevant differential seat. Record dimension from ring gear axis to seating surface of pinion under head bearing, it will be identified as A, to this end a plate is to be positioned center on caps, then probe the exact available space.

Contagem, MG Brazil 6-46790 July,2008

6011 -44

CONSTRUCTION

Each bevel pinion head face is marked with a number having (±) sign.

Said number, expressed in millimeter tenth, shows displacement from the theoretical dimension from pinion under head to ring gear axis. e.g.: -2 = - 0.20 mm therefore, the true dimension, identified as B, will be: B = 208 ± displacement in our case: B = 208 - 0.20 = 207,8 mm.

• Furthermore, measure pinion head height from bearing seating face to outer edge and mark as H. • Measure and record dimension relevant to width of pinion under head bearing as D. • Determine shim S thickness for correct axial position of bevel pinion: S = A - B – D • Add 0.05 mm to theoretical computed thickness to compensate the following bearing pre-load. Round up or down to the nearest tenth of millimeter the computed thickness.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -45

• Fit in pinion shank inner race (44) of under head bearing, heat or press-in part by installer.

• Insert adjustment shim (42) for axial position of pinion. Its value was computed previously; also, fit outer races of pinion under head (41) and shank bearings (40).

• Insert spacer (43) • Insert bevel pinion (36) in its seat on differential support • Fit bearing pre-load shims (39) (e.g., a shim of 1.5 mm); fit inner race (38) of pinion shank bearing.

• To simplify determination of pre-load, it is advisable to fit as many shims as required to warrant a pinion end play and with a preload (perhaps excessive) of bearings.

• Mount drive flange (5) on pinion, the washer (4) and screw the nut (3), place proper reaction tool and lock the nut (3) with a torque of 665 ÷ 735 Nm.

Contagem, MG Brazil 6-46790 July,2008

6011 -46

CONSTRUCTION

Check, by mean of a dial gauge end, play of pinion (for example, if play is 0.20 mm, decrease 0.25 mm from an adjusting shim); then disassemble and change adjustment shims (39) to eliminate all end play up to reach a pre-load.

• Reassemble components and check correct bearing pre-load, it should correspond to a rotating torque (no seal fitted) of: for new bearings: 2 ÷ 4 Nm for running bearings: 1 ÷ 2 Nm.

As bearing pre-load has been determined, remove drive flange and fit lip seal (37) in relevant seat, taking care to follow the assembling dimension indicated in figure 25, to apply the grease on inner diameter surface.

• Reassemble flange (5), the washer (4) and nut (3) and lock up definitively with a torque of 665 ÷ 735 Nm. • Perform the two securing notches on pinion nut.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -47

Assemble differential assembly (34) on support.

Lift up differential by a lifting tool with proper capacity.

• Replace O-ring (34) and fit the oil passage dowel (33).

• Install caps (29) and (30), and lock screws fixing to differential support with a torque of 32 ÷ 35 Nm. • Check by a dial gauge end play of differential unit.

• Screw in a threaded ring (31) so to have a notch aligned against spring lock pin (a) and actuate the opposite ring (32) one up to eliminate end play.

• As such a condition has been reached go on with bearing pre-load by screwing in ring nut (32) further one more notch.

Contagem, MG Brazil 6-46790 July,2008

6011 -48

CONSTRUCTION

Position a dial gauge perpendicular than the ring gear tooth and check, with pinion steady, backlash that has to be 0.20 ÷0.28 mm.

Otherwise rotate both threaded rings (31) and (32), by displacing them of the same number of notches and nearing ring gear to pinion, if backlash is excessive, by moving away on the contrary.

• Fit the roll pin (27) and screw the anti rotation screw (28).

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -49

It is a good rule to check the contact impression of the pinion’s toothing on the bevel gear.

• Apply marker to the crown and make the bevel gear and pinion do some revolutions.

• Check that the impression on the bevel gear is centered with respect of the tooth side, is both on the drive side and on the coast one (see Fig. 58). If this is not the case, adjust the spacer thickness to obtain an optimal bevel gear and pinion positioning (see Fig. 59), making sure the prescribed backlash and pre-load conditions are maintained.

Contagem, MG Brazil 6-46790 July,2008

6011 -50

CONSTRUCTION

Insert compression spring (22) thrust sleeve (23), axial roller bearing (24) and plate (25).

• Fit new O-ring (21) to piston (20).

• Fit the piston (20) and position the slit to align it with the anti rotation screw (28).

• Fit new O-rings (18) and (19) to piston back plate (17).

• Insert the piston (20) back plate (17).

• Fit the thread rod (a) with flange (b) and nut (c) assembled.

Position on the opposite side the flange (d) and screw the nut (e).

• Screw the nut (c) until the spring lockring has been fit correctly (16).

• Unscrew the nut (e) and remove tooling.

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011 -51

Should bevel gear set be renewed and replaced, lock fixing screws (8) of bevel gear to differential case (9) with a torque of 450 ÷ 480 Nm. • Assemble the crow guard (7), smear sealing compound and screw the three screws (6) with a torque of 50 ÷ 60 Nm. • Clean with care each contact surfaces, smear sealing compound, then install differential unit (2) on central axle case; screw in fixing screws (1) and lock with a torque of 285 ÷ 315 Nm. • Mount the two half-shafts and the axle supports as described before “Axle overhauling”.

• Refill with lubricant as specified in paragraph “AXLE PERIODIC SERVICING”.

Contagem, MG Brazil 6-46790 July,2008

6011 -52

CONSTRUCTION

TROUBLESHOOTING FAULT

CAUSE

SOLUCTION

• Oil leakage from wheel assembly

• Incorrect screws torque.

O-Ring damaged

• Oil leakage from seals

• Incorrect installation Seals damaged

• Replace seals.

Replace seals

• Oil leakage from breather

• High oil level

• Check oil level

• Lubricant with excessive foam

• Incorrect lubricant

• Replace the oil.

• Incorrect lubricant

• Replace the oil

• Low oil level.

• Check oil level

• Incorrect bearing adjustment

• Verify and adjust the bearing setting

• Bearing damaged

• Verify and change the bearing

• Gears damaged

• Verify and replace the gears.

• Incorrect lubricant

• Replace the oil

• Incorrect backlash

• Verify and adjust

• Incorrect bearing preload

• Verify and adjust

• Incorrect bevel pinion position

• Verify the pinion position

• Side gears thrust washer damaged

• Verify and replace.

• Final drive noise

• Differential assembly noise

Contagem, MG Brazil 6-46790 July,2008

• Check the torque Replace O-Ring

CONSTRUCTION

6011 -53

SPECIAL TOOLS

Tool PN. 4904506/00 4A94740 4A95443 4A95444

description Tool to install the ring retaining cup Tool for lifting the wheel assy Tool for fitting the lip seal Tool for rings retaining spring cups assembly

(Make in your shop)

Contagem, MG Brazil 6-46790 July,2008

drawing / detail see pages 60011- 54 and 55 60011 - 56 60011 - 57 60011 - 58

6011 -54

CONSTRUCTION

Tools to install the ring retaining cup (Qty. 01) Assembly 4904506/00

Ref

Description

Qty

Material

1

Bevel Pin

01

88 Mn 8V KU

2

Pusher

01

88 Mn 8V KU

3

Hand

01

Elesa PS.50 - M16

Tratament Temp and Reven.

Temp and Reven.

-

Contagem, MG Brazil 6-46790 July,2008

Dimension HRC 60 HRC 60 -

obs see pg 6011 - 55 see pg 6011 - 55

CONSTRUCTION

6011 -55

Item 1 (Assembly 4904506/00) Bevel Pin (Material = 88 Mn 8V KU) - Qty.01

item 2 (Assembly 4904506/00) Pusher (Material = 88 Mn 8V KU) - Qty.01

Contagem, MG Brazil 6-46790 July,2008

6011-56

CONSTRUCTION

Tools for lifting the wheel assembly (Qty.01) PN 4A94740

Material = FE 37 B Tratment = Norm. / Brun

Contagem, MG Brazil 6-46790 July,2008

CONSTRUCTION

6011-57

Tool for fitting the lip seal (Qty. 01) PN 4A95443

Material = 18 NiCrMo5 Tratment = CMT. / TMP. Dimens. = HRc.60- 62

Contagem, MG Brazil 6-46790 July,2008

6011 -58

CONSTRUCTION

Tool for rings retaining spring cups assembly (Qty. 01) PN 4A95444

Ref 01 02 03/N

Description PLATE BAR NUT

Qty 01 03 03

Material C40 M10 M10

Tratament BRUN.

Contagem, MG Brazil 6-46790 July,2008

Dimensions

CONSTRUCTION

6011-59

NOTES :

Contagem, MG Brazil 6-46790 July,2008

This page was left blank intentionally.

REAR AXLE ASSEMBLY (GRAZIANO MODEL)

845DHP(STD)

CNH Latin America Ltda 2237, General David Sarnoff Avenue Contagem - MG - Brasil

6-46791

Copyright © 2008 CNH Latin America Ltda All rights reserved Printed in Brazil Issued July, 2008

6012

Section 6012

6012 -2

CONSTRUCTION

INTRODUCTION This section has been prepared to provide the maintenance personnel with information and instructions on the maintenance and repair of the rear axle.

In order to become familiar with the various parts of the axle, its principle of operation, troubleshooting and adjustments, it is important for the mechanic to read / study all the instructions in this section carefully and use it as a reference when performing maintenance and repair operations.

Whenever repair or replacement of component parts is required, only CNH approved spares as listed in the applicable spare parts catalog should be used.

Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment.

The CNH does not guarantee non approved repair or replacement parts; nor failures resulting from the use thereof, which are not supplied by or approved by CNH.

Important: Always furnish the Axle serial and model number when ordering parts.

SAFETY THIS REPAIR MANUAL MUST BE READ BY THE CUSTOMER COMPLETELY, AS SOON AS RECEIVED AND, THEN, BY ALL PERSONNEL THAT IS IN CHARGE OF CONTINUOUS OR OCCASIONAL OPERATING AND/OR CARRYING OUT INTERVENTION ON THE MACHINE. THIS REPAIR MANUAL OR AN INTEGRAL AND PERFECTLY READABLE COPY OF IT MUST BE ALWAYS AVAILABLE FOR REFERENCE. THIS DOCUMENT SHALL BE KEPT IN AN EASILY VISIBLE POSITION AND PROTECTED BY AN ENVELOPE PREVENTING ITS DETERIORATION. THE MANUFACTURER DECLINES ALL RESPONSIBILITY IN CASE OF DAMAGES TO PEOPLE, ANIMALS OR THINGS RESULTING FROM ALTERATIONS OF THE ORIGINAL CONTENT OF THIS INSTRUCTION MANUAL.

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6012 -3

TABLE OF CONTENTS INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6012 - 2 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6012 - 3 REAR AXLE (Graziano) Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 4 to 5 REAR AXLE (Graziano) Product specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 6 REAR AXLE (Graziano) Product identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 7 to 12 REAR AXLE (Graziano) Service specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 13 REAR AXLE (Graziano) Periodic servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 14 REAR AXLE (Graziano) Disassembling, overhauling,re-assembling, adjusts and assembly. . . . . . . . . . . . 6012 - 15 to 52 REAR AXLE (Graziano) Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 53 REAR AXLE (Graziano) Special Tools (make in your shop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6012 - 54 to 59

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6012 -4

CONSTRUCTION

This sign identify important messages devoted to your safety.

Read carefully safety rules reported here and follow with the greatest care all recommended suggestion to avoid potential dangers and protect your health and personal safety.

AVOID CAUSALITIES Most of all injuries and accidents that are encountered in workshops are caused by disregarding some simple and basic caution and safety rule.

For this reason most of these events can be avoided. To anticipate possible causes will suffice and acting accordingly with proper care and caution.

Each kind of operating machine, even if correctly planned and assembled, cannot be absolutely safe.

A cautious and careful operator is the best warrant against injuries.

To comply carefully with safety rules will be sufficient to prevent many dangerous injuries.

SAFETY RULES GENERAL x

Follow strictly directions reported for servicing and repair operations.

x

Don’t wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves, unbuttoned jackets or overall with open zipper that could be entangled in moving parts.

x

It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes, gloves, goggles helmets, etc.

x

Don’t start any servicing operation on machine with anyone on driver seat, except for authorized operator that cooperate for the work to be done.

x

Don’t operate machine or use relevant equipment from position other than driver’s seat.

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CONSTRUCTION

6012 -5

x

Don’t service machine with engine running, if not specified by repair instructions.

x

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers, valves, etc.

x

All servicing operations must be performed with best attention and care.

x

Disconnect batteries and mark all controls to point out that servicing operations are on course. Lock machine, all equipment must be lifted up and mechanically secured accordingly, with the appropriate device.

x

Brakes are inoperative when released for servicing operations: in such a condition machine control should be provided by proper blocks or similar equipment.

x

Should heavy components be displaced or moved, use proper hoist or similar equipment.

x

Care for people near operation areas.

x

Never pour gasoline or diesel fuel into open, large and low containers.

x

Never use gasoline, diesel fuel or other flammable fluids as cleaning agents. Use only commercially available not toxic, not flammable cleaning agents.

x

When using compressed air for cleaning purposes wear goggles with side shields.

x

Pressure must be limited to 2.1 bar max., according current local or national safety rules.

x

Never use free flame for illumination when operations are devoted to repair or locate leaks.

x

Move carefully when repairs are carried out working under the vehicle, wear the safety equipment prescribed: helmets, goggles and safety shoes.

x

The area where servicing operations are carried out must be always kept CLEAN and DRY. Clean and dry immediately any oil or water puddle.

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6012 -6

CONSTRUCTION

!PRODUCT SPECIFICATIONS

Technical Features Type Differential: SMT Oil type and quantity: see page 6012-13

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CONSTRUCTION

6012 -7

PRODUCT IDENTIFICATION WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS IDENTIFICATION

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6012 -8

CONSTRUCTION

WHEEL ASSEMBLY WITH BRAKE SECTION COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Shelter Spring Cap Spring Threaded pin Sprocket on wheel Locking plate Out-put Shaft assembly Retaining washer Brake piston Brake disk assembly Steel Plate Brake disk drum Support brake Body Brake Adjusting Shim Tapered Roller Bearing Tapered Roller Bearing Lip Seal Screw Snap Ring Seal Seal Snap Ring Snap Ring O-ring Seal Interlocking Pin

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CONSTRUCTION

6012 -9

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS IDENTIFICATION

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6012 -10

CONSTRUCTION

AXLE SECTION – SIDE REDUCTION GEARS COMPONENTS DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Sprocket Adjusting Shim Check Washer Locking Plate Axle Shaft Snap Ring Gear Reducer Gear Reducer Support Tapered Roller Bearing Piastrina Per Semiasse Thrust Washer Planetary Gear Spacer Needle Rollers Pin Adjusting Shim Lip Seal Tapered Roller Bearing Reducer Hub Pin

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CONSTRUCTION

6012 -11

AXLE DIFFERENTIAL UNIT COMPONENTS IDENTIFICATION

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6012 -12

CONSTRUCTION

AXLE DIFFERENTIAL UNIT COMPONENTS DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Differential Support Bevel Gear Set Tapered Roller Bearing Tapered Roller Bearing Nut Washer Drive Flange Lip Seal Adjusting Spacer Pinion Adjusting Spacer Roller Bearing Connecting Frame Tapered Roller Bearing Ring Nut Pin Differential Housing Steel Discs Intermediate Clutch Discs Clutch Discs Planetary Gear Spider Bevel Thrust Washer of Side Gear Side Gear Tapered Roller Bearing

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CONSTRUCTION

6012 -13

REAR AXLE SERVICE SPECIFICATIONS x

SERVICE INTERVAL

Oil Level check interval............................... Every 500 hours of operation, with axle on horizontal position.

Oil Change interval ....................After the first 100 hours then every 2000 hours of operation.

x

OIL SPECIFICATIONS

Central Axle Oil specification………………… AKCELA AXLEPOWER SAE 80W-90 API GL5 Limited Slip Tandem Box (see section 6013) Oil specification : ……………………………………AKCELA TRANSAXLE FLUID SAE 20W- 40

x

OIL CAPACITY

Central Axle…………………………………………………………………….. 40.0 litres (10.5 gal.)

Tandem box (see section 6013) .…………………………………………… 60.0 litres (15.8 gal.)

x

LUBRICATION (GREASE)

Grease type………………CASE Molydisulfide Grease (AKCELA MOLYGREASE 1070173) Lubricate (grease) ……………………………………………………each 100 hours of operation

Axle Oil Level Remove level/ filler plug (2). Add oil as necessary to bring oil level to bottom of plug hole.

Install plug and be sure it is properly tightened.

Rear Axle Oil Change REAR AXLE HOUSING COMPARTMENT Change the axle oil every 2000 hours of operation.

1. Park the machine on a level surface. Apply the parking brake and stop the engine.

2. Clean the oil level and drain plugs.

3. Make sure the oil in the rear axle is near normal operating temperature.

4. Remove drain plug (1) and filler plug (2) to help oil drain more rapidly.

5. After draining, reinstall the drain plug and fill the housing to the level of the filler hole with the specified oil. Allow sufficient time for oil to fill all axle compartments. Wait 15 minutes and top off. Install and tighten filler plug.

IMPORTANT: ANY KIND OF WARRANTY EXPIRES IF THE END USER DOES NOT PERFORM NORMAL MAINTENANCE AND IF NOT APPROVED OIL IS USED.

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6012 -14

CONSTRUCTION

PERIODIC SERVICING Oil replacement procedure

Keep adequate containers corresponding to drain plugs.

Axle case • Remove oil filling and level checking plug (1).

• Remove drain plug (2) and fully drain the exhausted oil.

• Refit the drain plug (2).

IMPORTANT: Dispose of used oil in accordance with applicable local rules.

• Fill until oil flows from level hole (1).

• Refit the oil filling and level checking plug (1).

NOTE: DO NOT use an alternate oil in the axles.

The brake components in the axles could be damaged as a result of using an alternate oil.

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CONSTRUCTION

6012 -15

DISASSEMBLY, OVERHAUL AND RE-ASSEMBLY OF AXLE GENERAL INSTRUCTIONS Before starting the dismantling or assembling procedures of the Axle, bear in mind the following points: 1) When working on the axle observe high standards of cleanliness. All parts must be cleaned thoroughly prior to assembly.

2) The area where the procedure will be carried out must be fully dust-free and clean.

3) Make sure that all the required tools are available, particularly those identified in this manual. Parts fitted incorrectly can cause serious damages, as well as metal chips or foreign objects.

4) During the axle overhaul, it is recommended to replace the following components with new parts: sealing rings, gaskets, retaining rings and any parts damaged during dismantling.

5) In case of breakages inside the gearbox, all lines, casings must be cleaned thoroughly to prevent damage caused by residues left inside the system.

SHIMS During any adjustment, select the shims and measure them one by one with a micrometer gauge, then sum up all the values measured; do not trust in an incorrect measurement of a full pack or in the nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS Proceed as follows for correct fitting of oil seals on revolving shafts: x before assembly, seals should be soaked, for at least half an hour, in the same oil to be sealed; x

clean thoroughly shaft and make sure that working surface is not damaged; put the sealing lip against the fluid to be sealed. In case of hydrodynamic lip, the lines should be oriented in a way that, considering the direction of the revolving shaft, they lead fluid inside the seal.

x

smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space between sealing lip and dust shield lip, if using double sealing lip type seals;

x

press seal in relevant position or use a proper fitter with flat contact surface; never use hammer or mallet to fit seal;

x

when press fitting seal, make sure that it is correctly driven into relevant position, i.e. square with respect to its position; when fitting is completed make sure, if required, that seal itself is in contact with relevant shoulder;

x

to prevent damage of seal lip when inserting shaft, cautiously protect components during assembly.

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6012 -16

CONSTRUCTION O-RING SEALS Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS For matching surfaces identified by X use LOCTITE 510 compound or a similar one.

Clean matching surfaces as follows before applying the sealing compound: x remove old deposits using a metal brush; x remove accurately any grease from the surfaces.

BEARINGS When installing the bearings, it is recommended to proceed as follows: x heat them at 80 to 90 °C before fitting on relevant shafts; x cool them before inserting into relevant external position.

SPRING PINS When using spring pins be sure that the lengthwise slot is in position toward the stress on the pin.

Coil pins do not require any specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

STORAGE AND SERVICE INSTRUCTION In order to assure the right condition, handling and utilization of the equipment, comply with the following instructions: x

During handling of the equipment, avoid any shock in order not to damage the external and the internal components.

x

In case of long inactivity of the equipment, before installing or starting it, be sure that the equipment has not suffered any damage.

x

Do not energize the electrical components with incompatible voltage.

x

Never use petrol, solvents or other inflammable fluids, use only approved commercial solvents that are both not flammable no toxic.

x

In case of stopping and before leaving the vehicle, make sure the parking brake is engaged.

Non compliance with these instructions or an incorrect use of the equipment, may result in injuries to persons and damage to the equipment.

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CONSTRUCTION

6012 -17

REAR AXLE IDENTIFICATION PLATE The axle is identified by two numbers punched into the rear part of the axle housing:

A - Identification number for axle type: B - Manufacturer’s serial number.

Put the axel case on a suitable support.

Drain oil from the axle central section, refer to “Periodic Servicing” Section.

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6012 -18

CONSTRUCTION

Wheel assembly with Brake dismantling procedure

Install the tool, 4A94740, unscrew the screw (10) and remove wheel assembly (11).

Flatten locking plates (13) and unscrew the screw (12).

• Remove the locking plates (13).

• Remove the sprockets retaining plate (14).

• Remove the adjustment shim (15).

• Remove the sprockets (16).

Remove brake support (17), the cage with conical rollers bearing (18) end O-ring seal (19) from the support.

• Inspect the roller bearing outer race (18). If worn, remove it with a suitable puller, during assembly use a buffer.

.

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CONSTRUCTION

6012 -19

Remove the snap ring (20), remove brake disk drum (21).

• Remove the brake disks (22) and steel plates (23).

Remove the interlocking pin (27).

• Install the 4A95444 tool then screw the tool nuts until the snap rings (24) are removed.

• Remove the 4A95444 tool.

• Remove and retain the spring caps (25) and the springs (26).

Remove the brake piston (28)

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6012 -20

CONSTRUCTION

Press and remove the output shaft (29) from the brake body (30).

Use a suitable press, press out the bearing race (31) from the brake body (30).

• Remove the seals quadring (32) and (33).

Use a suitable extractor tool and remove the roller race of the bearing (35) from the output shaft.

• Remove the lip seal (34) and the shelter (36).

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CONSTRUCTION

6012 -21

Visually inspect studs (37) for damages or deformations on threads.

Replace, if required, using a press for removal; fit new studs, taking care not to damage threads. .

Wheel Assembly Maintenance and Overhaul: In order to carry out a visual inspection of the components, it is recommended to wash thoroughly all the metallic parts using a solvent, biodegradable if possible, then blow them with compressed air. x

Pay special attention to the internal lubrication channels, which must be spotlessly clean.

x

Check that the supports and the covers show no indentations and that the seats are intact, without scoring or ridging. If this is the case, they must be replaced immediately.

x

Make sure that the threading and the grooving on the shafts are in good condition.

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6012 -22

CONSTRUCTION

Wheel assembly with Brake re-assebling

Apply “LOCTITE 601” sealant or similar on shelter (36) and install on output shaft.

Fit the bearing race (31) on brake body.

• Lubricate the new seal quadrings (32) and (33) with “AKCELA MOLYGREASE” type or similar then insert them on brake body.

• Install the rollers race of bearing (35) on brake body.

• Use the tool 4A95443 and fit the lip seal (34) on brake body

Install the output shaft (29) on brake body (30).

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CONSTRUCTION

6012 -23

Insert the brake piston (28).

• Install the springs (26) and caps (25) on pins.

• Install the tool 4A95444, then screw the nuts of the tool to compress the springs in order to fit the snap rings.

Put the snap ring in position on the appropriate bevel tool (drawing 4904506); • Put the tool in upright position with the snap ring (27) on the pin and press.

Repeat this procedure on the remaining two snap rings.

• Remove the tool 4A95444.

• Apply “LOCTITE 270” or similar on the threading of the interlocking pin (27) and install.

Install brake disk drum (21) on output shaft and insert snap ring (20).

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6012 -24

CONSTRUCTION Insert first a steel plate (23), a brake disk (22) and alternate steel plate and brake disk.

IMPORTANT: In case of inverting disks positions, brake disks gets damaged.

Apply sealant on the contact surface of the brake body (30).

• Insert the a new O-ring (19) on the brake support (17).

IMPORTANT: Install the brake support (17) as shown in Fig. 19a. The slots (a) must be to the left of the oil inlet on the right front and left rear brake; and they must be to the right of the oil inlet on the left front and on the right rear brake.

• Install the roller race (18) of the bearing.

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CONSTRUCTION

6012 -25

Install the sprocket (16) on output shaft.

Measure the distance (s) between the sprocket plane and the output shaft.

• Subtract 0.05 mm from the distance measured, this is the thickness of the adjustment shim (15).

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6012 -26

CONSTRUCTION Install the adjustment shim (15) already calculated.

• Install the sprocket retaining washer (14), the locking plates (13), the screws (12) and torque them to 120 thru 130 Nm. • Check the rolling torque, it must be 15 thru 30 Nm without axial play.

• Bend the locking plates (13).

Install the tool 4A94740 on wheel assy (11).

• Clean and degrease the contact surfaces of the tandem housing and the wheel assy.

• Apply a uniform and continuous strip of LOCTITE 510 on the inner part of the tandem housing contact surface, circling the holes.

• Assemble the wheel assembly (11).

• Smear locking compound on fixing screws (10) and, tighten with a torque of 190 Nm ± 5%.

• Remove the tool 4A94740 from wheel assy.

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CONSTRUCTION

6012 -27

Axle overhauling: dismantling

Flatten locking plates (b) for capscrew (a) removal.

• Remove locking plates capscrew (b).

• Remove the sprockets retaining plate (c).

• Remove the adjustment shim (d).

• Remove the drive sprockets (e) from the drive shaft.

Position axle assembly vertically, with adequate support to avoid accidents.

• Remove the eight nuts (1).

• Remove the axle support (2).

Disassembly axle support with planetary spider: • Remove reduction support with proper lifting device.

• Remove the bearing cone from the hub (4).

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6012 -28

CONSTRUCTION Remove the ring gear (5).

• If necessary, replace the inner bearing (6) with universal puller. Reassemble heating the bearing (80 - 90 C°).

Remove the elastic pin (7).

• Remove the gear pin (8).

• Remove the planetary gear (9).

• Make the same procedure for the other two planetary gear.

Check needle bearings (10), thrust washer (13), pins (8), planetary gear (9) and if worn replace.

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CONSTRUCTION

6012 -29

If the removal of the hub from the support is necessary, remove the six screws.

At reassembly tighten screws with a torque of 470 Nm.

Re-assembly axle support with planetary spider: Apply grease to needle bearings (10) total 62.

IMPORTANT: In case of replacement, use the same class of bearing.

• Place the pin (8) on a flat surface; • insert a thrust washer (13) and apply grease to the pin (8); x

mount the first needle rollers (10);

• mount the spacer (12); • mount needle bearing rollers (10).

• position the planetary gear (9) and the second thrust washer (10), hold the two thrust washers and install the pin.

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6012 -30

CONSTRUCTION

Install the planetary gear assembly (9).

Position the pin (8), from the hole side, so that it is aligned with hole of the planetary spider hub.

• Align with a punch then install the elastic pin (7) and notch.

IMPORTANT: The elastic pin must not be longer than the diameter of the pin (fig. 33a).

• Make sure of free pin rotation and check the axial play.

• Repeat this procedure for the remaining two planetary gears.

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CONSTRUCTION

6012 -31

Put in position and install again the ring gear (5).

Inspect the bearings, axle support side, for wear and, if necessary, remove the outer races (14) and (16) using a punch.

• Install a new lip seal (15) at 6 mm from the stop plate of the outer bearing (Fig. 35a).

• Use a suitable sleeve having a diameter that will fit inside the cage I.D. and press in seal.

• Install with force the outer races (14) and (16) using a punch.

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6012 -32

CONSTRUCTION Position the reduction hub on a base (a) of 150 mm, the studs must not touch the surface.

• Mount the reduction unit on axle support, the lip seal (15) spring must not extend from seat.

Install the bearing cone after heating to 90 to 100°C (4).

Remove half-shaft assembly (17).

• Inspect components of half-shaft assembly for wear and if necessary replace.

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CONSTRUCTION

6012 -33

Determination of shims between half-shaft and reduction hub

Remove the half shaft thrust washer (18) and save shim pack (19).

Make a plate with same dimension of the thrust washer differing only thickness which should be 13 mm.

• Install this plate stop which will be dimension “E”.

• Install axle support assembly with halfshaft and measure GAP with feeler gauge at three points and average, dimension F”.

E - F = G i.e.: 13 - 0.5 = 12.5 mm Subtract dimension of plate stop 13mm “E” from dimension “F” (GAP) to obtain dimension “G”.

Determine shim pack thickness “X” by subtracting 11mm, original thurst washer thickness 10.5 mm add 0.5mm shaft end play, from dimension “G”.

X = 12.5 - 11 = 1.5 mm, this is the shim requested between thrust plate and reduction support assembly.

Contagem, MG Brazil 6-46791 July,2008

6012 -34

CONSTRUCTION

Install shims “X” already calculated, apply Loctite 270 to original thurst washer (18) and Install in reduction support assembly.

Clean with care each contact surfaces, smear sealing compound to mating surface of central housing.

Install axle support housing (2) on central housing, make sure of correct position reduction hub gears with input shaft.

• Apply loctite 242 on the thread of nuts (1), install washers and nuts then torque to 300 ± 5% Nm. • Make sure of correct rotation of reduction hub . .

Contagem, MG Brazil 6-46791 July,2008

CONSTRUCTION

6012 -35

Reinstall the drive sprockets (e) on the drive shaft, adjusting shim (d), sprockets retaining plate (c), locking plates (b), the screws (a) and torque them to 114 to 126 Nm. • Bend the locking plates (b).

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6012 -36

CONSTRUCTION

Overhauling of differential unit : dismantling Before the differential unit dismantling, dismantle the wheel assembly as described before “Wheel assembly with Brake Dismantling”, oscillations assembly dismantling as described before “Oscillation assembly overhauling and dismantle” the axle supports and remove the two half-shafts as described before “Axle overhauling”.

Unlock and undo screws (1) retaining differential group (2), then remove it from central axle case.

Place on proper support and lock the differential.

• Loosen the screws of the bevel gear.

• Mark trunion caps position before disassembly

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CONSTRUCTION

6012 -37

Dismantling of differential from support

Rotate drive head back through 90° to lie in the position shown in the illustration.

• Remove the elastic pins (3).

• Unlock and remove cap fixing screws (4).

• Remove caps (5), adjusting nuts (6-10) and bearings race (7-9).

• Remove the differential assembly (8).

Lift up differential by a lifting tool with proper capacity.

Remove the four screws (11) and pinion nose support bracket (12), use the extraction holes.

• Remove the split pin (13) and remove the retaining pin (15).

• Replace the pinion bearing (16) on the connecting frame (12).

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6012 -38

CONSTRUCTION

Straighten notches on pinion nut (17), then position reaction tool on P.T.O. flange (19) and unlock nut (17); release pinion nut and remove washer (18).

• Remove the drive flange (19) from pinion shank.

• Drive out bevel pinion (26) from differential support (2) hammering by a proper remover on shank, don't damage thread.

• Pry off seal (20) from PTO flange.

• Remove the taper roller bearing (21) and the adjustment spacer (23).

• Remove outer races of pinion shank (22) and under head bearings (25); save adjustment spacer (24) for axial position of pinion.

Remove the under head pinion bearing (27), and the inner ring (28) of the pinion bearing on the pinion nose support bracket.

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CONSTRUCTION

6012 -39

Differential Bevel gear, Replacement

Should bevel gears set be renewed, release fixing screws (29) and remove bevel gear (30) from the differential case (8).

Important The differential crown is supplied as a spare part together with the pinion (bevel gear and pinion): the two components must always be replaced together.

• Assembly differential bevel gear (30) and lock the screws (29) with a torque of 315 ÷ 345 Nm. Important After replacing the bevel gear, pinion and differential housing it is necessary to check the backlash with the pinion toothing and the differential roller bearing pre-load as described in the previous paragraph.

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6012 -40

CONSTRUCTION

Differential disassembling, overhauling and re-assembling

Replace, if required, the bearings (31) and (32), by removing them with a puller and assemble them Heat to 120°C.

Mark the two half cases, remove the screws (33) and open them.

Remove the planetary gear (34) with steel disc (a), intermediate clutch discs (b) and clutch disc (c).

Remove spider (35) with the four side gears and bevel thrust washers.

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CONSTRUCTION

6012 -41

Remove the planetary gear (36) with steel disc (a), intermediate clutch discs (b) and clutch disc (c), in half case on bevel gear side.

Differential Component Maintenance and Overhaul: Have visual and dimensional check of wear on sun and side gear, relevant thrust washers and spider.

• Clean thoroughly every differential component.

• Lubricate bearings and make turn freely the rollers carrying cage; rotation must be regular and without obstructions.

• Check support surfaces of ring gear and seat surface of half-case in order to have perfect ring gear adherence; deformation of those surfaces would cause vibration of fixing screw ring gear, thus compromising group good working.

• Clean thoroughly all thread to obtain correct adjusting and exact torques.

Contagem, MG Brazil 6-46791 July,2008

6012 -42

CONSTRUCTION

Re-assembling: Before re-assembling, each smooth face have to be lubricated with oil.

• Insert a first steel disc (a) in housing, then a friction clutch disc (b) (both surfaces are made of sintered material); alternate the other discs.

• Insert the outer cluth disc (c) with the smooth surface turned to the planetary gear..

• Apply oil and insert the bevel planetary gear (36).

Assemble the side gears with relevant thrust washers on the spider (35) and position them on the half-casing.

• Apply oil and position the planetary gear (34).

• Insert an outer clutch disc (c) with the smooth surface turned to planetary gear.

• Insert first steel disc (a), then a friction clutch disc (b) and the others alternately.

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CONSTRUCTION

6012 -43

Align the steel discs (a) tanges.

• Mount the half-casing aligned against the intermediate and shim discs, close the two half-casings, taking care to align the reference marked..

Torque the four screws, check the revolving torque of 90 ÷ 120 Nm. • Remove or add intermediate discs of adequate shims.

• Lock the union screws (33) and fix with 110 ÷ 120 Nm.

Contagem, MG Brazil 6-46791 July,2008

6012 -44

CONSTRUCTION

Differential unit re-assembling

Reassembly of bevel pinion and adjustment Prior to the installation of the bevel pinion in the differential support, it is necessary to measure the dimensions to define the thickness of the shim to be placed between the head bearing and the shoulder in the relevant seal in the differential.

Measure the dimension of the bevel gear center line at the shoulder of the head bearing, designated as “A”, positioning a cylinder on the caps, then feel in an accurate manner the gap to which it is necessary to add the radius 62.5 mm of the differential bearing. i.e.: A = dimension measured + 62.5 mm in this case: A = 162.60 + 62.50 = 225.10 mm

Contagem, MG Brazil 6-46791 July,2008

CONSTRUCTION

6012 -45

On the front of the head of the each bevel pinion, and number with mark (±) is stamped or marked.

This number, in tenth of millimeter, indicates the deviation from the theoretical dimension (184 mm) under the head of the pinion from the center line of the bevel gear.

Example: -1 = 0.10 mm in this case B = theoretical 184.00 mm - 0.10 = 183.90 mm

Measure the pinion head height from bearing seating face to outer edge and marked as H. i.e.: H = 82.00 mm

Measure the width of pinion under head bearing as D. i.e.: D = 37.00 mm

Contagem, MG Brazil 6-46791 July,2008

6012 -46

CONSTRUCTION Shim S thickness should be determined for correct axial position of bevel pinion: i.e.: S = A - (B + D) in our case: S = 225.10 - (183.90 + 37.00) = 4.20 mm Reduce by 0.05 mm the theoretical computed thickness to compensate the different dimension of bearing after press-fitting.

Round up or down to the nearest tenth of millimeter the computed thickness.

Fit the bearing inner ring (28) on the bevel pinion nose.

• Install the cone bearing (27) heat at 80 ~90°C 176 ~ 194°F.

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CONSTRUCTION

6012 -47

Insert adjusting shim (24) for axial position of pinion. Its value was computed previously; also, fit outer races of pinion under head (25) and shank bearings (22).

To assure the correct assembly of the differential, it is necessary to position the pinion in its seat and the cylinder on the caps and measure distance E. E = B - (62.50 + H) mm in our case: E = 183.90 - (62.50 + 82.00) mm = 39.40 mm In this phase the quota E, must be lower than 0 ÷ 0.05 mm, than theoretical calculation.

Contagem, MG Brazil 6-46791 July,2008

6012 -48

CONSTRUCTION

Fit on bevel pinion (26) the spacer adjusting (23) of bearing preload, To simplify the determination of the correct preload, it is advisable to insert as many adjusting spacer as required to assure a pinion end play and not a pre-load on bearings.

• Position the bevel pinion (26) in its seat, on the differential support (2).

• Fit the inner race (21) of the outer pinion bearing.

• Mount drive flange (19) on pinion, place proper reaction tool and lock the nut (17) with washer (18) with a torque of 570 ÷ 630 Nm.

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CONSTRUCTION

6012 -49

Check by a dial gauge end play of pinion; • Disassemble again and change adjusting spacer (23) in order to get the play till the preload.

• Reassemble components and check correct bearing pre-load, it should correspond to a rotating torque (no seal fitted) for new bearings 2 ÷ 4 Nm

As bearing pre-load has been determined, remove drive flange and fit lip seal (20) in relevant seat, to apply the grease on inner diameter surface.

• Reassembly flange (19), the washer (18) and nut (3), lock up definitively with a torque of 570 ÷ 630 Nm.

Mount the connecting frame (12) locking the four screws (11) with 315 ÷ 345 Nm.

Contagem, MG Brazil 6-46791 July,2008

6012 -50

CONSTRUCTION Assembly differential (8) on support.

• Install caps (5), being careful not to reverse positions and lock screws fixing to differential support with a torque of 315 ÷ 345 Nm. • Check, by mean of a dial gauge, end play of differential unit.

• Turn in a ring nut (6) so as to have a notch aligned against the hole (a) of lock spring pin (3) and actuate the opposite ring (10) one up to eliminate end play.

• Then adjust bearing pre-load by turning in ring nut one more notch.

Position a dial gauge perpendicular than the ring gear tooth and check, with pinion steady, backlash that has to be 0.18 ÷0.23 mm. Otherwise rotate both threaded rings (6) and (10) see fig. 81, by displacing hem of the same number of notches and nearing ring gear to pinion, if backlash is excessive, by moving away on the contrary.

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CONSTRUCTION

6012 -51

It is a good rule to check the contact impression of the pinion’s toothing on the bevel gear.

• Apply marker to the crown and make the bevel gear and pinion do some revolutions.

• Check that the impression on the bevel gear is centered with respect of the tooth side, is both on the drive side and on the coast one (see Fig. 74). If this is not the case, adjust the spacer thickness to obtain an optimal bevel gear and pinion positioning (see Fig. 75), making sure the prescribed backlash and pre-load conditions are maintained.

Contagem, MG Brazil 6-46791 July,2008

6012 -52

CONSTRUCTION Press fit spring pins (3) locking rings.

• Perform the two securing notches on pinion nut (17).

Clean with care contact surfaces, apply sealing compound and then mount the differential unit (2) on central axle case.

• Lock the screws (1) retaining differential unit with a torque of 105 ÷ 115 Nm. • Mount the two half-shafts and the axle supports as described before “Axle overhauling”.

• Refill with lubricant as specified in paragraph “AXLE PERIODIC SERVICING”.

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CONSTRUCTION

6012 -53

TROUBLESHOOTING FAULT

CAUSE

SOLUCTION

• Oil leakage from wheel assembly

• Incorrect screws torque.

O-Ring damaged

• Oil leakage from seals

• Incorrect installation Seals damaged

• Replace seals.

Replace seals

• Oil leakage from breather

• High oil level

• Check oil level

• Lubricant with excessive foam

• Incorrect lubricant

• Replace the oil.

• Incorrect lubricant

• Replace the oil

• Low oil level.

• Check oil level

• Incorrect bearing adjustment

• Verify and adjust the bearing setting

• Bearing damaged

• Verify and change the bearing

• Gears damaged

• Verify and replace the gears.

• Incorrect lubricant

• Replace the oil

• Incorrect backlash

• Verify and adjust

• Incorrect bearing preload

• Verify and adjust

• Incorrect bevel pinion position

• Verify the pinion position

• Side gears thrust washer damaged

• Verify and replace.

• Final drive noise

• Differential assembly noise

Contagem, MG Brazil 6-46791 July,2008

• Check the torque Replace O-Ring

6012 -54

CONSTRUCTION

SPECIAL TOOLS

Tool PN. 4904506/00 4A94740 4A95443 4A95444

description Tool to install the ring retaining cup Tool for lifting the wheel assy Tool for fitting the lip seal Tool for rings retaining spring cups assembly

(Make in your shop)

Contagem, MG Brazil 6-46791 July,2008

drawing / detail see pages 60012- 55 and 56 60012 - 57 60012 - 58 60012 - 59

8003-15

CONSTRUCTION

WHEEL DRIVE PUMP AND MOTOR HYDRAULIC SCHEMATIC

Contagem, MG Brazil 6-46880 July,2008

8003-16

CONSTRUCTION

FRONT WHEEL DRIVE HYDRAULIC PUMP MOUNTING

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

GASKET SPACER BOLT GASKET HPV-02 - PUMP ASSEMBLY WASHER WASHERLOCK BOLT (Tighten the bolt item 8 at xxx to xxx Nm / xxx to xxx pound-feet torque) KIT REPAIR PLUG SEAL RING BOLT WASHERLOCK FLANGE FILTER (NOTE)

NOTE: The filter supplied with the HPV pump has to be replaced 100 hours after final commissioning.

Further exchanges must be made after every 500 hours.

Contagem, MG Brazil 6-46880 July,2008

CNH AMERICA LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

North American English Part Number 71114197 NA Printed in U.S.A. • Bur