JCB Drivetrain SD 55 NT Axle Service Manual - PDF DOWNLOAD

Service Manual JCB Drivetrain Systems Ltd Wrexham Industrial Estate WREXHAM United Kingdom LL13 9UF Tel: (01978) 661140 Fax: (01978) 661863

General Information

1

Care & Safety

2

Routine Maintenance

3

Hydraulics

4

Axles

5

Brakes

6 NOTE

All references in this manual to ‘Forward’ and ‘Reverse’ assume a front-mounted engine.

SD 55/NT AXLE Publication No. 9803/9240 Issue 8

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 6th Update Date

Page

Issue

Sept 2003

Cover

7

Issue number raised.

1/3 - 1 1/4 - 1 1/4 - 3

3 2 3

Service Tool list Updated Service Tool deleted Service Tools Updated

1/4 - 4 1/4 - 5 3/1-1 3/ 4-1

1 1 2 2

New Page New Page SD40, SD55, SD70 No brakes added All reference to Mobil oil deleted

5/Cont i

4

5/1-1 5/2-1

4 3

Drive Head Solid Spacer Assembly, Two Piece LSD Dismantling and Assembly, SD40, SD70 Hub Dismantling and Assemble and Axle Hub bearing Removal Assembly added SD40 AND SD70 Hub reduction added Title changed

5/2-2 5/6-2

1 2

New Page Step 6 changed, step 10 deleted

5/6-4

2

5/7-1

2

Note regarding Soild Spacer, step 6 and 13 torque setting added, step 11 backlash changed Gasket deleted from illustration

5/7-2 5/7-3 5/7-4 5/7-5

3 2

5/7-8 to 7-12 5/8-1 5/9-1 5/9-2

1 2 5 5

5/9-3 5/9-4

5 3

5/9-7 5/9-9 5/9-10

5 5 2

2

Changes

Collapsible Deleted, Note regarding Two Piece LSD Gasket deleted from illustration Addition to step 6, step 17 torque setting added Note regarding Soild Spacer, Note regarding stake nut and washer Step 12 rolling torque change. Step 15 backllash change.

New Pages Note regarding stake nut, New assembly procedure Dirt Shield added Step 1 axle arm changed to axle stub, Step 3 pinon changed to gears. Note regarding Hub Service Kit Dirt Shield added Note regarding Hub Service Kit

5/9-11

2

Dirt Shield added Dirt Shield added Note regarding Hub Service Kit, Step 10 moved to after step 15 and steps renumbered, Item 14 torque change Item 14 torque change

5/10-1 to 10-5 5/11-1 to 11-7

1 1

New Pages New pages

5/14-1 - 14-4

1

New pages

1

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 5th Update Date

Page

Issue

Changes

Dec 1998

Cover

6

Issue number raised.

1/Cont i

3

Axle Build Specification was Limited Slip Differential.

5/9-1

3

Blanking plugs Y and Z added to illustration.

5/9-2

4

Note regarding square seals removed. Note regarding excessive wear added.

5/9-3

4

Blanking plugs Y and Z added to illustration.

5/9-4

4

Notes added to items 16 and 18. Item 18 changed.

5/9-5

2

Note regarding Residual Pressure added. Note regarding square seals removed. Item 23 changed.

5/9-6

2

Information moved from 9-5.

5/9-7

2

Information moved from 9-6. Sealing plugs Y and Z added to illustration.

5/9-8

2

Information moved from 9-7. Note regarding excessive wear added to item 10.

5/9-9

2

Information moved from 9-8.

5/9-10

1

New page.

5/9-11

1

New page.

6/Cont i

2

Residual Brake System Pressure added. Brake seal or component leakage added.

6/2-1

2

Residual Brake System Pressure added. (Taken from 9803/3620 - 520-50 S/M).

6/3-1

1

New page.

6/3-2

1

New page.

1

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 4th Update Date

Page

Issue

Nov 1998

Cover

5

Issue number changed.

Changes

2/4-2

2

Warnings GEN-1-12 and GEN-1-13 added.

1

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 3rd Update Date

Page

Issue

Sept 1998

Cover

4

Issue number raised.

Changes

1/1-1

3

Axle Build Identification heading was Limited Slip Differential.

1

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 2nd Update Date

Page

Issue

April 1998

Cover

3

Issue number raised.

5/i

3

Items added for splined hub - Dismantling and Assembly.

5/1-1

3

General Description added. Brake type added.

5/9-1

3

Sub-heading changed.

5/9-2

3

Item 1 changed, note added, Sub-heading changed. Warning 5-3-2-1 added. Note to item added.

5/9-3

3

Sub-heading changed.

5/9-4

3

Sub-heading changed.

5/9-5

3

Sub-heading changed. Item 20 was 17. Note to item 22 added.

5/9-6

1

New page.

5/9-7

1

New page.

5/9-8

1

New page.

5/9-9

1

New page.

8

Changes

1

SD 55/NT Transmission Service Manual Publication No. 9803/9240

Record of Changes 1st Update Date

Page

Issue

August 1997

Cover

2

Issue number raised.

Changes

Intro

2

Item 6 Brakes added.

1/i

2

Limited Slip Differential added to contents.

1/1-1

2

Limited Slip Differential information added.

1/2-1

2

Grade 12.9 bolt list added.

1/3-1

2

Part numbers revised.

1/4-3

2

Service Tools added.

1/5-1

2

Part numbers revised.

3/i

2

Lubricants - Health and Safety added to contents.

3/1-1

2

Oil and grease specification revised.

3/1-2

1

New page - Lubricants - Health and Safety information added.

3/2-1

2

Service schedules revised.

3/3-1

2

Annotations corrected.

4/1-1

2

Valve pressures removed.

4/2-1

2

Note revised.

4/3-2

2

Grease and Sealant specification revised.

4/5-1

2

Item 3 corrected.

5/i

2

Contents titles revised and corrected.

5/1-1

2

Mounting and input items revised.

5/2-1

2

Illustration revised.

5/5-1

2

Grease specification revised.

5/6-2

2

Item 2 revised.

5/7-2

2

Note regarding friction plates added.

5/9-1

2

Illustration revised.

5/9-2

2

Items 2, 8, 10 and 14 revised. Items 20 to 23 added.

5/9-3

2

Illustration revised.

5/9-4

2

Item numbers revised.

5/9-5

2

Item numbers revised.

6/1-1

2

Friction plates revised from 3 to 2.

1

Introduction This publication is designed for the benefit of Service Engineers.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools.

Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance - includes service schedules and recommended lubricants etc.

The remaining sections deal with Dismantling, Overhaul etc. of specific components:

*

4 5 6

= = =

Hydraulics Axles Brakes

The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.

Section contents, technical data, operation descriptions etc. are inserted at the beginning of each section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section containing the subject. For example: “24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section 6).”

Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.

Use the contents list at the beginning of each section to find the exact page number.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.

9803/9240

Issue 2*

Section 1

General Information

Section 1

i

i

Contents

*

9803/9240

Page No.

Unit Identification

1-1

Replacement Parts

1-1

Axle Build Identification

1-1

Torque Settings

2-1

Service Tools Numerical List

3-1

Service Tools

4-1

Sealing and Retaining Compounds

5-1

Issue 3*

Section 1

General Information

Section 1

1-1

1-1

Unit Identification Axle Serial Plate (Offset Drive Head) The axle serial number is stamped on a plate mounted on the face of the axle, as shown.

ITL00990

Replacement Parts 1

When replacement parts are required, always ensure that the correct parts are obtained, e.g. in the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

2

When ordering replacement parts, quote the details on the serial plate shown.

3

It is essential that all gaskets and seals removed while dismantling, should be renewed on reassembly.

* Axle

Build Identification

To identify an axle build, the number on the axle data plate should be cross-referenced with the part number in the parts information.

Example: 450 / 2760 / 1 / 0091

A

B C

A 450/2760: Axle assembly part number (450/27600) without the final zeros.

4

On reassembly care should be taken that all parts are correctly replaced since any component omitted or incorrectly assembled can lead to a complete failure.

5

Lubricants should comply with the recommended list as provided in this manual. It is important to adhere to the oil changing procedure.

6

It is advisable to lightly lubricate with a recommended lubricant, parts such as gears, shafts, thrust washers and oil seals during reassembly.

9803/9240

B

/1: Internal issue number of the main manufacturing drawing.

C /0091: Axle serial number. The complete 12 digit number

must be quoted for warranty purposes. The parts information will detail the number of friction plates required for the axle.

Issue 4

Section 1

General Information

Section 1

2-1

2-1

Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts Bolt Size in 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16

11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m

lbf ft

1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

10 20 36 58 87 125 175 300 480 715 1430 2500

Torque Settings kgf m

lbf ft

Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55

Nm 7 12 28 56 98 244 476 822 1633 2854

0.7 1.2 3.0 5.7 10 25 48 84 166 291

5 9 21 42 72 180 352 607 1205 2105

* Metric Grade 12.9 Bolts Bolt Size

M8 M10 M12 M14 M16

(mm)

Nm

(8) (10) (12) (14) (16)

48 94 166 320 400

Torque Settings kgf m 4.9 9.6 16.9 32.6 40.8

lbf ft 35 69 122 236 295

Note: All bolts are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/9240

Issue 2*

Section 1

General Information

3-1

3-1

Service Tools Numerical List * 445/12303 * 1315/3414Z * 1315/3835Z * 1370/0301Z * 1370/0401Z * 1370/0601Z * 1370/0701Z * 1315/3731Z * 1420/0009Z * 1420/0012Z 4003/0211 4101/0251 4101/0451 4101/0651 4101/0250 4102/0551 4102/1212 4102/1951 4104/0251 4104/0253 4104/1557 892/00174 892/00224 * 892/00225 * 892/00286 892/00333 892/00334 892/00812 892/00817 892/00818 892/00819 892/00822 892/00833 892/00891 * 921/52627 * 921/53300 992/00800 * 982/00918 * 892/01092 * 917/02800 * 992/04000 * 993/70111 * 992/07601 * 993/99512 * 993/99513 * 993/99514 * 993/99515 * 997/11000 * 998/10567 * 998/10623 * 998/10606 * 998/10607 * 998/10608 * 998/10610 * 998/10614 * 998/10615 * 998/10616 * 998/10624

9803/9240

Section 1

Page No.

Washer 4-3 Bolt M10 x 60 4-3 Bolt M20 x 300 4-3 Nut M10 4-3 Nut M12 4-3 Nut M16 4-3 Nut M20 4-3 Bolt M16 x 220 4-3 Washer M12 4-3 Washer M20 4-3 Anti-Seize Paste 5-1 Loctite 242 5-1 Loctite 932 5-1 Loctite 648 5-1 Loctite 243 5-1 Loctite 275 5-1 Loctite 574 or Permabond A136 5-1 Loctite 577 5-1 Activator (Aerosol) 5-1 Activator (Bottle) 5-1 Cleaner/Degreaser 5-1 Measuring Cup - Pinion Head Bearing 4-2 Impulse Extractor Set for Hub Bearing Seals 4-2 Adapter - Impulse Extractor 4-1 Surface Temperature Probe 4-1 Heavy Duty Socket 4-1 Gland Seal Fitting Tool 4-1 Drive Coupling Spanner 4-2 Heavy Duty Socket 4-1 Heavy Duty Socket 4-1 Heavy Duty Socket 4-1 Splined Bolt Socket 4-2 Annulus Removal Tool 4-2 Oil Seal Insertion Tool 4-3 Spacer 14.20 Service use 4-5 Spacer Kit- SD55 Axles 4-5 Extractor for Removing Axle Pivot Pin 4-2 Setting Tool Kit 4-5 Hub Service Kit 4-3 Bearing 4-3 Torque Multiplier 4-2 Breakback Torque Wrench 4-5 Spanner for Half Shaft Nuts 4-1 Spanner for Cylinder Piston Nut 4-1 Spanner for Cylinder Piston Nut 4-1 Spanner for Cylinder Piston Nut 4-1 Spanner for Cylinder Piston Nut 4-1 Support Bracket SD70, SD55 Front Axles4 - 5 Pinion Shaft Adaptor 4-5 Puller Beam 4-3 Bearing Fitting Tube 4-3 Inner Bearing Plate 4-3 Bearing Centre Puller 4-3 Puller Rod 4-3 Reaction Tube 4-3 Wheel Bearing Carrier Puller 4-3 Puller Handle Nut 4-3 Modified Wheel Stud 4-3

Issue 3*

Section 1

General Information

Section 1

4-1

4-1

Service Tools

JS07050

Cylinder Piston Nut removal/Fitting Spanner 993/99512 993/99513 993/99514 993/99515

892/00817 892/00818 892/00819 892/00333

Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm A/F Spanner 70 mm A/F

892/00225

17 mm A/F x 3/4 in square drive 22 mm A/F x 3/4 in square drive 15 mm A/F x 1/2 in square drive 19 mm A/F x 3/4 in square drive

892/00334

Adapter - Impulse Extractor Small 17 mm to 25 mm Medium 25 mm to 45 mm Large 45 mm to 80 mm

Gland Seal Fitting Tool

ITL01100

892/00286

9803/9240

Surface Temperature Probe

Issue 2*

Section 1

General Information

Section 1

4-2

4-2

Service Tools (cont'd)

992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)

S197030

892/00822 Splined Bolt Socket for driveshafts 892/00174 Measuring Cup - Pinion Head Bearing

S197060

S190770

S197070

892/00224 Impulse Extractor Set for Hub Bearing Seals

892/00812

Annulus Removal Tool

992/00800

Extractor for removing axle pivot pin

Drive Coupling Spanner for axle yoke couplings

S196720

9803/9240

892/00833

Issue 1

Section 1

General Information

Section 1

4-3

4-3

Service Tools (cont'd)

* Wheel Hub Service Tool A B C

A

Bearing Puller Bearing Press Hub Seal Dolly

5

1

Item Description A, B & C Hub Service Kit

Part No. 892/01092

Qty 1

6

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

8,9

Puller Beam Inner Bearing Plate Bolt M16x220 Nut M16 Reaction Tube ModifiedWheel Stud Wheel Bearing Carrier Puller Nut M20 Washer M20 Puller Rod Nut M12 Washer M12 Bearing Centre Puller Bolt M10x60 Nut M10 Bearing Fitting Tube Puller Handle Nut Bolt M20x300 Washer Bearing Seal Dolly

B

15

998/10623 998/10607 1315/3731Z 1370/0601Z 998/10614 998/10624

1 1 2 2 1 2

998/10615 1370/0701Z 1420/0012Z 998/10610 1370/0401Z 1420/0009Z 998/10608 1315/3414Z 1370/0301Z 998/10606 998/10616 1315/3835Z 445/12303 917/02800 892/00891

2 4 2 2 2 2 1 1 1 1 1 2 2 1 1

7 2

10

4

11,12

3

13 16

14 18

C

19, 20

8 21

17

A439160

9803/9240

Issue 3*

Section 1

General Information

Section 1

4-4

4-4

Service Tools (cont'd)

1 5

A396940

6 2

3

A396950

4

A396930

9803/9240

Issue 1*

Section 1

General Information

Section 1

4-5

4-5

Service Tools (cont'd)

Solid Spacer Setting Kit

1 2 3 4

892/00918 921/52627 993/70111 997/11000

7

998/10567

Setting Tool Kit Spacer 14.20 Service use Breakback Torque Wrench Support Bracket SD55, SD70 Front Axles Pinion Shaft Adaptor

6

921/53300

Spacer Kit - SD55 Axles

Comprises of: 921/53322 921/53323 921/53324 921/53325 921/53301 921/53302 921/53303 921/53304 921/53305 921/53306 921/53307 921/53308 921/53309 921/53310 921/53311 921/53312 921/53313 921/53314 921/53315 921/53316 921/53317 921/53318 921/53319 921/53320 921/53321

9803/9240

Spacer thickness mm 13.550 13.575 13.600 13.625 13.650 13.675 13.700 13.725 13.750 13.775 13.800 13.825 13.850 13.875 13.900 13.925 13.950 13.975 14.000 14.025 14.050 14.075 14.100 14.125 14.150

S261230

Torque Measuring Tool for Wheel Hub Seals Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force.

However, the torque can be measured using above locally manufactured tool.

Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft).

Issue 1*

Section 1

General Information

Section 1

5-1 * Sealing

5-1

and Retaining Compounds

Loctite 574 or Permabond A136

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

4102/1212

Loctite 275 or Permabond A140

For all size of flanges where the strength of the joint is important.

4102/0551

Loctite 932 or Permabond A137

For all retaining parts which are likely to be dismantled and for use on threads larger than 50 mm dia.

† 4101/0451

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25 mm diameter.

† 4101/0251

A medium strength locking fluid similar to Loctite 242 but with greater resistance to thread contamination.

4101/0250

Loctite 648 or Permabond A118

For retaining parts which are unlikely to be dismantled.

4101/0651

Loctite 577

A medium strength thread sealing compound.

4102/1951

Loctite Activator

A cleaning primer which speeds the curing rate of anaerobic products.

† 4104/0251 † 4104/0253

Aerosol Bottle

Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

† 4104/1557

Aerosol

A compound used for assembly and prevention of thread seizure.

† 4003/0211

Loctite 242 or Permabond A113

Loctite 243

Anti-Seize Paste

Note: The above list is the range of sealants and retaining compounds available. Items marked † are those referred to within the sections.

9803/9240

Issue 2*

Section 2

Care & Safety

Section 2

i

i

Contents

9803/9240

Page No.

Safety Notices

1-1

General safety

2-1

Operating safety

3-1

Maintenance safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

9803/9240

Issue 1

Section 2

Care & Safety

Section 2

2-1

2-1

All machinery, whether mobile or static, can be hazardous.

When equipment is correctly operated and properly maintained it can be safe to work with. But when it is carelessly operated or poorly maintained it can become a danger.

Do not work with any equipment until you are sure that it is serviceable, that you know how to control it and be aware of all relevant safety requirements.

If the equipment covered by this manual forms part of a larger product (eg. a vehicle) be sure to observe the safety requirements which relate to the product as a whole, as well as those given in this manual.

On this and the following pages and throughout this manual, you will find safety messages. Please read and understand these safety messages before using and working on the equipment covered in this manual.

Make sure you also read and understand all other safety messages contained in operator handbooks and service manuals concerned with the product of which this equipment forms part.

Remember BE CAREFUL BE ALERT BE SAFE

General Safety ! WARNING Decals This equipment may include safety decals You can be injured if you do not obey decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the equipment. Make sure replacement parts include warning decals where necessary.

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-7

! WARNING Clothing You can be injured if you do not wear the proper clothing.

Loose clothing can get caught in the equipment. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

! WARNING Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness.

! WARNING Raised Attachments Raised attachments on certain kinds of equipment can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked.

INT-1-3-8

! WARNING Care and Alertness All the time you are working with or on the equipment, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-9

9803/9240

Issue 1

Section 2

Care & Safety

Section 2

3-1

3-1

Operating Safety ! WARNING

! WARNING

Equipment Condition Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts.

Make sure all maintenance procedures are completed before using the equipment.

Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

! WARNING Controls You or others can be killed or seriously injured if you operate machine control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

! WARNING The transmission can be in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only the rear wheels are raised, the machine could still drive through the front axle.

! WARNING Equipment Limits Operating equipment beyond its design limits can damage the equipment, it can also be dangerous. Do not operate the equipment outside its limits. Do not try to upgrade the equipment performance with unapproved modifications.

! WARNING Engine/Steering Failure If the engine or steering on the ‘parent’ machine fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

! WARNING Engine The engine on the ‘parent’ machine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-2-10

! WARNING Exhaust Gases Breathing the ’parent’ machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air.

9803/9240

Issue 1

Section 2

Care & Safety

Section 2

4-1

4-1

Maintenance Safety ! WARNING

! DANGER

Repairs Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

GEN-1-5

! WARNING Modifications and Welding Non-approved modifications can cause injury and damage.

Welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your distributor for advice before modifying the equipment.

! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses.

INT-3-1-11/1

! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

INT-3-1-3

! WARNING ! WARNING

Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

INT-3-2-4

! WARNING

INT-3-1-4

! WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the vehicle battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidently flying out.

GEN 6-2

! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

INT-3-1-10/1

9803/9240

! CAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

Issue 1

Section 2

Care & Safety

Section 2

4-2

4-2

Maintenance Safety (cont'd) ! WARNING

! WARNING

Fires Do not use water to put out an equipment fire, you could spread an oil fire or get a shock from an elecrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible.

Firefighters should use self-contained breathing apparatus.

Fluoroelastomeric Materials Certain seals and gaskets (e.g. transmission oil seals) may contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

! WARNING

New fluoroelastomeric components at ambient temperature require no special safety precautions.

Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA.

INT-3-2-8

Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

! WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: - Damaged end fittings - Chafed outer covers - Ballooned outer covers - Kinked or crushed hoses - Embedded armouring in outer covers - Displaced end fittings.

INT-3-3-2

! WARNING Make the machine safe before working underneath it. Park the machine on level ground. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

! WARNING

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

3

Thoroughly wash contaminated area with detergent and water.

4

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

INT-3-3-5/1/IT

! WARNING

*

Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.

HYD 1-3

! WARNING

2-1-1-8/IT

2

If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.

GEN-1-2/IT

Some lubricants contain lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant.

Dispose of waste (rags etc.) in accordance with local regulations.

Ensure that components have cooled then remove and place material into plastic bags.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.

1

GEN-1-12

*

! WARNING Before carrying out any servicing, park the machine on firm level ground and apply the parking brake. Make sure the transmission selector and gear lever are in the neutral position. Switch OFF the engine and remove the starter key.

Operate the control levers and remove the hydraulic filler cap to vent any residual pressure. Disconnect the battery.

GEN-1 13

9803/9240

Issue 2*

Section 3

Routine Maintenance

Section 3

i

i

Contents Lubricants & Capacities * Lubricants - Health and Safety

9803/9240

Page No. 1-1 1-2

Service Schedules

2-1

Greasing - Axle

3-1

Axle Oil Level - Check Differential Oil Level - Change Differential Oil - Check Hub Oil Level - Change Hub Oil

4-1 4-1 4-1 4-1

Issue 2*

Section 3

Routine Maintenance

Section 3

1-1

1-1

Lubricants & Capacities ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gals

INTERNATIONAL SPECIFICATION

Axle - SD55/NT Housing

8.0

1.76

Q8 EL3857 / Mobil Fluid 424

API GL4, M2C41B/134D, F M1135/M1141/M1143

Hubs (x2) SD55 (Brakes)

2.0

0.44

Q8 EL3857 SAE90 / Mobil Fluid 424

API GL4, M2C41B/134D, MF M1135/M1141/M1143

1.0 1.8 2.0

0.22 0.40 0.44

Q8 T35 SAE90 / Mobilube HD90

API-GL5, MIL-L2105C

Grease Points

-

-

Mobil HP222

Mobil HP222

Brake System

-

-

Mobil DTE 11M CAUTION: Do not use ordinary brake fluid (J1703)

ISO VG 15

* SD40 (No Brakes) * SD55 (No Brakes) * SD70 (No Brakes)

Note 1: Q8 EL3857 / Mobil 424 should always be used for axles fitted with brakes. For axles without brakes Q8 T35 SAE90 / Mobilube HD90 or Q8 EL3857 / Mobil Fluid 424 can be used.

Note 2: For axles with limited slip differential, Q8 EL3857 / Mobil Fluid 424 must be used.

9803/9240

Issue 2*

Section 3 1-2

Routine Maintenance

Section 3

Lubricants - Health and Safety

1-2

Hygiene Lubricants are not a health risk when used properly for their intended purposes.

2

Apply a barrier cream to the skin before handling used oil.

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

3

Note the following when removing oil from skin:

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

a

Wash your skin thoroughly with soap and water.

b

Using a nail brush will help.

c

Use special hand cleansers to help clean dirty hands.

d

Never use petrol, diesel fuel, or paraffin for washing.

4

Avoid skin contact with oil soaked clothing.

5

Don't keep oily rags in pockets.

6

Wash dirty clothing before re-use.

7

Throw away oil-soaked shoes.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

First Aid - Oil

Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations.

Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

The collection and disposal of used oil should be in accordance with any local regulations. Never pour used oil into sewers, drains or on the ground.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Handling

Skin In the case of excessive skin contact, wash with soap and water.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Spillage

Used Oil

Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Used lubricants contain harmful contaminants.

Fires

Here are precautions to protect your health when handling used oil:

Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus.

1

Avoid prolonged, excessive or repeated skin contact with used oils.

9803/9240

Issue 1

Section 3

Routine Maintenance

Section 3

2-1

2-1

Service Schedules A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

! WARNING

A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years *

Service checks should be carried out as in the table at whichever time occurs first.

Pre-start Cold Checks Service Points and Fluid Levels

*

AXLES AND STEERING Axle Oil Level (incl. Hubs when applicable) Axle Oil (incl. Hubs when applicable) Drive Shafts Steer Axle Movement/Shimming Axle Pivot and Steering Joints ††

Operation

10 Hr

50 Hr

- Check - Change - Security/Grease - Check - Grease

HYDRAULICS Cylinders - Chrome Condition Functional Test and Final Inspection AXLES AND STEERING Steering Modes - Operation Wheel Nut Torque Steer Phasing Steer Cylinders - Balance Steer Circuit Pressure

†100 Hr

500 Hr

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

- Check Operation

- Check - Check - Check - Check - Check

1000 2000 Hr Hr

10 Hr

50 Hr

†100 Hr

500 Hr

1000 2000 Hr Hr

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

G

†

Note: First 100 Hours Service only, to be completed by your Distributor.

††

Note: Mobil HP222 Grease must be used at 500 hour intervals. If an alternative grease is used, the Service Interval must be reduced to 50 hours/weekly.

Note: Check for leaks every 50 hours, check level if leaking.

Note: Jobs which should only be done by a specialist are indicated by a .

*

Note: Check generally for leaks on ALL systems, for example, hydraulics, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the recommended fluid after repair. *

Note: Faults in the braking system must be rectified immediately. Ensure the correct brake fluid is used (see Lubricants and Capacities), and all equipment is clean and free from water contamination. Under no circumstances should water be allowed to enter the braking system.

9803/9240

Issue 2*

Section 3

Routine Maintenance

Section 3

3-1

3-1

Greasing SD55/NT Axles - Offset Drive Head - for Interval see Service Schedule Total 10 Grease Points Note: When greasing, raise the wheels and swing them from lock to lock. This will ensure full penetration.

*

3

5

1 2

4

6

8 7

9803/9240

9

0

Issue 2*

Section 3

Routine Maintenance

Section 3

4-1

4-1

Axle Oil Level Check Differential Oil Level - for Interval see Service Schedule

Change Hub Oil - for Interval see Service Schedule 1

1

Remove fill/level plug A and its bonded washer. Oil should be level with the bottom of the fill/level hole.

2

If necessary, top up oil as specified in Lubricants and Capacities, on page 3/1-1. Clean and refit fill/level plug A with new bonded washer.

Set the machine level, with the tyres just clear of the ground. Manually rotate the wheels to bring the OIL LEVEL mark on the hubs to the vertical position, with the fill/level plugs C at the bottom.

Change Differential Oil - for Intervals see Service Schedule Remove fill/level plug A and drain plug B, together with their bonded washers. Allow time for the oil to drain out.

2

Clean and refit drain plug B with a new bonded washer.

Tighten to 79 Nm (58 lbf ft).

3

Fill the axle with oil, as specified in Lubricants and Capacities, on page 3/1-1, through the fill/level hole A. Oil should be level with the bottom of the fill/level hole.

4

Clean and refit fill/level plug A with a new bonded washer.

OIL LEVEL

1

C

ITL00710

2

Remove fill/level plugs C. Allow time for the oil to drain out.

3

Set OIL LEVEL marks to the horizontal.

A

B

OIL LEVEL

C

ITL00700

Check Hub Oil Level - for Interval see Service Schedule 1

2

3

Make sure the OIL LEVEL mark on the hub is horizontal.

Remove fill/level plug C. Oil should be level with the bottom of the fill/level hole.

ITL00710

4

Fill the hubs with oil, as specified in Lubricants and Capacities, on page 3/1-1, through the fill/level holes C. Oil should be level with the bottom of the fill/level hole.

5

Clean and are fit fill/level plugs C.

If necessary, top up with oil as specified in Lubricants and Capacities, on page 3/1-1. Clean and refit fill/level plug C.

9803/9240

Issue 2*

Section 4

Hydraulics

Section 4

i

i

Contents

9803/9240

Page No.

Technical Data

1-1

Cylinders Steer Cylinder - Removal and Replacement - Dismantling and Assembly

2-1 3-1

Steering System - Bleeding Procedure

4-1

Gland Seal Fitting Procedure

5-1

Issue 1

Section 4 1-1

Hydraulics

Section 4

Technical Data

1-1

Steering * Relief Valve Pressure @ 1500 rpm * Shock Valve Pressure

Refer to Machine Operator Handbook Refer to Machine Operator Handbook

JCB Drivetrain Steer Cylinder Data Torque Settings Piston Head End Cap

300 Nm 450 Nm

30.6 kgf m 45.9 kgf m

221 lbf ft 332 lbf ft

Sizes Bore Diameter Rod Diameter

60 mm (2.36 in) 30 mm (1.18 in)

Note: The above data refers to JCB Drivetrain Steer Cylinders, please check the type of cylinder fitted before using this section. For different cylinders refer to original manufacturer’s data.

9803/9240

Issue 3

Section 4

Hydraulics

Section 4

2-1

2-1

Steer Cylinder Removal and Replacement This procedure is for a typical steering cylinder removal and replacement.

! WARNING A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

Removal

B

Disconnect and cap hydraulic hoses to prevent loss of fluid and ingress of dirt. Label hoses for identification and correct refitting.

Remove locking bolts A and pivot pins B. Remove steering cylinder from machine.

Replacement Replace steering cylinder by reversing the removal procedure.

Apply anti-seize paste, part number 4003/0211 to pivot pins B, to facilitate subsequent removal.

After connecting hoses check hydraulic fluid level, if necessary top up. * Bleed hydraulic steering system (see Steering System Bleeding Procedure).

A B

ITL00 ITL00580 0

9803/9240

Issue 2*

Section 4 3-1

Hydraulics

Section 4 3-1

Steer Cylinder Dismantling and Assembly

147640

9803/9240

Issue 1

Section 4

Hydraulics

Section 4

3-2

3-2

Steer Cylinder (cont’d) Dismantling and Assembly (cont’d)

Assembling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush.

For assembly the sequence should be reversed.

Dismantling

* Use Loctite Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and old Loctite. Allow 15 minutes for solvent to dry before applying Loctite.

Place cylinder assembly on a locally manufactured strip/rebuild bench as shown.

Ensure that lubricants used during assembly do not come into contact with Loctite.

Slacken end cap 1 using special spanner (see Service Tools, Section 1) and remove the piston rod assembly 2 from the cylinder.

Refer to the ‘Gland Seal Fitting Procedure’ on page 4/5 - 1.

Fit seals 10 and 11 into end cap then fit the end cap onto the piston rod.

! WARNING

* Apply Loctite Activator to threads of piston rod, end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite.

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted.

Severe injury can be caused by a suddenly released piston rod.

Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or ‘O’ rings.

HYD 1-2

Position piston rod assembly on bench in place of cylinder.

Remove seal and wear rings from piston head.

Remove locking ring 3.

* Apply Loctite 262 to all threads of piston rod. Renew ‘’O’ ring in piston head, lubricating only the ‘O’ ring with Mobil HP222 Grease. Fit and torque tighten the piston head. Fit a new locking ring 3.

Heat piston head to 180 - 210 °C to degrade the Loctite between piston head and rod. To check temperature, use Surface Temperature Probe (see Service Tools, Section 1).

Fit new seal and wear rings to piston head.

Position cylinder on bench and install rod assembly into cylinder.

CAUTION: Do not exceed 300 °C or the Loctite will char, causing thread pick-up.

Apply Loctite 932 to thread of end cap, fit a new ‘O’ ring 9 and torque tighten the end cap into the cylinder.

! WARNING

Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure time applies at 20 °C and is the minimum period between assembly and filling the cylinder with oil.

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.

HYD 1-3

Remove piston head from rod using special spanner (see Service Tools, Section 1).

Remove end cap from piston rod and remove the seals and ‘O’ ring.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the gland seal.

* Loctite 262 or 932 with Activator - 1 hour Torque Settings Item 7 1

Nm 405 678

kgf m 41.3 69.2

lbf ft 300 500

Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the cylinders are operated slowly to their full extent before commencing normal working.

9803/9240

Issue 2*

Section 4

Hydraulics

4-1

Section 4 4-1

Steering System - Bleeding Procedure Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows: With the engine running, this procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations.

1

Select 2 Wheel Steer a

Turn steering wheel to left, until front wheels are fully locked to the left. b Turn steering wheel to right, until front wheels are fully locked to the right.

2

Select 4 Wheel Steer a

3

Turn steering wheel to left, until front wheels are fully locked to the left.

Select 2 Wheel Steer a Turn steering wheel to full right lock. b Turn steering wheel to full left lock. c Turn steering wheel to full right lock.

4

Select 4 Wheel Steer a

5

Turn steering wheel to left, until the front wheels are fully locked to the left.

Select 2 Wheel Steer a Turn steering wheel to full right lock. b Turn steering wheel to full left lock. c Turn steering wheel to full right lock.

6

Select 4 Wheel Steer a

7

Turn steering wheel to left, until front wheels are fully locked to the left.

Select 2 Wheel Steer a Turn steering wheel to full right lock. b Turn steering wheel to full left lock. c Turn steering wheel to full right lock.

8

Select 4 Wheel Steer a

Turn steering wheel to left, until the front and rear wheels are fully locked.

9803/9240

Issue 1

Section 4

Hydraulics

5-1

Section 4 5-1

Gland Seal Fitting Procedure The size (diameter) and position of pins A is determined by the diameter and radial width of the gland seal being fitted.

The pins are screwed into threaded holes in the tool body, the spacing of the holes are designed to suit small or large diameter gland seals.

To fit a new gland seal:

1

Open the tool as shown at X and insert the new gland seal, the seal must be fitted behind the two front pins but in front of the rear pin as shown.

X

161750-X

2

Close the tool as shown at Y. The seal must form a reniform (kidney shape).

Y

161750-Y

*3

Locate the seal in the end cap groove, shown at Z, when the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

9803/9240

Z

Issue 2*

Section 5

Axles

Section 5

i

i

Contents

* * *

* * * * * *

9803/9240

Page No.

Technical Data SD55/NT Axle

1-1

Descriptions Cutaway of SD55/NT Axle

2-1

SD55/NT Axle - Pin Mounted Removal and Replacement

3-1

SD55/NT Axle - Pad Mounted Removal and Replacement

4-1

SD55/NT Axle Propshafts - Removal and Replacement 5-1 Drive Head - Dismantling 6-1 Drive Head - Assembly 6-2 Drive Head with Limited Slip differential - Dismantling 7 - 1 Drive Head with Limited Slip Differential - Assembly 7-3 Drive Head Solid Spacer - Assembly 7-8 Two Piece Limited Slip Differential - Dismantling 7 - 11 Two Piece Limited Slip Differential - Assembly 7 - 11 Renewing the Pinion Oil Seal 8-1 Axle Hub and Driveshaft (Dowelled) - 2 Plate, Positive Retraction Brakes - Dismantling 9-1 Axle Hub and Driveshaft (Dowelled) - 2 Plate, Positive Retraction Brakes - Assembly 9-3 Axle Hub and Driveshaft (Splined) - 2 Plate, Positive Retraction Brakes - Dismantling 9-6 Axle Hub and Driveshaft (Splined) - 2 Plate, Positive Retraction Brakes - Assembly 9-8 Axle Hub and Driveshaft (Splined) - SD40 Non Braked Hub - Dismantling 10 - 1 Axle Hub and Driveshaft (Splined) - SD40 Non Braked Hub - Assembly 10 - 3 Axle Hub and Driveshaft (Dowelled) - SD70 Non Braked Hub - Dismantling 11 - 1 Axle Hub and Driveshaft (Dowelled) - SD70 Non Braked Hub - Assembly 11 - 3 Axle Hub Bearing - Removal 14 - 1 Axle Hub Bearing - Replacement 14 - 3

Issue 4*

Section 5

Axles

Section 5

Technical Data

1-1

1-1

SD 55/NT Axle Type

JCB Drivetrain spiral bevel input with epicyclic hub reduction.

Designation

SD55/NT

* Type of Brakes

Oil immersed multi-plate disc located in hubs.

Installation

Centre pivot or rigid pad mount

Number of steer cylinders

1

Weight (dry, with no steer cylinders and without wheels)

Pin: 367 kg (809 lb) approximately; Pad: 365 kg (805 lb) approximately

Ratios Overall Crownwheel and Pinion

OPTION 1 OPTION 2 10.46:1 12.24:1 1.94:1 2.26:1

OPTION 3 OPTION 4 16.2:1 18.6:1 3.0:1 3.44:1

OPTION 5 19.2:1 3.55:1

OPTION 6 OPTION 7 20.93:1 23.625:1 3.875:1 4.375

Number of Teeth Crownwheel Pinion

31 16

33 11

32 9

31 8

* Hub Reduction

34 15

31 9

35 8

5.4:1 6.0:1 (SD40 and SD70 hubs only)

Input Type

1480 Half yoke

Toe-in

0째

Castor Angle

0째

Camber Angle

1째

Kingpin inclination

0째

General Description The later type SD55/NT axles have changed from ring dowel and Verbus Ripp bolt securing of the annulus carrier to the hub swivel to a splined annulus carrier and hub swivel with retaining plate. For Dismantling and Assembly procedures see pages 9 6 to 9 - 9.

9803/9240

Issue 5

Section 5 2-1

Section 5

Descriptions

2-1

SD 55/NT Axle with Braked Hub (Dowelled) (Steering cylinder not shown)

ITL007 0

*

Axles

9803/9240

Issue 3*

Section 5 2-2

Axles Technical Data

Section 5 2-2

SD 55/NT Axle with Non Braked Hub (Dowelled) (Steering cylinder not shown)

9803/9220

Issue 1*

Section 5

Axles

Section 5

SD 55/NT Axle - Pin Mounted

3-1

3-1

Removal and Replacement

E A

D F

C B

9803/9240

Issue 1

Section 5

Axles

Section 5

SD 55/NT Axle - Pin Mounted

3-2

3-2

Removal and Replacement ! WARNING A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

Removal

Replacement

1

Using Tool No. 892/00822 remove bolts A to disconnect the propshaft from the axle (refer to Page 3 - 1).

Replacement is the reverse of the removal sequence.

1

Apply Loctite 242 to the threads of bolts A.

2

Disconnect the brake pipes from the axle swivel hubs, blank off the exposed connections.

2

Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

3

Disconnect the hydraulic pipes from the steer cylinder, blank off all exposed connections.

4

Loosen the road wheel retaining nuts B.

5

Make sure that the wheels are blocked. Raise the machine and engage the parking brake if appropriate.

6

Prop the machine on each side as shown at C.

7

Remove the road wheels.

8

Position a jack underneath the balance point (see Note) of the axle and support the axle weight.

! WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

2-3-2-8

Torque Settings Item A B

Nm 40-48 680

kgf m 4.08-4.90 69

lbf ft 29.5-35.4 500

Note: Because the drive head assembly is offset, the balance point of the axle is not the centre of the axle. Attach a ‘cradle’ to the jack that will partially embrace the axle.

9

Remove nut D and pivot pin retaining bolt E.

10

Use puller (tool no. 992/08800) and remove the pivot pin F.

11

Lower the jack so that the axle is clear of the mounting yoke and remove the axle.

9803/9240

Issue 1

Section 5 4-1

Axles

Section 5

SD 55/NT Axle - Pad Mounted

4-1

Removal and Replacement

A

C B

E

F D

9803/9240

Issue 1

Section 5

Axles

Section 5

SD 55/NT Axle - Pad Mounted

4-2

4-2

Removal and Replacement ! WARNING A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

Removal

Replacement

1

Using Tool No. 892/00822 remove bolts A to disconnect the propshaft from the axle (refer to Page 4 - 1).

Replacement is the reverse of the removal sequence.

1

Apply Loctite 242 to the threads of bolts A.

2

Disconnect the brake pipes from the axle swivel hubs, blank off the exposed connections.

2

Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

3

Disconnect the hydraulic pipes from the steer cylinder, blank off all exposed connections.

4

Loosen the road wheel retaining nuts B.

5

Make sure that the wheels are blocked. Raise the machine and engage the parking brake if appropriate.

2-3-2-8

6

Prop the machine on each side as shown at C.

Bleed the brake system before driving the machine.

7

Remove the road wheels.

8

Position a jack underneath the balance point (see Note) of the axle and support the axle weight.

! WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

! CAUTION BRAK 1-6

Torque Settings

Note: Because the drive head assembly is offset, the balance point of the axle is not the centre of the axle. Attach a ‘cradle’ to the jack that will partially embrace the axle.

9

Remove nut D, bolts E and washers F.

10

Lower the jack and remove the axle.

9803/9240

Item A B D

Nm 20.9-23.7 680 476

kgf m 2.13-2.42 69 49

lbf ft 15.4-17.5 500 351

Issue 1

Section 5

Axles

Section 5

SD 55/NT Axle

5-1

5-1

Propshafts Removal and Replacement Removal Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal. * Replacement Upon reassembly, after lubricating sliding joints with Mobil HP222 Grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings.

B

A

Apply Loctite 242 to threads of all flange bolts.

Retaining straps C stretch with use, therefore these straps must always be replaced with new ones.

S157510

Note: Propshafts should be installed with their main shaft sections fitted to the axle end, and their sliding sections fitted to the transmission wheel drive unit.

Note: The propshaft must have both ends exactly on the same plane as shown at X. The yokes must not be at right angles as at Y or at an intermediate angle as at Z. Torque Settings Item A B

Nm 75 - 85 118

kgf m 7.7 - 8.7 12

C

lbf ft 55 - 63 87

A

X S232350

Y A

Z

A

S189610

9803/9240

S157500

Issue 2*

Section 5 6-1

Axles SD55/NT Axle

Section 5 6-1

Drive Head - Dismantling

ITL00670

9803/9240

Issue 1

Section 5

Axles SD55/NT Axle

6-2 * Drive

Section 5

Head - Dismantling (cont’d) ! WARNING

A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do no rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

6-2

Drive Head - Assembly Pinion Depth Setting Procedure (see Note)

Place new pinion head bearing assembly on a flat surface and position bearing cup 892/00174 over the bearing.

Measure gap A (e.g. 0.20 mm) and add this to the cup depth stamped on the tool (e.g. 30.01 mm) to obtain the bearing depth.

GEN-1-1

1

Drain the oil from the drive head. Remove the propshaft.

2

To remove the drive head it is necessary to withdraw both drive shafts from the axle (see Hub - Dismantling and Assembly).

3

Remove the drive head carrier bolts 1. Mark the installation position of drive head carrier 2 relative to the axle housing.

4

Remove the drive head carrier from the axle housing.

5

Pull out the roll pins 3 and remove the castellated nuts 4. Remove the outer races of bearings 5 and 6 from the drive head carrier bores.

*6

Remove bearings 5 and 6 together with inner bearing races.

7

Remove differential assembly 8 from carrier.

8

Loosen the differential case half bolts 7 and pull the case halves 8A and 8B apart. Remove the axle bevel gears 9, the differential bevel gears 10, trunnion pin 11 and thrust washers 12 from the case halves.

9

Remove the thrust washers 13 from both case halves.

10

Remove the bolts 14 and separate the crown wheel 15 from the case half 8A.

11

Remove pinion nut 16. Use Service Tool 892/00812 to prevent drive yoke 18 from rotating.

12

Remove the drive yoke.

13

Drive pinion shaft 20 out of drive head carrier 2.

14

Prise shaft seal 19 out of the bore.

15

Remove taper roller bearing 21 and tap out the outer bearing race.

16

Tap out the out race of bearing 22 from the opposite bearing housing and remove the drive pinion shim(s) 23.

17

Remove spacer 24 from drive pinion 20. Prise taper roller bearing 22 to raise it sufficiently to insert bearing pullers. Pull the bearing from the pinion shaft.

9803/9240

ITL00560

From the face of the pinion, obtain the etched deviation figure (e.g. + 2) which is in units of 0.01 mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.

Obtain the deviation figure (e.g. - 1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

Subtract the total of the above figures form the standard valve of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup.

Example (all dimensions in millimetres) Cup depth Cap A Bearing depth Pinion deviation (+ 2) Housing deviation (- 1) Total

30.01 +0.20 30.21 +0.02 +0.01 30.24

Standard value Less Total above Shim Thickness

31.19 30.24 0.95

Note: See page 5/6-5 for general guidance on crownwheel and pinion adjustment.

Issue 3*

Section 5 6-3

Axles SD55/NT Axle

Section 5 6-3

Drive Head - Assembly (cont’d)

ITL00670

9803/9240

Issue 1

Section 5 6-4

Axles

Section 5

SD55/NT Axle

6-4

Drive Head - Assembly (cont’d) Note 1 Both the crownwheel 15 and pinion 20 and the bevel gears 9 and 10 are matched and should be renewed as sets if any of their components are damaged or excessively worn. The two differential housing halves 8A and 8B are also matched. Do not use unmatched halves.

9

Drive bearing cones 5 and 6 onto differential case spigots. Lightly oil the bearings then fit their bearing cups and castellated nuts 4 into drive head carrier 2.

Do not fit the roll pins 3 at this stage.

10

Adjust castellated nuts 4 to give an increase in input pinion rolling torque of between 1.36 - 2.5 Nm (12 - 22 lbf in) more than that recorded in Step 4.

11

Measure the backlash between crownwheel 15 and pinion 20, which should be 0.17 - 0.28 mm (0.006 0.011 in). Adjust castellated nuts 4 by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins 3.

12

Check tooth marking as per page 5/6-5. If incorrect, adjust.

13

Apply Loctite 275 to the mating faces of drive head carrier 2 and the axle casing. Fit the drive head carrier to the axle casing, taking note of the mark made during dismantling. Fit securing bolts 1 and and torque tighten see note below:

Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set.

1

Select shim 23 required for pinion depth setting and fit behind new bearing cup 22. (See Pinion Depth Setting Procedure, page 5/6-2).

2

Fit new pinion head bearing cone 22 onto pinion 20.

3

Fit a new collapsible spacer 24 onto pinion 20. Lightly oil pinion head bearing 22. Lightly oil pinion tail bearing 21 and fit the bearing. Using a suitable drift tap the tail bearing fully into position in the carrier. Locate the pinion in carrier 2. (Before inserting, ensure that the pinion matches crownwheel 15.) Insert a new oil seal 19 into housing. Pack grease between the seal lips. Fit drive yoke 18 using a new stake nut 16.

* Note:

The preferred option is to fit a solid spacer 24. See Soild Spacer Assembly.

4

Tighten the stake nut 16 to collapse spacer 24 until end float is almost zero, then check the seal drag torque is between 0.40 - 0.75 Nm (3.54 - 6.64 lbf in). Continue to tighten the stake nut to collapse spacer 24 and give a rolling torque of 1.5 - 2.8 Nm (1.1 - 21 lbf in) (excluding seal drag). Rotate flange 18 in each direction to bed in the bearings before measuring. Stake the nut when the pre-load is correct.

Note 2: If the specific rolling torque is exceeded, the collapsible spacer will be distorted. Renew the spacer and start again.

5

Assembly the trunnion pin 11, bevel gears 9 and 10 and their thrust washers 12 and 13 into differential half case 8A (see Note 1 above).

*6

Position differential half case 8B onto half case 8A, aligning the match-mark letters (see Note 1 above).

Apply Loctite 242 to the threads of bolts 7, then fit and torque tighten, see Note. Check the gears for free rotation.

*

*

* Note: Torque Settings for bolt 1 is dependent on the type of bolt used: M10 56 Nm (42 lbf ft, 6 kgf m) M10 Verbus Ripp 94 Nm ( 69 lbf ft, 9.6 kgf m)

14

Reassemble both driveshafts and hub assemblies (refer to page 5/9-4).

Re-fill the hubs and differential with the correct grade of oil (see Lubricants and Capacities, Section 3). Refit the propshaft.

* Note: Torque Settings for bolt 7 are dependent on the type of bolt used: M8 46 Nm (34 lbf in, 4.7 kgf m) M10 56 Nm (41 lbf in, 5.7 kgf m) M10 Flange head bolt 98 Nm (72 lbf in, 10 kgf m) 7

Fit crownwheel 15 using new Verbus Ripp bolts 14 tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

8

Locate crownwheel assembly (without bearings) into housing.

9803/9240

Issue 2*

Section 5 6-5

Axles

Section 5

SD55/NT Axle

6-5

Drive Head - Assembly (cont’d) Crownwheel and Pinion Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion.

The marking will then be transferred to the crown wheel teeth.

Correct tooth marking.

ITL00600

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

ITL00610

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

ITL00620

9803/9240

Issue 1

Section 5 7-1

Axles SD55/NT Axle

Section 5 7-1

Drive Head with Limited Slip Differential - Dismantling

9803/9240

Issue 2*

Section 5

Axles

Section 5

SD55/NT Axle

7-2

7-2

Drive Head with Limited Slip Differential Dismantling (cont’d)

10

*Note: Some axles may be fitted with a Two Piece Limited Slip Differential, see Two Piece Limited Slip Differential for dismantling and assemby.

Rotate side gears 15 to eject planet gears 13 and thrust washers 14. Lift out side gears, pressure plates 19,counter plates 17, friction plates 18 and shims 16.

11

Check the condition and security of bushes 20 (see Note below).

Note: The number of friction and counter plates shown in the illustration is typical only. The actual number of plates is specified by the manufacturer and must not be altered without approval.

Note: Later type differential assemblies are not fitted with bushes 30; instead, the differential assembly is machined so that it supports the driveshaft.

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

! WARNING A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

1

Remove the planet gear carrier from both hub assemblies and withdraw both drive shafts. (Refer to page 5/9-2 for details of hubs and driveshafts dismantling.)

2

Remove the propshaft.

3

Drain oil from differential casing and remove securing bolts 1. Discard gasket 3. Lift drive head 2 from casing.

Note: Item 3 is not fitted on later axles, instead Loctite 275 sealant is used.

4

Drive out roll pins 4 and unscrew castellated nuts 5 and 5A. Remove bearing cups 6.

5

Identify the manufacturer’s marks on the drive head casing 2 and the bearing caps 2A for subsequent assembly.

*

Remove bolts 2B and remove the differential from the drive head. Remove bearings 7.

6

Using Service Tool 892/00812, remove drive yoke 22 and drive out pinion 23 complete with spacer 24.

Remove oil seal 25 and pinion tail bearing 26. Drive pinion head bearing cone 27 from the pinion.

7

Remove pinion head bearing cup 28 with its shims 29.

8

Unscrew Verbus Ripp bolts 9 using heavy duty socket 892/00819 and remove crownwheel 10.

9

Remove bolt 11 and drive out trunnion pin 12.

9803/9240

Issue 3*

Section 5 7-3

Axles SD55/NT Axle

Section 5 7-3

Drive Head with Limited Slip Differential - Assembly

9803/9240

Issue 2*

Section 5 7-4

Axles

Section 5

SD55/NT Axle

7-4

Drive Head with Limited Slip Differential Assembly (cont’d) 1

Fit side gears 15, with pressure plates 19, counter plates 17 and friction plates 18 onto differential case 8.

8

Determine Pinion Depth Setting (see Note 1) a

Note: Do not fit the shims 16 at this point.

Position planet gears 13 and thrust washers 14 until they are engaged with side gears and diametrically opposed. Rotate side gears until planet gears and washers align with trunnion pin bore.

2

Drive in trunnion pin 12 until bolt 11 can be located.

3

Using a dial test indicator, with two screwdrivers or suitable levers, gently apply pressure to side gear 15 away from the trunnion pins 12 as shown. Measure and note the end-float of the side gear.

Place new pinion head bearing assembly on a flat surface and position bearing cup 892/00174 over the bearing. Measure cap A (e.g. 0.20 mm) and add this to the cup depth stamped on the tool (e.g.

30.01 mm) to obtain the bearing depth.

ITL00560

b From the face of the pinion, obtain the deviation figure (e.g. +2) which is in units of 0.01 mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth. c

Obtain the deviation figure (e.g. -1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

d Subtract the total of the above figures from the standard value of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup.

Example (all dimensions in millimetres) S171590

4

Turn the differential assembly over and repeat step 3 for the second side gear.

5

Dismantle the differential assembly. Add shims 16 to give end float between 0.1 and 0.2 mm (0.004 and 0.008 in).

*6

Repeat steps 2, 3 and 4. If the end float is correct.

Remove bolt 11 apply Loctite 275 to threads of bolt then fit and tighten to 28 Nm (20 lbf ft). If the end float is not correct, adjust the shims accordingly.

7

Fit crownwheel 10 using new Verbus Ripp bolts 9 tightened to 94 Nm (70 lbf ft).

Cup depth Cap A Bearing depth Pinion deviation (+ 2) Housing deviation (- 1) Total

30.01 +0.20 30.21 +0.02 +0.01 30.24

Standard value Less Total above Shim Thickness

31.19 30.24 0.95

Note1: See page 5/6-5 for general guidance on crownwheel and pinion adjustment.

Note 2: Both the crownwheel 10 and pinion 23, side gears 15 and planet gears 13 are matched and should be renewed as pairs if any of their components are damaged or excessively worn.

9

9803/9240

Select shims 29 required for pinion depth setting and fit behind new bearing cup 28.

Issue 2*

Section 5 7-5

Section 5

Axles SD55/NT Axle

7-5

Drive Head with Limited Slip Differential Assembly (cont’d) 10

Press new pinion head bearing cone 27 onto pinion 23 using press 892/00179 with adapters 992/07608 and 992/07609.

11

Fit a new collapsible spacer 24 onto the pinion 23.

Lightly oil pinion head bearing 27 and locate the pinion in the housing. (Before inserting, ensure that the pinion matches the crownwheel 10.) Lightly oil pinion tail bearing 26 and fit the bearing. Using a suitable drift, tap the tail bearing fully into position in the housing. Insert a new oil seal 25 into housing. Pack grease between the seal lips. Fit the drive flange 22 using a new stake nut 20 and washer 21.

* Note:

The prefered option is to fit a solid spacer 24. See Solid Spacer Assembly.

17

*

Using a new gasket 3 (see Note), fit differential to axle casing with crownwheel towards long driveshaft. Fit securing bolts 1 and torque tighten see note below.

Reassemble both driveshafts and hub assemblies and re-fill hubs and differential with the correct grade of oil (see Lubricants and Capacities, Section 3). Refit the propshaft.

Note: On later axles, the gasket 3 is replaced by Loctite 275.

*

Note: Torque Settings for bolt 1 is dependent on the type of bolt used: M10 56 Nm (42 lbf ft, 6 kgf m) M10 Verbus Ripp 94 Nm ( 69 lbf ft, 9.6 kgf m)

* Note:

On later machines, stake nut 20 and washer 21 are combined. The separate nut and washer should be discarded and replaced with the new combined nut and washer.

12

*

Tighten the stake nut 20 to collapse spacer 24 until end float is almost zero, then check the seal drag torque is between 0.40 - 0.75 Nm (3.54 - 6.64 lbf in). Continue to tighten the stake nut to collapse spacer 24 and give a rolling torque of 1.5 - 2.8 Nm (1.1 - 21 lbf in) (excluding seal drag). Rotate flange 22 in each direction to bed in the bearings before measuring. Stake the nut when the pre-load is correct.

Note: If the specified rolling torque is exceeded, the collapsible spacer will be distorted. Renew the spacer and start again.

13

Fit bearing caps 2A using bolts 2B tightened to 165 Nm (121 lbf ft). Make sure the correct manufacturer’s marks are aligned.

Locate differential assembly (without bearings) into drive head.

Note: Drive head casing 2 and bearing caps 2A are matched and should be renewed as a complete assembly if damaged or worn.

14

Drive bearing cones 7 onto spigots, lightly oil the bearings then fit bearing cups 6 and castellated nuts 5.

Do not fit the roll pins 3 at this stage.

* 15

Adjust castellated nut 5 on crownwheel side until backlash is 0.17 - 0.28 mm (0.006 - 0.010 in).

16

Adjust castellated nut 5A until there is no end float and no pre-load, ensuring that bearings are bedded in by rotating in each direction. Tighten nut 5A by a further 4 castellations to set pre-load, ensuring that correct backlash is maintained. Fit roll pins 4.

9803/9240

Issue 2*

Section 5 7-6

Axles

Section 5

SD55/NT Axle

7-6

Drive Head with Limited Slip Differential Assembly (cont’d) Crown Wheel and Pinion - Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion. the marking will then be transferred to the crown wheel teeth. After every repair, check the markings to verify settings.

Correct tooth marking.

ITL00600

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner bearing cap and the axle casing. Move the crownwheel towards the pinion to correct the backlash.

ITL00610

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

Note: Crownwheel teeth will fail prematurely if run in this condition.

ITL00620

9803/9240

Issue 1

Section 5 7-8

Transmission SD55/NT Axle

Section 5 7-8

Drive Head Solid Spacer- Assembly

ITL00670

9803/9240

Issue 1*

Section 5

Transmission

Section 5

SD55/NT Axle

7-9

7-9

Drivehead Soild Spacer - Assembly (cont’d) The outline procedure below refers to the fitting of a soild spacer to the drivehead assembly. For dismantling and assembly of the drivehead see the relevant DriveHead Dismantling and Assembly sections.

Note: Special tools are required for the following procedure, see Solid Spacer Setting Kit in Service Tools 1

Install pinion and bearings into the drive head casing.

Install largest available solid spacer 24 e.g (14.20 mm) and fit pinion tail bearing 21 (lightly oiled). Do not fit the oil seal 19 at this stage.

Note: It should be noted that the axle is assembled using a solid spacer. However, in the absence of the special tools required or the correct size solid spacer 24 it is acceptable to fit a collapsible spacer, refer to applicable Axle Hub and Driveshaft Assembly.

2

3

E

Fit special tool sleeve B and special pinion shaft adapter C. Tighten adapter C to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

D

C B

Fit special bracket D to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar E to bracket D so that the fork end engages in adapter C. Ensure that fork E is centrally located on adapter C. If necessary, re-align bracket D to suit.

4

Fit dial test indicator (DTI) F. Ensure that the DTI is mounted on the drive head and not on bracket D.

5

Set torque wrench G to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft.

6

To select the right size spacer 24, subtract the end float obtained at step 7 from the solid spacer size (14.20 mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the solid spacer setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to Service Tools - Axles.

Example Temporary spacer size Subtract end-float

14.20 0.25

Total

13.95

Subtract tolerance & preload Result

348030

G F

348040

0.04 13.91

(No spacer available this size, use next nearest size spacer i.e 13.900)

9803/9240

Issue 1*

Section 5 7 - 10

Transmission SD55/NT Axle

Section 5 7 - 10

Drivehead Soild Spacer - Assembly (cont’d) 7

Remove sleeve B and temporary spacer. fit correct size spacer from solid spacer setting kit, refer to Service Tools - Axles. During removal take care to avoid damaging the outer bearing.

8

Fit sleeve B. Tighten adapter C to no more than 50 Nm to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate. Check there is no end float and pinion is free to turn smoothly by hand. Remove adapter C and fit nut 16. Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly.

Note: If the pinion is not free to rotate check the correct size spacer has been fitted.

9

If rolling torque measured at step 8 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

10

Remove adapter C and sleeve B. Fit new oil seal 19, grease between seal lips before fitting. Fit coupling yoke 18 and NEW stake nut 16.

11

Progressively torque tighten stake nut 16, occasionally rotating coupling yoke, up to 250 Nm. Providing the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note: The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm. 12

Finally stake the nut 16 into the slot.

9803/9240

Issue 1*

Section 5

Transmission

Section 5

Rear Axle

7 - 11

7 - 11

Two Piece Limited Slip Differential

5 6

7

8

14 9

1

10

13

12 10 9

8 7

6

3

11

4 2

S171530

S212790

9803/9240

Issue 1*

Section 5 7 - 12

Transmission Rear Axle

Section 5 7 - 12

Two Piece Limited Slip Differential Dismantling

Friction Plate Wear Limits

The numerical sequence shown on the illustration is intended as a guide to dismantling

Measure and note the thickness of the friction plate, the result must not be less than 1.25 mm (0.049 in).

The two differential halves are matched, before dismantling mark the two halves for subsequent assembly.

Check the condition of the friction material, which should be even over both surfaces.

Note the relative positions of the friction and counter plates before dismantling, they must be fitted in the same positions.

If in doubt, discard the set (friction and counter plates).

If worn, the friction and counter plates must be renewed as a complete set.

Assembly 1

Assemble trunnion pins 12, side gears 11 with pressure plates 10, counter plates 8, friction plates 9, planet gears 13 and thrust washers 14 into the 'crownwheel half of the differential assembly 5.

Note: Do not fit the shims 6 at this point.

2

Align the two halves of the differential assembly with the marks made during dismantling. Assemble using bolts 3.

3

Using a dial test indicator (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to side gear 11 away from the trunnion pins 12 as shown.

Measure and note the end-float of the side gear.

4

Turn the differential assembly over and repeat step 3 for the second side gear.

5

Dismantle the differential assembly. Add shims 6 to give end-float between 0.1 and 0.2mm (0.004 and 0.008in.).

Note: Shimming must be carried out whenever the differential is dismantled, however the end float 0.1 and 0.2 mm (0.004 and 0.008 in.) can be exceeded on previously assembled differential as this is only an initial setting figure which allows for bedding in.

6

Repeat steps 2, 3, and 4. If the end float is correct, tighten bolts 3 to 56 Nm (41 lbf ft 5.7 kgf m).

7

Fit crownwheel 2 using new Verbus Ripp bolts 1, tighten bolts to 94 Nm (69 lbf ft 9.6 kgf m).

9803/9240

Issue 1*

Section 5

Axles

Section 5

SD55/NT Axle

8-1

8-1

Renewing the Pinion Oil Seal The pinion oil seal 4 may be renewed without removing the axle from the machine.

*4

Check the sealing surface on the yoke for wear or damage, renew the yoke if necessary.

! WARNING

*5

Fit the yoke and temporarily fit the old stake nut 2.

Tighten the nut with a torque wrench, aligning the scriber marks. Note the tightening torque required.

*6

Remove and discard the old nut. Fit a new nut and tighten to the torque determined at step 5.

A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

6.1 Measure the rolling torque. The reading should be 0.5 to1Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m) more than that recorded in Step 1 (see Note).

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-1

1

2

Remove the roadwheels and uncouple the axle propshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.

Using Service Tool 892/00812, remove the drive yoke 1 together with its stake nut 2 and washer 3.

* Note:

On later machines, stake nut 2 and washer 3 are combined. The separate nut and washer should be discarded and replaced with the new combined nut and washer.

3

Remove the seal 4 and fit a new one.Take care not to damage the seal housing. Pack between the lips of the new seal with grease before fitting.

9803/9240

6.2 If necessary, progressively torque tighten the nut to a maximum of 300 Nm (221 lbf ft) to achieve correct rolling torque.

Note: If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft; 0.1 kgf m) or more, or a minimum torque of 250 Nm (184 lbf ft) can not be achieved then the pinion assembly must be rebuilt using a solid spacer, see the appropriate axle assembly procedure.

6.3 Stake the nut using a square ended staking tool.

7

Refit the roadwheels and couple the propshaft.

Issue 2*

Section 5

Axles

9-1

SD55/NT Axle

Section 5 9-1

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) Dismantling *

Z

Y

9803/9240

Issue 5*

Section 5

Axles SD55/NT Axle

9-2

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d) Dismantling (cont’d)

Remove brake piston back-up bolt 13A and spring 13B (2 or 3 off each). Carefully withdraw brake piston 13 from its housing, if removal is necessary. A hydraulic hand pump can be used to force the piston out of the housing, or if the brakes system is still connected use the brake pedal. Remove and discard seals 14 and 15.

9

Remove brake plate carrier C and spacer D.

10

Remove Verbus Ripp bolts 18. These bolts are very tight and care must be taken not to distort the bolt heads. Use as short an extension bar as possible with a six sided socket. Discard Verbus Ripp Bolts after removal.

11

Using special tool (part number 892/00833) as jacking screws, jack the annulus assembly 21, 22 and 23 off bearing carrier 19. Ensure that ring dowels 20 remain either in the axle arm or the annulus carrier 21.

5-3-2-1

Disconnect the track rod and steering rams, drain oil from the axle hub, remove bolts 1.

Note: If the track rod is to be removed completely, identify R.H. and L.H. ends to ensure correct assembly.

2

3 *

Using a soft-faced mallet, tap the planet gear carrier 2 to ‘crack’ the joint between the carrier and bearing carrier 19, then lever the planet gear carrier off the bearing carrier. Remove and discard ‘O’ ring 3.

9-2

8

! WARNING Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake engaged and the transmision is in neutral. Disconnect the battery. chock both side of all four wheels. *1

Section 5

Note: Fretting between the hub swivel and annulus carrier mating faces might be evident; this condition is normal, do not attempt to repair. If the hub swivel and annulus carrier are to be re-used, the carrier must be assembled in the same angular position it was removed; match mark the hub swivel and carrier before removing the carrier.

Remove a planet gear 4 only if it is defective. Note that a planet gear can only be renewed as an assembly, which comprises the gears, the bearing 5 and two ‘L’ shaped circlips 6. To remove a planet gear, first remove external circlip 7, then pull off the planet gear. Remove circlip A, sun gear B.

12

Remove internal circlip 22 to separate annulus ring 23 from annulus carrier 21.

* Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings. See Axle Hub Bearing, Removal and Replacement.

4

The stubshaft thrust pad 8 is drilled and tapped M6 for removal purposes.

5

Remove circlip 9 and brake pressure plate 10. Remove shims X.

13

6

There are three counterplates 11 and two friction plates 12. If the brake pack is to be re-used, note the positions of the plates before removing them.

Pull off bearing carrier 19 together with outer wheel bearing cone and cup 24. Withdraw the inner bearing cup from the inboard side of the carrier.

14

Pull off inner wheel bearing 25.

15

Remove combination seal 26.

7

Wear limit of friction plates 12 is to the depth of the crosshatching. Check all plates for flatness and damage. (Wear and polishing of the counterplates 11 is normal.) Renew the brake pack complete if excessively worn or damaged. Do not renew individual plates.

Note: Excessive wear of the brake and counter plates can indicate sticking brakes or possible residual pressure in the braking system. See Residual Brake System Pressure, Section 6.

Note: Later type axles have ‘paper’ friction plates, these can be readily identified because they do not have radial slots.

DO NOT mix the two differential types of friction plates.

A276990

9803/9240

* 16

Remove dirt shield 38 (if fitted).

Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated), the only difference being that shims * (if fitted) 29 are fitted to the top trunnion only.

17

Mark position of top and bottom trunnions 28, remove bolts 27 and remove trunnions. Retain shims 29 (if fitted) with top trunnion. Withdraw the hub carrier 30.

* Note: Trunnions may be removed easily and without damage to the shims (if fitted) by pumping grease through the grease nipple.

18

Remove the top and bottom trunnion seals 31 and bearings 32.

19

Withdraw driveshaft 33 from the axle casing. Prise out driveshaft outer oil seal 34. Remove bearing 35 using tool 892/00225.

20

Prise out driveshaft inner oil seal 36.

22

Remove circlip 37.

22

Remove bearing 38 using tool 892/00225.

23

If there has been a component failure remove all traces of debris and clean the magnetic drain plug.

Issue 5*

Section 5

Axles

Section 5

SD55/NT Axle

9-3

9-3

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d) *

W

Z

Y

9803/9240

Issue 5*

Section 5 9-4

Axles SD55/NT Axle

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d)

11

Assembly (cont’d)

*

Tap the driveshaft inner bearing 38 into position in the axle casing.

2

Fit circlip 37.

3

Fit new oil seal 36. Pack grease between the lips of the seal.

4

Tap the driveshaft outer bearing 35 into position in the hub swivel driveshaft bore.

5

Fit new oil seal 34. Pack grease between the lips of the seal.

6

Fit driveshaft 33, taking care to locate the inner end into the splines of the differential gears.

7

Press new top and bottom trunnion oil seal 31 into position followed by bearings 32. Grease bearing and oil seal before fitting axle.

8

Locate hub swivel 30 and fit bottom trunnion 28. Apply Loctite 242 to threads of bottom trunnion bolts 27 and then torque tighten bolts to 98 Nm (72 lbf ft; 10 kgf m).

9-4

Refit top trunnion. Apply Loctite 242 to the top trunnion bolt threads, fit and tighten to 98 Nm (72 lbf ft; 10 kgf m).

Check spring balance reading which should be 4.5 kgf (10 lbf) more than the reading recorded at Step 9.

Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated), earlier axles may have shims 29 fitted to the top trunnion.

1

Section 5

*

12

Connect the track rod and steering cylinder to the axle steer knuckles.

13

Lightly oil inner wheel bearing 25 and its cup, then fit them into bearing carrier 19.

Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings and seals. See Hub Bearing, Removal and Replacement.

X

A272

0

14

Fit a new combination seal 26 into the bearing carrier.

Using service tool 892/00891, drive the seal squarely into the carrier until flush as at X. Do not lubricate before fitting.

15

Install the cup of outer wheel bearing 24 into the bearing carrier 19. Grease the bore of the seal and the surface of the stub.

* 16

Check condition and refit the dirt shield 38 (if fitted). Fit bearing carrier 19 onto hub swivel 30.

Note: On later models without shims 29, torque tighten the top bolts 27. Turn the swivel by hand, to ensure smooth operation. If swivel is stiff to turn, dismantle and check that seal 31 is seated correctly. Go to step 12.

Note: The bearing carrier must be fully supported during the fitting operation; do not allow any weight to rest on the bearings otherwise the inner bearing will be displaced an d damage the seal.

S160251

9

10

Attach a spring balance to track rod swivel as shown and note the reading. Tighten the top trunnion bolts 27 to eliminate end float but without bearing pre-load, i.e. no increase in spring balance reading.

Measure gap at top trunnion and subtract 1 mm (0.040 in) to give shim thickness (bearing pre-load). For example: Gap = 1.55 mm (0.061 in) less = 1.00 mm (0.040 in) Shim = 0.55 mm (0.021 in)

Note 1 : If the gap measures 1 mm, then no shim is required.

Note 2: If, after fitting shims the bearing pre-load is unattainable, fit new bearings.

9803/9240

Note: After assembling the bearing carrier to the swivel hub, make sure that there is sufficient clearance between the hub and seal.

17

Lightly oil the bearing race of outer wheel bearing 24.

Fit the bearing onto the axle stub. Rotate carrier 19 (and therefore the bearings) during fitting.

18

Assemble the annulus ring 23 to annulus carrier 21.

Secure with circlip 22. Make sure the two blanking plugs Z are fitted to the annulus carrier. Apply Loctite 242 to threads.

*

Note 2: Inspect the inside of the annulus carrier and piston for marks. Any signs of scoring on a seal contact surface can cause leaks.

Note 3: Make sure blanking screws Y are fitted. Apply Loctite 242 to threads.

Issue 5*

Section 5 9-5

Axles

Section 5

SD55/NT Axle

9-5

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d) Assembly(cont’d) * 19

Fit the annulus assembly in the same angular position as removal (see Note, Dismantling, Step 11) using new Verbus Ripp bolts 18. Do not fully tighten bolts but allow the bearing carrier to rock slightly.

* 23

Carefully press the piston 13 all the way into its housing. Fit brake piston back-off springs 13B and bolts 13A (2 off each). Torque tighten to 5 Nm (0.5 kgf m, 3.5 lbf ft).

20

Temporarily refit the planet gear carrier 2, DO NOT fit the sun gear.

24

Assemble the friction plates 12 and counterplates 11 onto the stubshaft and annulus ring 23. If the original brake pack is being re-used, return the plates to their original positions (see Dismantling, Step 6). Soak new friction plates in gear oil before assembly.

25

Add shim(s) X (if fitted)and assemble the brake pressure plate 10 with its chamfer towards the brake pack. Make sure the shim(s) fit between items 10 and 11. The shim(s) should give a gap of 1.5 mm to 1.8 mm (0.060 to 0.070 in). This can be measured by putting a dial test indicator (DTI) on the end face of item 10 and pressurising the brakes, or alternatively, use feeler gauges inbetween items 10 and 9. When the correct gap has been achieved fit circlip 9.

Check the seal drag rolling force: i

Use a spring balance and cord wrapped around the planet gear carrier flange as shown. Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

* Note: Shims X are only fitted to early axles.

Note 4: Where axles are fitted to machines utilising the main hydraulic circuit to operate the brakes:

ii

Remove the planet gear carrier and tighten M14 Verbus Ripp bolts 18 to 320 Nm (236 lbf ft, 33 kgf m).

i

Bleed the brake system. Gently apply the brakes and release the pressure with the engine running. Check the piston activates and retracts correctly and does not stick in the applied position before fitting the hub carrier.

ii

If the brake piston has not yet retracted, the brake seal or piston assembly may have been assembled incorrectly. Alternatively, there may be residual hydraulic brake pressure holding the piston - Release the brake bleed nipple with the engine running and check if the piston retracts when the pressure is released.

Investigate the cause if the piston remains in the applied position (see Residual Brake System Pressure, Section 6).

26

Fit sun gear B and circlip A.

27

Press the stubshaft thrust pad 8 (chamfered side lowermost) into the recess in the planet gear carrier 2.

28

Fit new planet gears 4 in place of any that were removed (see Step, 3 in Dismantling). Secure with circlip 7.

iii Repeat steps 20, 20i and record the reading. iv

To get the rolling force, subtract seal drag rolling force (see Step 20i) from reading obtained at this step, the result should be 13.6 to 150 N, (3 to 34 lbf; 1.4 to 15.3 kgf).

If the resulting figure is outside these limits check; the seal 26 is fitted correctly; and/or renew bearings 24 and 25.

Note: A high rolling force reading may indicate that the oil seal was damaged during fitting. v

Remove the planet gear carrier 2.

Note: Large radius at end of bearing bore fits onto pin first.

21

Fit spacer D and brake plate carrier.

22

Lubricate new seals 14 and 15 with hydraulic oil and fit them into their grooves in the brake piston 13 and annulus carrier 21. Make sure they seat squarely in their grooves.

9803/9240

Issue 5*

Section 5 9-6

Axles SD55/NT Axle

*

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d)

*

Assembly(cont’d)

* 29

Section 5 9-6

Fit new ‘O’ ring 3.

Fit the planet gear carrier 2 onto the bearing carrier 19, turning it slightly to engage the gear teeth and aligning the two tapped holes W in the planet gear carrier with their mating holes in the bearing carrier. (The tapped holes are diametrically opposite one another.) Ensure the planet gear carrier butts fully against the bearing carrier.

* Note: Do not strike the centre of the planet gear carrier 2 when fitting, as this may dislodge the stubshaft thrust pad 8. * 30

Fit bolts 1 and torque tighten to 52 Nm (38.3 lbf ft, 5.3 kgf m).

* 31

Fill the axle hub with oil (see Lubricants and Capacities, Section 3).

9803/9240

Issue 2*

Section 5 9-7

Axles

Section 5

SD55/NT Axle

9- 7

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Splined) *

Dismantling

Z

Y

9803/9240

Issue 3*

Axles

Section 5

Section 5

SD55/NT Axle

9-8

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Splined) (cont’d) Dismantling (cont’d) ! WARNING

9-8

Note: Excessive wear of the brake and counter plates can indicate sticking brakes or possible residual pressure in the braking system. See Residual Brake System Pressure, Section 6.

11

Remove Verbus Ripp bolts 14 and remove retaining plate 15.

12

Remove brake seal 16 then mark the relationship between the annulus carrier 17, annulus ring 18 and hub swivel 30, remove the annulus carrier 17 with annulus ring 18 from the hub swivel 30.

Disconnect the track rod and steering rams. Remove plug 1 and drain the oil from the hub.

13

Remove circlip 19 to separate annulus ring from annulus carrier. Remove brake seal 20 from hub swivel.

Note: If the track rod is to be removed completely, identify R.H. and L.H. ends to ensure correct assembly.

14

Remove brake piston back off bolt 21A and spring 21B (3 off each). Carefully withdraw brake piston 21 from its housing. A hydraulic hand pump can be used to force the piston out of the housing.

15

Remove and discard seals 22 and 23. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid.

Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake engaged and the transmission is in neutral. Disconnect the battery. Chock both side of all four wheels.

5-3-2-1

1

2

Remove bolts 2.

3

Lever off the planet gear carrier 3 at the levering points.

Remove and discard ‘O’ ring 4.

4

Remove planet gears 5 only if defective. Note that the gears can only be removed as assemblies, which comprise the gear, the bearing and two ‘L’ shaped circlips. To remove a planet gear, first remove the external circlip 6.

5

Pull off the planet gear 5.

6

The driveshaft thrust pad 7 is drilled and tapped M6 for removal purposes.

7

Remove circlip 8 to allow the sun gear 9 to be slid off the driveshaft.

8

Remove circlip 10 to allow the brake pack assembly to be slid off the driveshaft.

9

Remove brake pressure plate 11, counter plates 12 and friction plates 13.

Note: If the brake pack is to be re-used, note the positions of the plates before removing.

10

Examine friction plates, wear limit is to the depth of the crosshatching. Check all plates for flatness and damage. Some scoring of the counterplates is normal.

Renew the brake pack complete if worn or damaged.

Do not renew individual plates.

* Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings. See Axle Hub Bearing, Removal and Replacement.

16

Pull off bearing carrier 24 together with the outer bearing 25.

17

Pull off inner bearing 26.

* 18

Remove seal 27 and remove dirt shield 38.

Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated).

19

Mark the position of the top and bottom trunnions 33, remove bolts 32 and remove trunnions. Withdraw the hub carrier 30.

20

Remove the top and bottom trunnion seals 34 and bearings 35.

21

Withdraw driveshaft 31 from the axle casing. Prise out driveshaft inner oil seal 29. Remove bearing 28 using tool 892/00225.

32

33 30

34

35 A276990

S303741

9803/9240

Issue 3*

Section 5 9-9

Axles

Section 5

SD55/NT Axle

9-9

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Splined) (cont’d) *

Assembly

*

Z

Y

A A 06

9803/9240

0

Issue 3*

Axles

Section 5 9 - 10

Section 5

SD55/NT Axle

9 - 10

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Splined) (cont’d) Assembly (cont’d) 1

Tap driveshaft inner bearing 29 into position in the hub swivel driveshaft bore.

2

Fit new oil seal 28. Pack grease between lips of seal.

3

Fit driveshaft 31, taking care to locate inner end into the splines of the differential gears.

4

Press new top and bottom trunnion oil seal 34 into position followed by bearing 35. Grease bearing and oil seal before fitting to axle.

5

Locate hub swivel 30 and fit bottom trunnion. Apply Loctite 242 to threads of trunnion bolts 32 and then torque tighten bolts.

6

Fit top trunnion 33, apply Loctite 242 to the threads of trunnion bolts 32 and then torque tighten bolts.

7

Lightly oil the inner wheel bearing race 26. Assemble the bearing cup and bearing race into the bearing carrier 24.

* Note:

A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings and seals. See Hub Bearing, Removal and Replacement.

X

A272

8

Fit new brake seal 20 to hub swivel.

12

Lubricate and fit new seal 22 onto the piston 21 and seal 23 into the annulus carrier 17. Make sure they seat squarely in their grooves.

13

Carefully press the piston 15 all the way into the annulus carrier housing 17. Fit brake back-off springs 21B and bolts 21A (2 off each). Torque tighten to 5 Nm (0.5 kgf m, 3.5 lbf ft).

14

Align relationship marks made on dismantling.

Assemble the annulus ring 18 to the annulus carrier 17.

Secure with the circlip 19. Make sure the two blanking plugs X are fitted to the annulus carrier. Apply Loctite 242 to threads.

Note: Inspect the inside of the annulus carrier and piston for marks. Any signs of scoring on a seal contact surface can cause leaks.

Note: Make sure blanking screws Y are fitted. Apply Loctite 242 to threads.

15

Fit annulus assembly onto splined hub, check that relationship mark aligns. Push the annulus assembly onto the splined hub until the splines of the annulus assembly are flush with the end of the splined hub. Fit brake seal 16 onto hub swivel.

16

Fit retaining plate 15, make sure the brake galleries align. Secure using new Verbus Ripp bolts 14 and tighten until the annulusw assembly just rocks.

17

Measure seal drag rolling force, see page 5/9-5, Step 20i to v. Note: Torque tighten the new Verbus Ripp bolts 14 to 166 Nm (72 lbf ft, 10 kgf m)

18

Assemble the friction plates 13 and counterplates 12 onto the carrier. If the original brake pack is being used, return the plates to their original positions as noted during dismantling. Soak new friction plates in gear oil before assembly.

19

Fit brake pressure plate 11 and circlip 10.

20

Press the driveshaft thrust pad 7 (chamfered side lowermost) into the recess in the planet carrier 3.

21

Fit new planet gears 5 in place of any that were removed during dismantling. Secure with circlip 6.

22

Slide sun gear 9 onto the driveshaft and secure with circlip 8. Fit a new ‘O’ ring 4 in place of the one discarded during dismantling.

23

Fit planet carrier 3 onto bearing carrier 24 ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and tighten bolts 2 after applying Loctite 242 to the threads.

24

Reconnect the steer arms.

0

Fit combination seal 27 into the bearing carrier.

Using service tool 892/00891, drive the seal squarely into the carrier until flush as at X. Do not lubricate before fitting.

*9

Inspect and fit dirt shield 38.

* 10

Lightly oil the outer wheel bearing race 25 and inner bore of seal 27. Assemble the bearing cup and bearing race into the bearing carrier 24. Fit the bearing carrier 24 onto the axle stub.

Note: The bearing carrier must be fully supported during the fitting operation; do not allow any weight to rest on the bearings, otherwise the inner bearing will be displaced and damage the seal.

9803/9240

11

Issue 2*

Section 5

Axles SD55/NT Axle

9 - 11

Section 5 9 - 11

Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Splined) (cont’d) Assembly (cont’d) Torque Settings

*

Item 1 2 14 21A 32

Nm 70 - 100 56 166 5 98

kgf m 7.1 - 13.8 5.71 10 0.5 10

lbf ft 51.5 - 73.75 41.3 72 3.5 72

32

33 30

34

35

S303741

9803/9240

Issue 2*

Section 5 10 - 1

Axles SD55/NT Axle

Section 5 10 - 1

Axle Hub and Driveshaft SD40 Non Braked Hub Dismantling

9803/9240

Issue 1*

Section 5 10 - 2

Axles

Section 5

SD55/NT Axle

10 - 2

Axle Hub and Driveshaft SD40 Non Braked Hub (cont’d) Dismantling (cont’d) 15 1

Drain oil from the axle hub.

2

Remove bolts 24.

3

Using a soft-faced mallet, tap the planet gear carrier 18 to ‘crack’ the joint between the carrier and bearing carrier 8, then lever the planet gear carrier off the bearing carrier. Remove and discard ‘O’ ring 23.

4

5

Remove planet gears 25 only if it is defective. Note that a planet gear can only be renewed as an assembly, which comprises the gears, the bearing 5 and two ‘L’ shaped circlips 19. To remove a planet gear, first remove the external circlip 4, then pull off the planet gear.

The driveshaft thrust pad 17 is drilled and tapped M6 for removal purposes.

6

Remove external circlip 22 and spacer 35.

7

Remove Verbus Ripp bolts 16. These bolts are very tight and care must be taken not to distort the bolt heads. Use as short an extension bar as possible with a six sided socket. Discard the Verbus Ripp bolts after removal.

8

Pull the annulus assembly 12, 13 and 14 off the bearing carrier 8.

Mark position of top and bottom trunnions 27, remove bolts 26 and remove trunnions.

Note: Trunnions may be removed easily by pumping grease through the grease nipple.

16

Remove the top and bottom trunnion seals 29 and bearings 30 only if they are to be replaced. Removing. will damage the seals.

17

Withdraw drive shaft 21 from the axle casing.

18

Prise out drive shaft outer oil seal 2.

19

Remove bearing 1 using tool 892/00225.

20

Prise out driveshaft inner seal 31.

21

Remove circlip 32.

22

Remove bearing 33 using tool 892/00225.

23

If there has been a component failure, remove all traces of debris and clean the magnetic drain plug.

Note: Ensure annulus ring position is marked for reassembly.

If the hub swivel and annulus carrier are to be renewed they must be renewed as pairs and not individually.

9

Remove internal circlip 14 to separate the annulus ring 12 from the annulus carrier 13.

10

Pull off the bearing carrier 8 together with the outer wheel bearing cone and cup 11. Withdraw the inner bearing cup from the inboard side of the carrier.

Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings. See Axle Hub Bearing, Removal and Replacement.

11

Pull off the inner wheel bearing 6.

12

Remove the dirt shield 34.

13

Remove and discard combination seal 9.

14

Disconnect the track rod and steering cylinder from the axle steer knuckles.

Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated).

9803/9240

Issue 1*

Section 5 10 - 3

Axles

Section 5

SD55/NT Axle

10 - 3

Axle Hub and Driveshaft SD40 Non Braked Hub (cont’d) Assembly

A

9803/9240

Issue 1*

Section 5 10 - 4

Axles

Section 5

SD55/NT Axle

10 - 4

Axle Hub and Driveshaft SD40 Non Braked Hub (cont’d) Assembly (cont’d) Note: The top and bottom trunnions are very similar (bottom trunnion not illustrated), 1

Tap the drive shaft inner bearing 33 into position in the hub swivel driveshaft bore, secure with circlip 32.

2

Fit new oil seal 31. Pack grease between lips of seal.

3

Fit driveshaft 21, taking care to locate inner end into splines of differential gears.

4

Tap driveshaft outer bearing 1 into position in the hub swivel.

5

Fit new oil seal 2. Pack grease between the lips of the seal.

6

Press new top and bottom trunnion oil seals 29 into position followed by bearings 30. Grease bearing and oil seal before fitting axle.

7

Locate hub swivel 3 and fit bottom trunnion 27. Apply Loctite 242 to threads of bottom trunnion bolts 26 and then torque tighten bolts. Torque tighten the top bolts 26. Turn the swivel by hand, to ensure smooth operation. If swivel is stiff to turn, dismantle and check that seal 29 is seated correctly. Go to step 11.

Note: Item 26 M10 bolts torque to 56 Nm (42 lbf ft; 6 kgf m).

M12 bolts torque to 98 Nm (72 lbf ft; 10 kgf m).

8

Connect the track rod and steering cylinder to the axle steer knuckles.

Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings and seals. See Hub Bearing, Removal and Replacement.

9

Inspect and fit dirt shield 34.

10

Lightly oil the inner wheel bearing 6 and its cup 7, then fit them into the bearing carrier 8.

11

Fit a new combination seal 9 into the bearing carrier.

Do not lubricate before fitting. Using service tool (892/00891) and spacer, drive the seal squarely into carrier 19, until flush, as shown at X.

13

Install the cup of outer wheel bearing 10 into the bearing carrier 8. Lubricate the bore of the seal and the surface of the stub.

X

A272

0

14

Fit the bearing carrier 8 onto the hub swivel 3.

15

Lightly oil the bearing race of outer wheel bearing 11.

Fit the bearing onto the axle arm. Rotate the carrier 8 (and therefore the bearings) during fitting.

16

Assemble the annulus ring 12 to the annulus carrier 13.

Secure with circlip 14.

Note: After assembling the bearing carrier to the swivel hub, make sure that there is sufficient clearance between the hub and seal.

17

Fit annulus assembly in the same angular position as removal (see Note on page 5/10-2) using new Verbus Ripp bolts 16. Do not fully tighten bolts but allow the bearing carrier to rock slightly.

Note: Steps 18 describe measurement of rolling force. To measure rolling torque (simplified process), a special tool is available. Refer to Service Tools.

cont..

9803/9240

Issue 1*

Section 5

Axles

Section 5

SD55/NT Axle

10 - 5

10 - 5

Axle Hub and Driveshaft SD40 Non Braked Hub (cont’d) Assembly (cont’d) 18

21

Check the seal drag rolling force:

Fit spacer 35 and secure driveshaft with circlip 22. Fit a new ‘O’ ring 23.

i

Use a spring balance and cord wrapped around the planet carrier flange as shown. Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

Fit planet gear carrier 27 onto bearing carrier 8, turning it slightly to engage the gear teeth and aligning the two tapped holes A in the bearing carrier. (The tapped holes are diametrically opposite one another.) Ensure the planet gear carrier butts fully against the bearing carrier.

ii

Remove the planet gear carrier and tighten new Verbus Ripp bolts 16 to 166 Nm (122 lbf ft, 17 kgf m).

Note: Do not strike the centre of the planet gear carrier 18 when fitting, as this may dislodge the driveshaft thrust pad 17.

iii Repeat steps 19, 19i and record the reading.

22

Fit bolts 24 and torque tighten to 56 Nm (41.3 lbf ft, 5.71 kgf m).

23

Fill the axle hub with oil (see Lubricants and Capacities, Section 3).

iv To get the rolling force, subtract seal drag rolling

force (see Step 19i) from reading obtained at this step, the result should be 2 to 22 Nm, (3 to 34 lbf; 1.4 to 15.3 kgf).

If the resulting figure is outside these limits check the seal 9 is fitted correctly and/or renew bearings 6 and 11.

Note: A high rolling force reading may indicate that the oil seal was damaged during fitting.

19

Press the driveshaft thrust pad 17 (chamfered side lowermost) into the recess in the planet gear carrier 18.

20

Fit new planet gears 25 in place of any that were removed (see Dismantling, Step 4 ). Secure with circlip 5.

Note: The large radius at end of bearing bore fits onto the pin first.

9803/9240

Issue 1*

Section 5

Transmission

11 - 1

SD55/NT Axle

Section 5 11 - 1

Axle Hub and Driveshaft SD70 Non Braked Hub 16

Dismantling 7

4 5

6

15

6

13

2 9 12

14

34

10 11

35

8 43

20

3 17

19

1

27 28

18

24

29 25

31

23

32 30

21 22

26 710050

9803/9240

Issue 1*

Section 5 11 - 2

Transmission

Section 5

SD55/NT Axle

11 - 2

Axle Hub and Driveshaft SD70 Non Braked Hub (cont’d) Dismantling (cont’d) 1

Disconnect the steering track rod. Drain oil from the hub.

Note: The illustration shows a typical axle.

2

Remove bolts 1.

3

Lever the planet gear carrier 2 off the bearing carrier.

Clean off all traces of sealant from the mating faces or remove ‘O’ ring as applicable.

4

Remove planet gears 4 only if defective. Note that gears can only be removed as assemblies, which comprise the gear 4, the bearing 5 and two 'L' shaped circlips 6.

To remove a planet gear, first remove the external circlip 7.

5

Pull off the planet gear 4.

6

The driveshaft thrust pad 8 is drilled and tapped M6 for removal purposes.

7

Remove circlip 9 to allow the sun gear to be slid off the drive shaft 34.

8

To remove the ‘Verbus Ripp’ bolts 12, it is necessary to remove the spacer 11. Revolve the spacer with a suitable drift to align the holes in the spacer with the space between the bolts.

9

Using two dowels and two heel bars, remove the spacer 11 using the method shown.

10

Remove the 'Verbus Ripp' bolts 12 using a special tool (part number 892/00333). These bolts are very tight and care must be taken not to distort the bolt heads. Use as short an extension bar as possible.

11

Using 2 high grade M12 bolts as jacking screws, remove the annulus carrier.

8

255920

Note: Fretting between the hub swivel and annulus carrier mating faces might be evident; this condition is normal, do not attempt to repair. If the hub swivel and annulus carrier are to be re-used, the carrier must be assembled in the same angular position it was removed; match mark the hub swivel and carrier before removing the carrier.

12

Remove circlip 15 to separate the annulus ring from the annulus carrier.

255930

9803/9240

Issue 1*

Section 5

Transmission

11 - 3

SD55/NT Axle

Section 5 11 - 3

Axle Hub and Driveshaft SD70 Non Braked Hub (cont’d) Dismantling (cont’d) Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings. See Hub Bearing, Removal and Replacement.

13

X

Pull off the bearing carrier 17 together with the outer bearing cone 18 and its bearing cups.

Note: To prevent damaging the axle case inner seal, do not lever against the half shaft. Place a tube over the half shaft and lever against the tube, as shown at X. 14

Pull off the inner bearing 19 - see Note at step 13.

A258390

15

Remove and discard the seal 20.

Note: The inner bearing and oil seal may withdraw with the bearing carrier.

16

Remove and discard the combination seal. When assembling the axle, a new combination seal must be used.

17

Remove the dirt shield 35.

18

Mark position of top and bottom trunnions 27, 3 and remove. Withdraw the hub carrier.

Note 1: Trunnions may be removed easily by pumping grease through the grease nipple.

Note 2 : Earlier axles are fitted with shims 29. Remove shims and retain for assembly.

19

Use an adaptor with slide hammer tool 892/00224 and remove driveshaft seal 21 and needle roller bearing 22 from the hub carrier 30.

20

Use a puller to remove the trunnion seal 31 and bearing 32.

21

Withdraw drive shaft 34.

22

Prise out drive shaft inner oil seal 23.

23

Remove circlip 24

24

Remove bearing 25 using tool 892/00225.

9803/9240

Issue 1*

Section 5

Transmission

11 - 4

SD55/NT Axle

Section 5 11 - 4

Axle Hub and Driveshaft SD70 Non Braked Hub 16

Assembly 7

4 5

6

15

6

13

2 9 12

14

34

10 11

35

8 43

20

3 17

19

1

27 28

18

24

29 25

31

23

32 30

21 22

26 710050

9803/9240

Issue 1*

Section 5

Transmission

11 - 5

SD55/NT Axle

Section 5 11 - 5

Axle Hub and Driveshaft SD70 Non Braked Hub (cont’d) Assembly (cont’d) 1

Tap drive shaft inner bearing 25 into position and secure with circlip 24.

2

Fit new oil seal 23. Pack grease between lips of seal.

3

Fit drive shaft 34, taking care to locate inner end into splines of differential gears.

4

Fit new trunnion oil seal 31 into position followed and press bearing 32 into position. Grease bearing and oil seal before fitting to axle.

5

Fit driveshaft needle roller bearing 22 to the hub carrier 30. Pack the cavity between the oil seal lips with grease and then fit the seal 21.

6

Locate hub carrier and fit bottom trunnion 3. Apply Loctite 242 to the bottom trunnion bolt threads 26, fit and tighten to 98Nm (72 lbf ft). Fit top trunnion 27 and leave top trunnion bolts 26 finger tight.

Note: On later models without shims 29, torque tighten the top bolts 27. Turn the swivel by hand, to ensure smooth operation. If swivel is stiff to turn, dismantle and check that seal 31 is seated correctly and check bearings 32. Go to step 11.

7

Attach a spring balance to track rod swivel as shown and note the reading. Tighten the top trunnion bolts 26 to eliminate end float but no bearing pre-load, ie no increase in spring balance reading.

Note: Earlier axles are fitted with shims 29.

Measure gap at top trunnion and subtract 1 mm (0.040 in) to give shim thickness (bearing pre-load).

07 60

S248850

For example: Gap = 1.55 mm (0.061 in) less 1.00 mm (0.040 in) Shim =

0.55 mm (0.021 in)

Note 1: If the gap measures 1 mm, then no shim is required.

8

Refit top trunnion. Apply Apply Loctite 242 to the top trunnion bolt threads 27, fit and tighten to 98 Nm (72 lbf ft). Check spring balance reading which should be 4.5 kgf (10 lbf) more than the reading recorded at step 7.

Note 2: If after fitting shims, the bearing pre-load is unattainable, fit new bearings.

9

Lightly oil the inner wheel bearing 19. Assemble the inner and outer bearing cups, and the inner bearing cone into the bearing carrier 17.

Note: A Hub Service Kit (892/01092) is available for the removal and replacement of the hub bearings and seals. See Hub Bearing, Removal and Replacement.

9803/9240

Issue 1*

Section 5

Transmission

11 - 6

SD55/NT Axle

Axle Hub and Driveshaft SD70 Non Braked Hub (cont’d)

Section 5 11 - 6

Y

X

35

Assembly (cont’d) 10

Inspect and fit dirt shield 35.

11

Fit a new combination oil seal 20. Do not lubricate before fitting. Use seal dolly L (892/00891) to fit the seal. Be sure to use the correct side of the dolly (the dolly is stamped A and B) as follows: Axles with steel dirt shield 35, use side A as shown at X. Axles with no dirt shield 35, use side B as shown at Y. Fit the seal over the dolly and then use a soft faced hammer to drive the seal squarely into the carrier until the dolly flange is up against the carrier.

12

Fit the bearing carrier 17 onto the axle arm. Lightly oil the outer wheel bearing race 18 and inner bore of seal 20. Fit the bearing onto the axle stub. Rotate the bearing during fitting.

13

Assemble the annulus ring 16 to the annulus carrier 13.

Secure with the circlip 15.

14

Fit annulus assembly in the same angular position as removal (see Note, Dismantling, step 11) using new 'Verbus Ripp' bolts 12. Do not fully tighten bolts but allow the bearing carrier to rock slightly. Measure seal drag rolling force - see step 14.

B

A 20

20

L

A

17

B A

02 0

Note: Steps 13 to 16 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool is required. Refer to Service Tools.

15

To measure seal drag rolling force: -

Refit the planet gear carrier - DO NOT FIT THE SUN GEAR 10.

-

Use a spring balance and cord wrapped around the planet carrier flange as shown.

-

Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

-

Remove planet gear carrier 2.

16

Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 16.

17

To measure rolling force: -

Refit the planet gear carrier - DO NOT FIT THE SUN GEAR. Use a spring balance and cord wrapped around the planet gear carrier flange as shown. Pull the spring balance so that the hub rotates and record the reading.

-

To get the rolling force, subtract seal drag rolling force (see step 14) from reading obtained at this step, the result should be 64 to 117 N (14 to 26 lbf).

9803/9240

S248540

Issue 1*

Section F 11 - 7

Transmission

Section F

Front Axle - SD55, SD70

11 - 7

Axle Hub and Driveshaft SD70 Non Braked Hub (cont’d) Assembly (cont’d) 17 cont’d - If the resulting figure is outside these limits check: the seal is fitted correctly; and/or renew bearings if necessary; and /or new fitted components.

- Remove planet gear carrier 2.

18

Press the drive shaft thrust pad 8 (chamfered side lowermost) into the recess in the planet carrier.

19

Fit new planet gears in place of any that were removed.

(See step 4 in 'Dismantling'). Secure with circlip 6.

8

Note: Make sure that the SMALL radius on the gear bearing internal diameter is facing uppermost, that is at the circlip end of the planet pin.

255920

20

Fit spacer 11 and slide the sun gear 10 onto the driveshaft 34 and secure with circlip 9. Fit a new ‘O’ ring 3 in position X.

Note: Some machines may have sealant instead of an‘O’ ring - where appropriate fit a new ‘O’ ring.

Note: The sun gear must be fitted with the 1.5 mm (0.060 in) x 45° chamfer inboard.

21

X

Fit the planet carrier 2 onto the bearing carrier, ensuring that the two tapped holes are in line with those on the bearing carrier 17. Fit and torque tighten bolts 1 to 56Nm (41Ibf ft; 5.7kgf m) after applying Loctite 242 to the threads.

Note: Rotate planet gear carrier slightly to align the gears.

Do not strike the centre of the planet gear carrier when fitting as this may dislodge the driveshaft thrust pad 8 fitted at step 17.

22

Fill the axle hub with oil (see Lubricants and Capacities, Section 3) S258230

9803/9240

Issue 1*

Section 5 14 - 1

Transmission SD55/NT Axle

Section 5 14 - 1

Axle Hub Bearing Removal

9803/9240

Issue 1*

Section 5 14 - 2

Transmission

Section 5

SD55/NT Axle

14 - 2

Axle Hub Bearing Removal (cont’d) 1

Y

Remove the planet gear carrier 2, annulus ring 16 and the annulus carrier 14. See Axle Hub and Driveshaft Dismantling.

C

Note: The Bearing Puller from the Wheel Hub Service Kit 882/01092 (see Service Tools) is required throughout steps 13 to 17.

2

Assemble the puller B, screwing the legs A onto, two diametrically opposite wheel studs and placing reaction tube C over the driveshaft.

A D

B

Note: Reaction Tube C, MUST be used, otherwise damage to the driveshaft and drive shaft bearings will occur.

A439380

Note: On five wheel stud axles, the modified wheels studs from the Wheel Hub Service Kit must be used. Bolt to two diametrically opposite holes provided on the bearing carrier 12.

3

X

Screw in D slowly until the bearing carrier together with the outer bearing cone and its cup are released from the axle. If the wheel hub starts to turn use a suitable bar Y to prevent further rotation.

Note: If D becomes to hard to turn, tap the back of the hub with a plastic hammer to help release the bearing.

4

Remove and discard the outer part of combination seal 19 by cutting the outer seal with a sharp chisel X. Carefully force the inner seal fully on to the stub axle, taking CARE not to damage the seal seat on the stub axle. If a dirt shield 22 is fitted, it may need to be removed (clearance for the inner bearing plate E is required).

5

Assemble the puller B, with the inner bearing plate E clamped around the inner bearing 18, (If a dirt shield 22 is fitted, it may need to be removed) attach the puller rods F and reaction tube C over the driveshaft 26.

C

Note: Reaction tube C, MUST be used, otherwise damage to the driveshaft and driveshaft bearings will occur.

6

Slowly screw in D until the bearing 18 is released.

Remove and discard the inner section of seal 19.

E F

D B

9803/9240

A439390

Issue 1*

Section 5 14 - 3

Transmission SD55/NT Axle

Section 5 14 - 3

Axle Hub Bearing Replacement

9803/9240

Issue 1*

Section 5 14 - 4

Transmission

Section 5

SD55/NT Axle

14 - 4 23

Axle Hub Bearing Replacement (cont’d)

H

1 Fit the dirt shield 22 to the stub 23 (if fitted).

Note: The bearing press from the wheel hub service Kit 882/1092 (see Service Tools) is required throughout steps 2 to 11.

2

Attach the bearing centre puller H to the centre of the hub 23 using the existing ‘Verbus Ripp’ bolts 11.

Note: When refiting the annulus carrier 14, NEW ‘Verbus Ripp’ bolts must be used.

3

Install outer bearing race from bearing 17 into bearing carrier 12.

4

Install the inner bearing 18 into the bearing carrier 12.

Fit a new combination oil seal 19. Do not lubricate before fitting. Use seal dolly L (892/00891) to fit the seal. Be sure to use the correct side of the dolly (the dolly is stamped A and B) as follows: Axles with steel dirt shield 22, use side A as shown at X. Axles with no dirt shield 22, use side B as shown at Y. Fit the seal over the dolly and then use a soft faced hammer to drive the seal squarely into the carrier until the dolly flange is up against the carrier.

5

X

22

B 19

A 19

L

A

12

B

Lightly oil the inner wheel bearing 18 and seal 19 inner diameter. Position the bearing carrier (complete with inner bearing) onto the stub over the centre puller H.

6

Slide the bearing fitting tube K over the centre bearing puller H (the wide opening towards the bearing). Make sure that the bearing and carrier are square to the shaft.

7

Attach the puller handle J to the bearing centre puller H, making sure that the thrust bearing is fitted between two thrust washers at L. Using the puller handle, screw in the bearing fitting tube K until the inner bearing 18 is pressed correctly into postion.

8

Remove the puller handle J and bearing fitting tube K.

9

Install the outer bearing 17 in the bearing carrier 12.

10

Assemble the puller handle J and bearing fitting tube K onto the centre puller H.

11

Using the puller handle J, screw in the bearing fitting tube K until the outer bearing 17 is pressed correctly into postion so as to remove most of the free play. Do not over tighten as this may cause damage to the bearing.

12

Y

A

02 0

L

K

See Axle Hub and Driveshaft Assembly.

J 9803/9240

Issue 1*

Section 6

Brakes

Section 6

i

i

Contents

Page No.

Service Brakes

9803/9240

Technical Data

1-1

Bleeding Procedure

2-1

Dismantling and Assembly

2-1

*

Residual Brake System Pressure

2-1

*

Brake Seal or Component Leakage

3-1

Issue 2*

Section 6 1-1

Brakes Technical Data

Section 6 1-1

Service Brake - 2 Plate, Positive Retraction (Power Braked Machines) Type

Oil-immersed multi-plate disc

Actuation

Hydraulic

Location

Outboard - Axle Hub

* Friction Plates Outside diameter Inside diameter Nominal facing area/plate

9803/9240

2 per brake (i.e. 4 per axle) 220 mm (8.66 in) 180 mm (7.09 in) 12616 mm2 (19.5 in2)

Issue 2*

Section 6

Brakes

Section 6

Service Brakes

2-1

Bleeding Procedure

2-1

* Residual

Bleed as follows: a

Attach tube to bleed screw A, ensuring that free end of tube is immersed in hydraulic fluid contained in a suitable jar.

b

Open bleed screw A and apply one rapid stroke of the brake pedal followed by three rapid short strokes from the pedal half way position. After the third short stroke allow the pedal to return quickly to its stop.

c

Continue bleeding normally until all air is expelled.

Close bleed screw A with the pedal fully depressed.

d

Repeat the procedure for the other side.

Brake System Pressure

If residual pressure is greater than the pressure required to overcome the brake retraction springs in the axle, brake piston retraction will not occur resulting in excessive heat and wear of brake components.

If the residual pressure in the braking system is above 0.35 bar (5 lbf/in2) in the hot condition, the system should be checked to identify the cause of the problem.

Note: Pressure cannot build up in the hydraulic tank until the oil is hot, or if the pressure is vented by removing the tank cap/breather.

Checking for Residual Pressure The following checks should be done with the engine running and the oil at working temperature.

Dismantling and Assembly

1

Apply and release the brakes. Check the brakes release immediately.

The brakes are located in the wheel hubs. Instructions for dismantling and assembly are detailed under Axles - Axle Hub and Driveshaft, Section 5.

2

If the brakes do not release immediately, place a container under the axle hub to catch any spilt oil.

Unscrew the bleed nipple on the axle hub to release any residual pressure.

Note: The same effort should be needed to rotate the hub with the bleed nipple either open or closed. If the problem affects one hub only, strip and inspect the affected hub.

A

3

If the brakes release immediately, residual pressure should be suspected.

4

If the brakes do not release immediately, tighten the bleed nipple and check the following: (a) (b) (c) (d)

Foot brake valve adjustment and linkage Operation of the hydraulic tank breather Clear plastic return lines from foot valve are not restricted Hydraulic tank not over-filled

S144521

9803/9240

Issue 2*

Section 6

Brakes

3-1

Section 6 3-1

Service Brakes

Brake Seal or Component Leakage 3.3 If the pressure falls off rapidly, or if no pressure reading can be obtained, a seal is severely damaged and needs replacing, or a leak path exists.

The following procedure explains how to check if a brake seal or component is severely damaged/perished, or if the seal has a small cut or nick. The test must only be done when the axle is COLD.

3.4 Remove planet hub and identify the source of the leakage before proceeding any further.

! WARNING

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

Test For a Low Pressure Leak

BRAKE 1-4

4

! WARNING Do not drive the machine with any part of its brake system disconnected. When the following test has been completed reconnect all brake pipes and bleed the brake system using the recommended procedure.

Check for small cuts or nicks in the piston seal: 4.1 Install an adapter fitted with a piece of clear tube to the brake piston port B, as shown at Y. Note: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine.

BRAKE 2-1

Test For a High Pressure Leak

4.2 Fill the tube until approximately three quarters full with Mobil DTE 11M Hydraulic Fluid

1

Remove and cap brake piston feed pipe A.

2

Fill the brake piston housing with Mobil DTE 11M Hydraulic Fluid.

3

Check for severe piston seal damage:

4.3 Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at C. 4.4 After approximately 1/2 hour, check if the level has dropped below the original marked line, if it has then check the brake component for slight nicks, cuts, leak paths or generally for wear.

3.1 Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to port B, as shown at X. Note: The hand pump MUST be filled with Mobil DTE 11M Hydraulic Fluid. DO NOT exceed 69 bar 2 (1000 lbf/in ).

3.2 Use the hand pump to generate a pressure in the brake piston housing.

5

Repeat steps 1 to 4 for the opposite brake piston seal.

6

Reconnect all brake pipes and bleed the brake system as recommended on page 6/2-1.

X

Y

C

B

B A

A

159831

9803/9230

Issue 1

Section 6

Brakes

Section 6

Service Brakes

3-2

3-2

Brake Seal or Component Leakage (cont’d) The most common reason for internal piston seal leakage is a build-up of axle contamination from excessive brake wear caused by extended service periods. This allows metal particles to build-up on the sealing surfaces causing scoring and allowing low pressure leaks.

The following areas identify where leakage can commonly occur.

Low Pressure: A

Swivel to annulus carrier sealing o-rings and sealing surfaces.

There are two types of internal leakage that can occur within the axle and hub:

B

Brake piston seals.

(a)

C

Annulus carrier to swivel sealing o-ring surfaces.

D

Piston and annulus carrier sealing surfaces (porosity, scores, nicks & scratches etc.).

(b)

Low Pressure Leaks - Seal damage, or scoring to seal component surfaces.

High Pressure Leaks - Mechanical leakage through a porous casing, or blanking screw threads.

Note: The low pressure leak test should be performed first.

Low pressure leaks are difficult to find using a high pressure test - seals and other components can distort and form a seal under pressure.

High Pressure: E

Blanking screws (x2) - missing, loose or no thread sealant used.

F

Porosity through casing from internal galleries.

G

Blanking screws (x2) - missing, loose or no thread sealant used.

H

Annulus carrier to piston seals sealing surfaces.

G

B E F

D

H C 316010

A 9803/9230

Issue 1