JCB Drivetrain SD 55 Power Track Rod High Pivot Mount Service Manual - PDF DOWNLOAD

Service Manual

General Information

1

Care & Safety

2

Routine Maintenance

3

Hydraulics

4

Axles

5

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

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

SD 55 POWER TRACK ROD HIGH PIVOT MOUNT Publication No. 9803/9286 Issue 2

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.

9803/9286

Issue 1

Section 1

General Information

Section 1

i

i

Contents

9803/9286

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 1

Section 1

General Information

Section 1

1-1

1-1

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

SD 55

A403640

Replacement Parts

Axle Build Identification

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.

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

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.

Example:

4

5

6

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.

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

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

9803/9286

450 / 2760 / 1 / 0091

A

B C

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

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 2

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.

9803/9286

Issue 1

Section 1

General Information

3-1

3-1

Service Tools Numerical List 4003/0211 4101/0251 4101/0451 4101/0250 4102/0552 4102/1212 4102/1951 4104/0251 4104/0253 4104/1557 892/00174 892/00179 892/00224 892/00225 892/00333 892/00812 892/00817 892/00818 892/00819 892/00822 892/00891 892/00918 892/01092 921/52627 921/53300 992/04000 993/59500 993/68100 993/70111 997/11000

Anti-Seize Paste Loctite 242 Loctite 932 Loctite 243 Loctite 275 Loctite 574 or Permabond A136 Loctite 577 Activator (Aerosol) Activator (Bottle) Cleaner/Degreaser Measuring Cup - Pinion Head Bearing Bearing Press Impulse Extractor Set for Hub Bearing Seals Adaptor - Impulse Extractor Heavy Duty Socket Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Splined Bolt Socket Oil Seal Insertion Tool Setting Tool Kit Hub Service Kit Spacer 14.20 Service use Spacer Kit Torque Multiplier Adapter-Impulse Extractor Slide Hammer Kit Breakback Torque Wrench Support Bracket

Page No. 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-2 4-1 4-2 4-1 4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-3 4-4 4-3 4-3 4-2 4-1 4-2 4-3 4-3

Solid Spacer Setting Kit

4-3

Torque Measuring Tool (Manufactured locally)

4-1

9803/9286

Section 1

Issue 1

Section 1

General Information

Section 1

Service Tools

4-1

4-1

Axles

892/00179

Bearing Press (use with appropriate adapters) 892/00812

Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle

S107750 S188200

892/00225

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

993/59500

Adapter - Impulse Extractor

S261230

S197080

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.

S216290

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

9803/9286

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

Issue 1

Section 1

General Information

Section 1

Service Tools

4-2

4-2

Axles (cont'd)

992/04000

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

S197030

892/00224

Impulse Extractor Set for Hub Bearing Seals

892/00174

Measuring Cup - Pinion Head Bearing

S190770

S197070

892/00822

Splined Bolt Socket for driveshafts

S197060

Slide Hammer Kit - 993/68100 1 :993/68101 Slide Hammer 2 :993/68102 End Stops 3 :993/68103 Adaptor - M20 x 5/8" UNF 4 :993/68104 Adaptor - M20 x 1" UNF 5 :993/68105 Adaptor - M20 x M20

6 7 8 9 10 11

:993/68106 :993/68107 :993/68108 :993/68109 :993/68110 :993/68111 2

11

Adaptor - M20 x M24 Bar - M20 x M20 X 800MM Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x 5/8" UNF (Shoulder) Adaptor - M20 x 1/2" UNF 2 5

1

3

6

2

4

9 10 8 7

S196910

9803/9286

Issue 1

Section 1

General Information

Section 1

Service Tools

4-3

4-3

Axles (cont'd)

Solid Spacer Setting Kit

1

1 2 3

3

2 S316260

997/11000

892/00918 993/70111 921/52600 921/52627 Comprises of: 921/52601 921/52602 921/52603 921/52604 921/52605 921/52606 921/52607 921/52608 921/52609 921/52610 921/52611 921/52612 921/52613 921/52614 921/52615 921/52616 921/52617 921/52618 921/52619 921/52620 921/52621 921/52622 921/52623 921/52624 921/52625 921/52626

Setting Tool Kit Breakback Torque Wrench Spacer Kit Spacer 14.20 Service use Spacer 12.75 Spacer 12.80 Spacer 12.85 Spacer 12.90 Spacer 12.95 Spacer 13.00 Spacer 13.05 Spacer 13.10 Spacer 13.15 Spacer 13.20 Spacer 13.25 Spacer 13.30 Spacer 13.35 Spacer 13.40 Spacer 13.45 Spacer 13.50 Spacer 13.55 Spacer 13.60 Spacer 13.65 Spacer 13.70 Spacer 13.75 Spacer 13.80 Spacer 13.85 Spacer 13.90 Spacer 13.95 Spacer 14.00

Support Bracket

A396930

9803/9286

Issue 1

Section 1

General Information

Section 1

Service Tools

4-4

4-4

Axles (cont'd)

Wheel Hub Service Tools: 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

9803/9286

Issue 1

Section 1

General Information

Section 1

5-1

5-1

Sealing 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.

† 4102/0552

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.

9803/9286

Issue 1

Section 2

Care & Safety

Section 2

i

i

Contents

9803/9286

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

9803/9286

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

! 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.

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.

! 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.

9803/9286

INT-1-3-8

! 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.

INT-1-3-9

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.

9803/9286

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

9803/9286

! 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

! 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.

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

GEN-1-2/IT

! WARNING 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

! WARNING 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.

2-1-1-8/IT

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: 1

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

2

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.

DO NOT BURN FLUOROELASTOMERIC MATERIALS. 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.

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.

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

9803/9286

Issue 1

Section 3

Routine Maintenance

Section 3

i

i

Contents

9803/9286

Page No.

Lubricants & Capacities

1-1

Lubricants - Health and Safety

1-2

Service Schedules

2-1

Greasing

3-1

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

4-1 4-1 4-2 4-2

Issue 1

Section 3

Routine Maintenance

Section 3

1-1

1-1

Lubricants & Capacities ITEM

CAPACITY Litres UK Gals

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Axle - SD 55 Housing Hubs (x2)

7.6 1.9

1.67 0.42

Q8T35

Q8T35 SAE90 API-GL-5.

Grease Points

-

-

Mobil HP222

Mobil HP222

9803/9286

Issue 1

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

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

3

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.

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

Note the following when removing oil from sk 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.

9803/9286

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 Hub Oil Level M Axle Hub Oil Centre Case Oil Level Centre Case Oil Steer Axle Movement/Shimming N Axle Steering Joints †† HYDRAULICS Cylinders - Chrome Condition Functional Test and Final Inspection AXLES AND STEERING Steering Modes - Operation Steering Proximity Switch - Operation N Wheel Nut Torque Steer Phasing N Steer Cylinder - Balance N Steer Circuit Pressure N

Operation

10 Hr

50 Hr

- Check - Change - Check - Change - Check - Grease

†100 Hr

500 Hr

z

z

- Check - Check - Check - Check - Check - Check

z

z

z

z

z

z z

z

z

z

z

z

z

z

z

z

z

z

z

- Check Operation

1000 2000 Hr Hr

10 Hr

50 Hr

†100 Hr

500 Hr

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

1000 2000 Hr Hr

z

†

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 Intervals must be reduced to 50 hours/weekly.

M

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

N

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

9803/9286

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

3-1

3-1

Axles SD55 Total 5 Grease Points.

12

9803/9286

5

43

1

3

2

4

S260210

Issue 1

Section 3

Routine Maintenance

Section 3

Axles

4-1

Checking the Differential Oil Level

4-1

Changing the Differential Oil

! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery.

It is important that the oil is changed regularly as specified in the service schedule.

Consult your distributor for advice if necessary.

2-3-2-2

! WARNING

! CAUTION The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given.

Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery.

2-3-2-2

16-3-5-3

1

Park the machine on level ground. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Clean the area around fill/level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

3

Clean and refit the plug and its washer.

1

Park the machine on level ground. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Place a container of suitable size beneath plug B to catch the oil. Remove the drain plug B and its seal.

Allow oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed).

Fit drain plug B and its washer. Tighten to 79 Nm (60 lbf ft).

3

Fill with recommended oil through fill/level hole A. Clean and refit plug A and its seal. Tighten to 79 Nm (60 lbf ft).

FRONT S260420

A B Note: This illustration is typical only.

9803/9286

Issue 1

Section 3

Routine Maintenance

Section 3

Axles

4-2

4-2

Checking the Hub Oil Levels

Changing the Hub Oil

Check each hub separately.

Change the oil in each hub separately.

1

1

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.

2

Place a container of suitable size beneath plug C to catch the oil. See Lubricants and Capacities.

Park the machine on level ground with the OIL LEVEL mark horizontal. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Clean the area around the fill/level plug C. Remove the plug. Oil should be level with the bottom of the hole. If necessary, add recommended oil. See Lubricants and Capacities for recommended oil. Clean the plug before refitting it.

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

3

Set OIL LEVEL marks to the horizontal. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

Fill the hubs with recommended axle oil, through the fill/level holes C. See Lubricants and Capacities. Oil should be level with the bottom of the fill/level hole.

4

Clean and refit fill/level plugs C.

OIL LEVEL

C C

356040

9803/9286

S209320

Issue 1

Section 4

Hydraulics

Section 4

i

i

Contents

Page No.

Hydraulic Rams Power Track Rod - Removal and Replacement of Power Track Rod - Link Arms - Removal and Replacement - Rams - Dismantling and Assembly Service Porcedures Steering System - Bleeding

9803/9286

1-1 2-1 3-1 4-1

Issue 1

Section 4

Hydraulics

Section 4 1-1

Power Track Rod

1-1

Removal and Replacement This procedure is for a typical power steering track rod removal and replacement.

! WARNING Make the machine safe before working underneath it.

Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

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

A

GEN-1-2

! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

C011020

GEN-3-2

Removal 1

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

2

Remove the locknut and nut A. Remove the track rod ball joint from the wheel hub assembly.

3

Remove the four fixing bolts G (2 off) and F (2 off).

2WS, 4WD FRONT AXLE

G F

9803/9286

G F a

A706900

Issue 1

Section 4

Hydraulics

Section 4 1-2

Power Track Rod

1-2 Replacement

Replace the power track rod by reversing the removal procedure but note the following: 1

On 4WD machines make sure that the split pin is fitted.

If the locknut cannot be fitted after torque tightening the nut A, tighten further to a maximum of 150 Nm until the locknut can be fitted.

2

Note the applicable torque values for the track rod fixing bolts according to axle type. See the Torque Settings table.

3

After connecting hoses check hydraulic fluid level, if necessary top up.

4

Bleed hydraulic steering system, refer to Steering System - Bleeding at the end of this section.

A

C011020

Torque Settings Item bolt grade A F G 8.8 G 10.9

Nm 140 476 476 510

kgf m 14 48 48 52

lbf ft 103 351 351 376

2WS, 4WD FRONT AXLE

G F

9803/9286

G F a

A706900

Issue 1

Section 4

Hydraulics

Section 4 2-1

Power Track Rod

2-1

Link Arms - Removal and Replacement

L M

A258480

B

N K

J

F

E

M A258470

C010970

X C

C

Y 9803/9286

S258450

Issue 1

Section 4

Hydraulics

Section 4 2-2

Power Track Rod

2-2

Link Arms - Removal and Replacement Removal

Replacement

1

Fix the assembly on a locally made strip/rebuild bench as shown.

Replacement is the reverse of removal but note the following:

2

Using two suitable open ended spanners at L and M react against each other until one ball joint unscrews.

1

Use Loctite 242 on the trackrod link arms.

2

If the link arms have been renewed, the wheel alignment must be checked as follows:

3

4

Unscrew the ball joint L until an open ended spanner can be fitted on the rod N. Screw the ball joint against the spanner to secure the spanner and to prevent damage to the rod.

By reacting against the spanner at N and M undo the other ball joint.

Note 1: Flats at ‘E’ are: 4 Wheel drive machines - 40 mm A/F x 4 mm wide.

Note 2: The piston rod operates at full length, any damage to the surface will cause fluid leaks. DO NOT attempt to grip the rod diameter with pipe grips etc.

5

a

Set the wheels to the straight ahead position and measure dimensions X and Y (at the outer edge of the wheel hub). Alignment is correct if the difference between X and Y is a maximum of 1 mm.

b

To adjust the wheel alignment undo the lock nuts (H or K as applicable). Turn the threaded adjusters J equally to obtain the correct alignment. Tighten the lock nuts (H or K as applicable).

Note 4: AWS machines shown at A. Note 5: The illustration shows a typical axle.

Repeat the procedure for the remaining link arm assembly.

Note 3: If the inner or outer ball joints need to be renewed, then a replacement link arm assembly must be fitted.

Torque Settings AWS/4WD

C 270/280 Nm (199/206 lbf ft)

H 70/85 Nm (51/62 lbf ft)

E 450 Nm (331 lbf ft)

AWS/4WD

C 270/280 Nm (199/206 lbf ft)

K 390/410 Nm (287/302 lbf ft)

E 450 Nm (331 lbf ft)

9803/9286

Issue 1

Section 4

Hydraulics

Section 4 3-1

Power Track Rod

3-1

Rams Dismantling and Assembly

A

1 A258580

7 6

5 8

3 4

D

3

5

8

S258430

1 2 6 7

B

C

A258590

9803/9286

Issue 1

Section 4 3-2

Hydraulics

Section 4 3-2

Power Track Rod

Rams Dismantling and Assembly

Assembly

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

1

Clean the threads of the end caps and cylinder using a wire brush.

For assembly the sequence should be reversed.

2

Use Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying Loctite 275.

Dismantling 1

Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at A.

2

Remove both end caps, using a special spanner (refer to Service Tools). Pull the piston rod assembly from the cylinder.

Ensure that lubricants used during assembly do not come into contact with the Loctite 275.

3

Clamp the cylinder vertically and lower the piston rod assembly in from the top, as shown at B. Take care not to allow the piston rod to come into contact with the cylinder bore. Be sure to engage the piston head new wear rings and seal carefully into the cylinder. If the piston head wear rings or seal are damaged during this stage, they must be renewed.

4

Apply Loctite Activator to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the Loctite 275.

Note 1: DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling.

3

Position the piston rod assembly on a bench in place of the ram cylinder. Remove the seal and wear rings from the piston head.

Note 2: The piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly.

4

Carefully inspect the bore of the cylinder and the piston rod outer diameter for scoring, nicks and burrs. If such damage is visible the components must be renewed.

Note 4: Neither the Loctite 275 nor Activator must be allowed to contact seals, bearing rings or ‘O’ rings.

5

Apply Loctite 275 to threads of the ends caps, fit new ‘O’ ring 5.

6

Ensure that there are no burrs at the ends of the piston rod, see Dismantling - Note 3:

7

Fit an end cap over the piston rod. Apply light hand pressure to the cap to engage the gland seal on the piston rod. DO NOT use excessive force. Screw on the first end cap and then fix the assembly on the strip/rebuild bench as shown at A. Fit the remaining cap and then torque tighten both caps.

Note 3: If burrs are evident on the ends of the piston rod at positions C or D remove by careful filing.

Both end cap assemblies are the same, dismantle as follows: 5

Remove the ‘O’ ring 5, end cap seal 6 and wiper seal 7.

6

The bearing bush 8 can be renewed if necessary.

However, time will be saved if a complete end cap and bush assembly is obtained.

Note 5: If hydraulic oil contacts the uncured Loctite 275 a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Torque Settings Item 1

Nm 678

kgf m 69.2

lbf ft 500

Note 6: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the track rod is operated slowly to its full extent in both directions before commencing normal working.

9803/9286

Issue 1

Section 4 4-1

Hydraulics Service Procedures

Section 4 4-1

Steering System - Bleeding Note: This is a guide only. Refer to OEMs specific recommendations.

Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows.

With the engine running, the following 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) Turn steering wheel to left, until front wheels are fully locked to the left.

3

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

5

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

7

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.

9803/9286

Issue 1

Section 5

Axles

Section 5

i

i

Contents Technical Data - SD55 Axle

1-1 1-2

Propshafts - Removal and Replacement

2-1

Axle - Removal and Replacement Drive Head - Dismantling - Assembly Hub - Dismantling - Assembly Hub Swivel and Driveshaft - Dismantling - Assembly Service Procedures Renewing the Pinion Oil Seal Collapsible Spacer Assembly Pinion Depth Setting Crownwheel and Pinion Meshing

9803/9286

Page No.

3-1 4-1 4-3 6-1 6-5 6 - 10 6 - 10

8-1 8-2 8-3 8-4

Issue 1

Section 5

Axles

Section 5

Technical Data

1-1

1-1

Axle Type Designation Installation Weight (dry, with no steer rams and without wheels) Hub reduction Input Type Oscillation Toe-in Castor angle Camber angle Kingpin inclination Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion

9803/9286

Spiral bevel input with epicyclic hub reduction SD55 Centre pivot 371 kg (818 lbs) approximately 5.4:1 Yoke ±5° 0° 0° 1° 0° OPTION 1 OPTION 2 OPTION 3 16.2:1 19.2:1 14.123:1 3:1 3.556:1 2.615:1

OPTION 4 15.78:1 2.923:1

33 11

38 13

32 9

34 13

Issue 1

Section 5 1-2

Section 5

Axles Descriptions

1-2

SD55 (ITS0137)

C010960

9803/9286

Issue 1

Section 5

Axles

Section 5

Propshafts

2-1

2-1

Propshafts Removing and Replacing When Removing Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

When Replacing 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.

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.

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

Nm 75 - 85

kgf m 7.7 - 8.7

lbf ft 55 - 63

C X

A

S232350

Y A

A

Z

S157500 S189610

FRONT 9803/9286

Issue 1

Section 5

Axles

Section 5 3-1

Front Axle - SD55

3-1

Removal and Replacement Note: This illustration is intended as a guide only. Refer to OEM for specific instructions.

K

C

-238.14

A

J

J

C D

B

H

F E

B

G A401290

9803/9286

Issue 1

Section 5

Axles Front Axle - SD55

3-2

Section 5 3-2

Removal and Replacement (cont’d) Note: Refer to OEM for specific recommendations.

Note: The following procedure can be applied to both AWS and 2WS machines. Dis-regard information not applicable to your machine type, for instance, 2 wheel steer machines will not have steering proximity switches fitted.

! 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

! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

GEN 3-2

1

Release screws J and remove the front grille.

2

Remove the cover K from the proximity switch and then remove the bracket and switch assembly.

3

Using tool 892/00822 remove bolts A to disconnect the drive shaft from the axle.

4

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

5

Disconnect remote grease nipple hose H.

6

Loosen the road wheel retaining nuts D.

7

Make sure that the rear wheels are blocked, use the loader arms to raise the front end of the machine.

8

Prop the machine on each side as shown at C.

9

Remove the front road wheels.

10

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

Note: Because the drivehead 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.

11

Remove nut E and pivot pin retaining bolt F.

12

Remove pivot pin G seals, use puller (tool no.

993/68100) and remove the pivot pin G and axle shims.

13

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

9803/9286

Issue 1

Section 5

Axles

Section 5 3-3

Front Axle - SD55

3-3

Removal and Replacement (cont’d) Note: Refer to OEM for specific recommendations.

Replacement Replacement is the reverse of the removal sequence.

Y

! 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

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

Apply Loctite 242 to the threads of bolts A. The front axle must be shimmed to give a maximum fore and aft movement of 0.5 mm (0.020 in).

Nylon shims must be fitted as follows: AWS Machines a

Fit a 5.0 mm thick master shim (coloured blue) between the front of the axle and the yoke plate as shown at X.

b

Measure the fore and aft movement and subtract 0.5 mm to obtain the required shim thickness. Fit the correct thickness shim between the rear of the axle and the yoke plate as shown at Y.

X

2WS Machines a

Fit a 5.0 mm thick master shim (coloured blue) between the rear of the axle and the yoke plate as shown at Y.

b

Measure the fore and aft movement and subtract 0.5 mm to obtain the required shim thickness. Fit the correct thickness shim between the front of the axle and the yoke plate as shown at X.

A258180

Note 1: DO NOT fit more than 2 shims (including the master shim).

Note 2: To assist assembly, use the double sided tape ring supplied to retain the shims on the yoke plate.

If the setting of the steering proximity switch has been disturbed, then complete the front axle proximity switch setting procedure.

Torque Settings Item A D

Nm 79 680

9803/9286

kgf m 8 69

lbf ft 58 500

Issue 1

Section 5 4-1

Axles Front Axle - SD55

Section 5 4-1

Drive Head - Dismantling

ITL00670

9803/9286

Issue 1

Section 5 4-2

Axles Front Axle - SD55

Section 5 4-2

Drive Head - Dismantling (cont’d) 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.

3

Remove the drive head carrier screws 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 inner bearing races of 5 and 6.

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 Verbus Ripp bolts 14 and separate the crownwheel 15 from the case half 8A.

11

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

12

Mark the position of the drive yoke on the splined shaft.

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 outer 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. Insert bearing pullers to remove bearing 22. Pull the bearing from the pinion shaft.

9803/9286

Issue 1

Section 5 4-3

Axles Front Axle - SD55

Section 5 4-3

Drive Head - Assembly

ITL00670

9803/9286

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

4-4

4-4

Drive Head - Assembly (cont’d) The outline procedure below refers also to the following aspects of the drivehead assembly, which are covered separately in detail as sub topics later in this section:

6

Pinion Depth Setting Collapsible Spacer Assembly Crown Wheel and Pinion Meshing

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.

Note: 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.

E

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

1

Determine the correct thickness required for the shims 23, refer to Pinion Depth Setting.

2

Fit shims 23 behind new bearing cup 22.

3

Fit new pinion head bearing cone 22 onto pinion 20.

4

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 Collapsible Spacer Assembly.

5

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

348030

7

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

8

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

G F

348040

9803/9286

Issue 1

Section 5 4-5

Axles

Section 5

Front Axle - SD55

4-5

Drive Head - Assembly (cont’d)

X

9803/9286

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

4-6

4-6

Drive Head - Assembly (cont’d) 9

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, Section 1.

Example Temporary spacer size Subtract end-float

14.20 0.25

Total

13.95

Subtract tolerance & preload Result

16

Note: Trunnion pin 11 fits over roll pin X, which is pressed into the housing.

17

Position differential half case 8B onto half case 8A, aligning the match-mark letters. Apply Loctite 242 to the threads of bolts 7, then fit and torque tighten to 46 Nm (34 lbf ft, 4.7 kgf m). Check the gears for free rotation.

18

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

19

Locate crownwheel assembly (without bearings) into housing.

20

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.

21

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 14.

22

Measure the backlash between crownwheel 15 and pinion 20, which should be 0.17 - 0.28 mm (0.006 0.010 in). Adjust castellated nuts 4 by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins 3.

23

Check tooth marking to verify crownwheel and pinion are set correctly, refer to Crownwheel and Pinion Meshing.

24

Apply Loctite 574 to the mating faces of drive head carrier 2 and the axle casing. Fit the drive head carrier to the axle casing with the crownwheel towards the short drive shaft. Fit securing bolts 1 and tighten to 98 Nm (72 lbf ft, 10 kgf m).

25

Reassemble both driveshafts and hub assemblies, refer to Axle Hub and Driveshaft - Dismantling and Assembly.

26

Re-fill the hubs and differential with the correct grade of oil, refer to lubricants and Capacities.

27

Refit the propshaft, refer to Propshafts - Removing and Replacing.

0.04 13.91

(No spacer available this size, use next nearest size spacer i.e 13.900) 10

11

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

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.

12

13

14

If rolling torque measured at step 10 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.

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.

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. 15

Assemble the trunnion pin 11, bevel gears 9 and 10 and their thrust washers 12 and 13 into differential half case 8A.

Finally stake the nut 16 into the slot.

9803/9286

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-1

6-1

Hub Dismantling

2

16

14

12

15

17 18 19

22

23

4 5 13

26

7 6

8

9

29

10

9803/9286

11

3

28

27

A706420

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-2

6-2

Hub Dismantling (cont’d)

7

! 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.

2

4

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

8

GEN 1-1

The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle.

1

Drain oil from the hub.

2

Remove screws 1.

3

Lever the planet gear carrier 2 off the bearing carrier.

Remove and discard ‘O’ ring 3.

4

Remove planet gears 4 only if defective. Note that gears can only be removed as assemblies, which comprise the gear, 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.

6

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

7

Remove circlip 10 to allow the sun gear 29 to be slid off the drive shaft.

8

To remove the ‘Verbus Ripp’ bolts 11, it is necessary to remove the spacer 10. Revolve the spacer with a suitable drift to align the holes in the spacer 10 with the space between the bolts.

10

11

A

29

9

10

11

9

Using two dowels and two heel bars, remove the spacer using the method shown at A. Remove the 'Verbus Ripp' bolts 11 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.

255930

C

Using 2 high grade M12 bolts B as jacking screws, remove the annulus carrier assembly. Shown at C.

Note: Fretting between the hub swivel 23 and annulus carrier 14 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 16 from the annulus carrier 14.

9803/9286

B

B

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-3

6-3

Hub Dismantling (cont’d)

2

16

14

12

15

17 18 19

22

23

4 5 13

26

7 6

8

9

29

10

9803/9286

11

3

28

27

A706420

Issue 1

Section 5 6-4

Axles

Section 5

Front Axle - SD55

6-4

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

13

Y

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

C

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

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.

A D

B A439380

14

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.

X

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

15

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.

16

Assemble the puller B, with the inner bearing plate E clamped around the inner bearing 18, attach the puller rods F and reaction tube C over the driveshaft 26.

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

17

Slowly screw in D until the bearing 18 is released.

Remove and discard the inner section of seal 19.

Note: Do not attempt to remove the dirt shield 22 (if fitted) unless it requires replacement.

18

C

Press out bearing cups 17 and 18 from the wheel bearing carrier if replacing.

E F

D B

9803/9286

A439390

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-5

6-5

Hub Assembly

2

16

14

12

15

17 18 19

22

23

4 5 13

26

7 6

8

9

29

10

9803/9286

11

3

28

27

A706420

Issue 1

Section 5 6-6

Axles

Section 5

Front Axle - SD55

6-6 23

Hub Assembly (cont’d) Note: The bearing press from the wheel hub service Kit 882/1092 (see Service Tools) is required throughout steps 1 to 10.

1

H

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

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

2

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

3

Install the inner bearing 18 into the bearing carrier 12.

Fit a new combination oil seal 19 as follows: Lightly lubricate outside diameter of seal.

Use seal dolly M (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.

Y

X

22

B 19

A 19

M

A

12 4

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

5

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.

6

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 position.

7

Remove the puller handle J and bearing fitting tube K.

8

Install the outer bearing 17 in the bearing carrier 12.

9

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

10

Using the puller handle J, screw in the bearing fitting tube K until the outer bearing 17 is pressed correctly into position so as to remove most of the free play.

B

A440240

M

L

Note: DO NOT overtighten.

11

Remove service tool H.

K J 9803/9286

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-7

6-7

Hub Assembly (cont’d)

2

16

14

12

15

17 18 19

22

23

4 5 13

26

7 6

8

9

29

10

9803/9286

11

3

28

27

A706420

Issue 1

Section 5

Axles Front Axle - SD55

6-8

Section 5 6-8

Hub Assembly (Cont’d) 11

Assemble the annulus ring 16 to the annulus carrier 14.

Secure with the circlip 15. Make sure that dowels 13 are correctly located.

12

Fit annulus assembly in the same angular position as removal (see Note, Dismantling, step 11) using new 'Verbus Ripp' bolts 11. Do not fully tighten bolts but allow the bearing carrier to rock slightly. Measure seal drag rolling force - see step 13.

Note: Steps 13 to 15 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool is required. Refer to Service Tools, Section 1.

13

To measure seal drag rolling force: -

Refit the planet gear carrier 2 - DO NOT FIT THE SUN GEAR 29.

-

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.

14

Tighten M14 Verbus Ripp bolts 11 to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 15.

15

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 13) from reading obtained at this step, the result should be 2 to 22 Nm (1.5 to 16 lbf ft).

-

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.

9803/9286

Issue 1

Section 5

Axles

Section 5

Front Axle - SD55

6-9

6-9

Hub Assembly (Cont’d) 16

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

17

Fit new planet gears 4 in place of any that were removed.

(See step 4 in 'Dismantling'). Secure with circlip 7.

Note: When fitting the planet gear assemblies be sure to orientate them correctly. Fit the large radius end of inner bearing over the pin first as shown at A. 18

A

7 A706450

4 2

Fit spacer 10 and slide the sun gear 29 onto the driveshaft 26 and secure with circlip 9. Fit a new ‘O’ ring 3.

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

19

Fit the planet carrier 2 onto the bearing carrier 12, ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and torque tighten screws 1 to 56 Nm (41 Ibf ft; 5.7 kgf m) after applying Loctite 242 to the threads.

3

Note: Do not strike the centre of the planet gear carrier when fitting as this may dislodge the driveshaft thrust pad 8 fitted at step 16.

Re-fill hubs with the correct grade oil.

Torque Settings Item 1 11

Nm 56 320

kgf m 5.7 33

10 Ibf ft 41 238

29 9

S440360

1 S258220

9803/9286

Issue 1

Section 5 6 - 10

Axles

Section 5

Front Axle - SD55

6 - 10

Hub Swivel and Driveshaft -

Hub Swivel and Driveshaft -

Dismantling

Assembly

Note: The hub assembly must be removed before attempting the remove the hub swivel and driveshaft, see the applicable axle hub removal procedure.

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

1

Tap the drive shaft inner bearing 32 into position in the axle casing.

2

Fit circlip 31.

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

3

Fit new oil seal 30. Pack grease between the lips of the seal.

2

Mark position of top and bottom trunnions 20, remove bolts 21 and remove trunnions. Withdraw the hub swivel 23.

4

Tap the driveshaft outer bearing 28 into position in the hub swivel driveshaft bore.

5

Fit new oil seal 27. Pack grease between lips of seal.

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

6

Fit driveshaft 26, taking care to locate inner end into splines of differential gears.

3

Remove the top and bottom trunnion seals 24 and bearings 25 (only if they are to be renewed).

7

Press new trunnion oil seals 24 into position followed by bearings 25. Grease bearing and oil seal before fitting to axle.

4

Use adaptor 993/59500 with slide hammer tool 892/00224 and remove driveshaft seal 27 and needle roller bearing 28 from the hub swivel.

1

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

5

Withdraw drive shaft 26 from the axle.

6

Prise out drive shaft inner oil seal 30 from the axle arm.

7

Remove circlip 31.

8

Remove bearing 32 using tool 892/00225.

9

If there has been a component failure (bearing 32 for example), remove all traces of debris from the axle and clean the magnetic drain plug.

9803/9286

Note: In the following step, take care not to damage seal 24 when tightening the trunnion bolts.

8

Locate hub swivel 23 and fit top and bottom trunnions.

Apply Loctite 242 of trunnion bolts 21 (8-off). Finger tighten all bolts, then sequentially tighten them to bring the two trunnions together. Torque to 98 Nm (72 lbf ft, 10.0 kgf m).

9

Make sure that the swivel rotates smoothly on its trunnions. Notchy, stiff movement may result if seals 24 have become dislodged and damaged during assembly.

10

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

Issue 1

Section 5

Axles Service Procedures

8-1

Section 5 8-1

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

! 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-001

1

Remove the roadwheels and uncouple the axle propshaft. Measure the axle rolling torque and record the reading.

2

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

3

Remove the seal 4 and fit a new one. Pack between the lips of the new seal with grease before fitting.

4

Fit the coupling yoke, and a new stake nut: a

Using Service Tool 892/00812, tighten the nut to 200 Nm (148 lbf ft; 20.4 kgf m).

b

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.

c

Progressively torque tighten nut to achieve correct rolling torque or a maximum of 300Nm (287 lbf ft).

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, this would indicate that a collapsible spacer has been fitted which MUST be renewed. d 5

Stake the nut using a square ended staking tool.

Refit the roadwheels and couple the propshaft.

Note: All axles are built with a solid spacer on the input pinion.

4 2 9803/9286

1

S380610

Issue 1

Section 5 8-2

Axles Service Procedures

Section 5 8-2

Collapsible Spacer Assembly When assembling the axle, if the special tools listed in the Service Tools - Section 1 or if the correct size solid spacer is not available it is acceptable to fit a collapsible spacer using the procedure below.

1

Smear output shaft inner bearing 27 with Mobil HP222 before refitting. Fit bearing cup 28 over pinion shaft 23 and assemble into drive head casing.

2

Fit NEW collapsible spacer 24, after smearing with Mobil HP222 fit outer bearing 26 followed by a new oil seal 25.

Grease between seal lips before fitting. Assemble yoke 22 and NEW stake nut 20 with integral washer.

3

Tighten stake nut to achieve a rolling torque of 1.5 to 2.8 Nm (1.1 to 21. lbf ft), inclusive of seal drag.

Note: If this figure is accidentally exceeded the output shaft must be dismantled and the collapsible spacer 24 renewed.

4

Finally stake nut into slot.

S235760

9803/9286

Issue 1

Section 5

Axles

Section 5

Service Procedures

8-3

8-3

Pinion Depth Setting 1

Place new pinion head inner bearing assembly on a flat surface and position service tool 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.

2

From the face of the pinion, obtain the etched deviation figure B (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.

3

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

4

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.

A

A184400

B

Example (all dimensions in millimetres) Cup depth Gap A Bearing depth Pinion deviation B (+ 2) Housing deviation C (- 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

S256110

Note: In the event that the setting data stamp has been ommited from the drivehead casing, adopt the following setting procedure: Revise the shim pack size by the difference in setting height marked on the old and new crownwheel pinion sets.

9803/9286

C S256120

Issue 1

Section 5 8-4

Axles Service Procedures

Section 5 8-4

Crownwheel and Pinion Meshing 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.

A386940

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.

A386950

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.

A386960

9803/9286

Issue 1