JCB Drivetrain SD 70 PT Axles Central And Offset Drive Head Service Manual - PDF DOWNLOAD

Service Manual

General Information

1

Care & Safety

2

Routine Maintenance

3

Hydraulics

4

Axles

5

Brakes

6

JCB Drivetrain Systems Ltd 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 70/PT AXLES CENTRAL AND OFFSET DRIVE HEAD Publication No. 9803/9280 Issue 6

x

SD70/PT Axles Service Manual Publication No. 9803/9280

Record of Changes 4th Update Date

Page

Issue

Novs 2002

Cover

5

Issue number raised.

Changes

1/1-3

2

Addition to Service Tools list.

1/4-3

2

Addition to Service Tools illustrations.

6/Cont-1

2

Additions as details following:

6/1-1

2

Parking brake added to Technical Data.

6/6-1

1

New page - New parking brake torque figures.

6/6-2

1

New page - Parking brake caliper - removal and replacement.

6/6-3

1

New page - Parking brake component list illustration.

6/6-4

1

New page - Parking brake caliper - dismantling and assembly.

6/6-5

1

New page - Parking brake caliper illustration.

6/6-6

1

New page - Parking brake caliper - assembly.

6/6-7

1

New page - Parking brake disc, removal and replacement.

6/7-1

1

New page - Service procedures - Park brake, testing.

6/7-2

1

New page - Service procedures - Park brake, adjustment.- Type A

6/7-3

1

New page - Service procedures - Park brake, switch adjustment- Type A

6/7-4

1

New page - Service procedures - Park brake adjustment - Type B

6/7-5

1

New page - Service procedures - Park brake adjustment - Type B

6/7-6

1

New page - Service procedures - renewing brake pads.

1

x

SD70/PT Axles Service Manual Publication No. 9803/9280

Record of Changes 3rd Update Date

Page

Issue

May 2001

Cover

4

Issue number raised.

Changes

5/Cont i

2

Additions as details following.

5/1-2

2

Trunnion Mounted added to Installation.

5/2-3

1

New Page - Illustration - Description Cutaway of SD70/PT Axle - Central Drive Head (with Dropbox) added

5/7-1

2

Page heading - (Pad Mounted) added.

5/7-2

2

Page heading - (Pad Mounted) added.

5/7-3

2

Page renumbered - illustration Central Drive Head (Trunnion Mounted) added.

5/7-4

2

Page renumbered - New Text - Central Drive Head (Trunnion Mounted) added.

5/7-5

1

New Page - Text Proximity Switch Settings Procedure moved from 7-3.

5/7-6

1

New Page - Text/illustrations - Propshafts, Removal and Replacement move from 7-4.

5/10-8

1

New Page - Central Drive Head - Drop Box (with no Park Brake - 2/4WD fitted).

5/10-9

1

New Page - Central Drive Head - Drop Box (with no Park Brake - 2/4WD fitted).

5/10-10

1

New Page - Drop Box (with no Park Brake -2/4WD fitted).

5/10-11

1

New Page - Drop Box (with no Park Brake - 2/4WD fitted).

5/10-12

1

New Page - Drop Box (with no Park Brake fitted)

5/10-13

1

New Page - Drop Box (with Park Brake fitted).

5/10-14

1

New Page - Drop Box (with Park Brake - 2/4WD fitted).

5/10-15

1

New Page - Drop Box (with Park Brake - 2/4WD fitted).

5/10-16

1

New Page - Drop Box (with P{ark Brake - 2/4WD fitted).

5/10-17

1

New Page - Drop Box (with Park Brake - 2/4WD fitted).

5/10-18

1

New Page - Drop Box (with Park Brake fitted (Yokes fitted to Driveshafts)).

5/10-19

1

New Page - Drop Box (with Park Brake fitted (Yokes fitted to Driveshafts)).

5/10-20

1

New Page - Drop Box (Optional 2/4WD Disconnect).

1

x

SD70/PT Axles Service Manual Publication No. 9803/9280

Record of Changes 2nd Update Date

Page

Issue

Dec 1998

Cover

3

Issue number raised.

Changes

1/Cont i

2

Axle Build Identification was Limited Slip Differential.

2/4-2

2

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

1

SD70/PT Axles Service Manual Publication No. 9803/9280

Record of Changes 1st Update Date

Page

Issue

Changes

Sept 1998

Cover

2

Issue number raised.

1/1-1

2

Axle Build Identification heading was Limited Slip Differential.

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.

9803/9280

Issue 1

Section 1

General Information

Section 1

i

i

Contents

*

9803/9280

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 2*

Section 1

General Information

Section 1

1-1

1-1

Unit Identification

Replacement Parts

Axle Serial Plate (Central Drive Head)

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.

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.

The axle serial number is stamped on a plate mounted to the front face of the axle, as shown.

* 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.

B

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

C /0091: Axle serial number. The complete 12 digit number 147950

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

Axle Serial Plate (Offset Drive Head) The axle serial number is stamped on a plate mounted on the axle.

9803/9280

Issue 3*

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.

9803/9280

Issue 1

Section 1

General Information

3-1

3-1

Service Tools Numerical List 4003/0211 4101/0250 4101/0251 4101/0451 4101/0651 4102/0551 4102/1212 4102/1951 4103/0955 4104/0251 4104/0253 4104/1557 892/00174 892/00182 892/00224

*

892/00333 892/00334 892/00812 892/00817 892/00818 892/00819 892/00822 892/00833 992/00800 892/00891 992/04000 992/04800 992/07601 992/07603 992/07604 992/07606 992/07607 992/07609 992/07614 993/59500

9803/9280

Section 1

Page No.

Anti-Seize Paste Loctite 243 Loctite 242 Loctite 932 Loctite 648 Loctite 275 Loctite 574 or Permabond A136 Loctite 577 Superbonder Activator (Aerosol) Activator (Bottle) Cleaner Degreaser Measuring Cup - Pinion Head Bearing Bearing Pad Driver Impulse Extractor Set for Hub Bearing Seals Heavy Duty Socket Gland Seal Fitting Tool Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Splined Bolt Socket Annulus Removal Tool Extractor for Removing Axle Pivot Pin Oil Seal Insertion Tool Torque Multiplier Flange Spanner Spanner for Half Shaft Nuts Replacer - Pinion Head Bearing Cup Replacer - Crownwheel Bearing and Differential Cones Measuring Cup - Pinion Bearing Spacer - Pinion Bearing Preload Adapter - Steer/Drive Axle Pinion Bearing Cone Adapter Set - Bull Pinion Bearing Remover/Replacer Adapter - Impulse Extractor

5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-2 4-2 4-2 4-1 4-2 4-1 4-1 4-1 4-1 4-2 4-3 4-2 4-3 4-2 4-3 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-3

Issue 2*

Section 1

General Information

Section 1

4-1

4-1

Service Tools

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

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

892/00182

Bearing Pad Driver

892/00812

Drive Coupling Spanner for axle yoke couplings

892/00174 Measuring Cup - Pinion Head Bearing

S190770

892/00822 Splined Bolt Socket for driveshafts

S197070

892/00224 S197060

Impulse Extractor Set for Hub Bearing Seals

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

S197030

9803/9280

Issue 1

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 5:1multiplication when tightening pinion nuts)

S197030

892/00174 Measuring Cup - Pinion Head Bearing

S190770

992/00800

Extractor for removing axle pivot pin

892/00822 Splined Bolt Socket for driveshafts

S197070

892/00224 Impulse Extractor Set for Hub Bearing Seals

892/00812

S197060

Drive Coupling Spanner for axle yoke couplings

S196720

892/00334

9803/9280

Gland Seal Fitting tool

Issue 1

Section 1

General Information

Section 1

4-3

4-3

Service Tools (cont'd)

892/00833

Annulus Removal Tool

892/00225

Adapter - Impulse Extractor

A272520

892/00891

Oil Seal Insertion Tool

* 992/04800 Flange Spanner - for locking pinion flange while pinion nut is slackened or torque set

S197040

9803/9280

Issue 2*

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 50 mm diameter, and for hydraulic fitttings 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

Superbonder

Bonding/Sealant

† 4103/0955

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.

9803/9280

Issue1

Section 2

Care & Safety

Section 2

i

i

Contents

9803/9280

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

9803/9280

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.

9803/9280

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.

9803/9280

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

9803/9280

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

! WARNING

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.

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 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:

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.

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.

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.

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.

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

GEN-1-2/IT

INT-3-3-5/1/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.

! 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

GEN-1-12

! 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

*

! 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

9803/9280

Issue 2*

Section 3

Routine Maintenance

Section 3

i

i

Contents

9803/9280

Page No.

Lubricants & Capacities

1-1

Lubricants - Health and Safety

1-2

Service Schedules

2-1

Greasing - SD70/PT Axle - Offset Drive Head - SD70/PT Axle - Central Drive Head

3-1 3-2

Axle Oil Level - SD70/PT Offset Drive Head - Check Differential Oil Level - Change Differential Oil - Check Hub Oil Level - Change Hub Oil

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

Axle Oil Level - SD70/PT Central Drive Head - Check Differential Oil Level - Change Differential Oil - Check Hub Oil Level - Change Hub Oil

4-2 4-2 4-2 4-2

Issue 1

Section 3

Routine Maintenance

Section 3

1-1

1-1

Lubricants & Capacities ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gals

INTERNATIONAL SPECIFICATION

Axle - SD70/PT Offset Drive Head Housing Hubs (x2)

18.0 2.0

3.96 0.44

Mobilube HD90

API-GL-5, MIL-L-2105C

Axle - SD70/PT Central Drive Head Housing Hubs (x2)

18.0 2.0

3.96 0.44

Mobil Fluid 424

API GL4, M2C-41B/134D, JD20C MF M1135/M1141/M1143

Grease Points

-

-

Mobil HP222

Mobil HP222

Brake System

-

-

Mobil DTE 11M ISO VG 15 CAUTION: Do not use ordinary brake fluid (J 1703)

Note 1: Mobil 424 should always be used for axles fitted with brakes. For Axles without brakes Mobilube HD90 or Mobil Fluid 424 can be used.

Note 2: Axles with limited slip differentials must use Mobil Fluid 424

9803/9280

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

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.

9803/9280

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) ➀ Axle Oil (incl. Hubs when applicable) Drive Shafts Steer Axle Movement/Shimming ➁ 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 Steering Proximity Switch - Operation ➁ Wheel Nut Torque Steer Phasing ➁ Steer Cylinders - Balance ➁ Steer Circuit Pressure ➁

†100 Hr

500 Hr

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

- Check Operation

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

10 Hr

50 Hr

●

●

●

●

†100 Hr

500 Hr

1000 2000 Hr Hr

●

1000 2000 Hr Hr

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

†

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.

➀

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

➁

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

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.

9803/9280

Issue1

Section 3

Routine Maintenance

Section 3

3-1

3-1

Greasing SD70/PT Axle - Offset Drive Head - for Interval see Service Schedule 5 Grease Points Note: Grease point 5 is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

5 1 2

3

1

2

9803/9280

4

3

S260220

4

Issue 1

Section 3

Routine Maintenance

Section 3

3-2

3-2

Greasing SD70/PT Axle - Central Drive Head - for Interval see Service Schedule 4 Grease Points

1 2

3 4

S260230

9803/9280

Issue 1

Section 3

Routine Maintenance

Section 3

4-1

4-1

Axle Oil Level - SD70/PT - Offset Drive Head Check Hub Oil Level - for Interval see Service Schedule Check Differential Oil Level - for Interval see Service Schedule 1

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

2

If necessary, top up with recommended axle oil (see Lubricants and Capacities). Clean and refit fill/level plug A, torque tighten to 79 Nm (58 lbf ft).

1

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

2

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

3

If necessary, top up with recommended axle oil (see Lubricants and Capacities). Clean and refit fill/level plug C.

Change Differential Oil - for Interval see Service Schedule

Change Hub Oil - for Interval see Service Schedule

1

Remove fill/level plug A and drain plug B. Allow time for the oil to drain out.

1

2

Clean and refit drain plug B, torque tighten to 79 Nm (58 lbf ft).

3

Fill the axle with recommended axle oil (see Lubricants and Capacities) 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, torque tighten to 79 Nm (58 lbf ft).

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 plug C at the bottom.

113430

ITL00520

2

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

3

Set OIL LEVEL marks to the horizontal.

S260420

A B

9803/9280

ITL00530

4

Fill the hubs with recommended axle oil through the fill/level hole C (see lubricants and capacities). Oil should be level with the bottom of the fill level hole.

5

Clean and refit fill/level plug C.

Issue 1

Section 3

Routine Maintenance

Section 3

4-2

4-2

Axle Oil Level - SD70/PT - Central Drive Head

1

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

2

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

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

3

If necessary, top up with recommended axle oil (see Lubricants and Capacities). Clean and refit fill/level plug A.

If necessary, top up with recommended axle oil (see Lubricants and Capacities). Clean and refit fill/level plug C.

Change Hub Oil - for Interval see Service Schedule

Check Differential Oil Level - for Interval see Service Schedule 1

2

Check Hub Oil Level - for Interval see Service Schedule

Change Differential Oil - for Interval see Service Schedule 1

Remove fill/level plug A and drain plug B. Allow time for the oil to drain out.

2

Clean and refit drain plug B.

3

Fill the axle with recommended axle oil through the fill/level hole A (see Lubricants and Capacities). Oil should be level with the bottom of the fill/level hole.

4

Clean and refit fill/level plug A.

1

Set the machine level, with the tyre just clear of the ground. Manually rotate the wheel to bring the OIL LEVEL mark on the hub to the vertical position, with the fill/level plug C at the bottom.

2

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

A B 113430

S260430

3

Set OIL LEVEL mark to the horizontal

ITL00530

9803/9280

4

Fill the hub with recommended axle oil through the fill/level hole C (see Lubricants and Capacities). Oil should be level with the bottom of the fill level hole.

5

Clean and refit fill/level plug C.

Issue 1

Section 4

Hydraulics

Section 4

i

i

Contents Technical Data Cylinders Power Track Rod - Removal - Replacement Link Arms - Removal - Replacement Cylinder - Dismantling - Assembly Steering System - Bleeding Procedure Gland Seal Fitting Procedure

9803/9280

Page No. 1-1

2-1 2-1 3-1 3-1 4-1 4-2 5-1 6-1

Issue 1

Section 4 1-1

Hydraulics Technical Data

Section 4 1-1

Steering Relief Valve Pressure @ 1500 rpm Shock Valve Pressure

Refer to Machine Operator Handbook Refer to Machine Operator Handbook

Sizes Bore Diameter Rod Diameter

90 mm (3.54 in) 50 mm (1.96 in)

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

9803/9280

Issue 2

Section 4

Hydraulics

Section 4

2-1

2-1

Power Track Rod 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.

GEN-1-2

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

A

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

A258490

Remove the four fixing bolts D. Replacement Replace the power track rod by reversing the removal procedure. Make sure that the split pin is fitted.

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

Bleed hydraulic steering system (see Steering System Bleeding Procedure).

D D

Torque Settings D Bolt Grade 8.8 10.9

Nm 476 620

Kgf m 48 63

lbf ft 351 457

D D

A258500

Note: In order to obtain an accurate torque setting, a bolt head socket must be used. In some cases, in order to gain access to the bolt head, the axle may require lowering (see Axles - Removal and Replacement, Section 5).

9803/9280

Issue 1

Section 4

Hydraulics

Section 4

3-1

3-1

Power Track Rod (cont’d) Link Arms Removal and Replacement

X

Y S258450

A

J H A258480

9803/9280

F

E

G A258470

Issue 1

Section 4

Hydraulics

3-2

Section 4 3-2

Power Track Rod (cont’d) Link Arms (cont’d) Removal and Replacement (cont’d) Removal If the power track rod cylinder is to be dismantled, or the link arms replaced, proceed as follows: 1

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

2

Use a special spanner (see Service Tools, Section 1) to grip the piston rod at the flats E. Use an open ended spanner to grip the inner ball joint at F. Unscrew the ball joint/link arm assembly from the piston rod.

Note: Flats at ‘E’ are 40 mm A/F x 4 mm wide.

Note: 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.

3

Repeat the procedure for the remaining link arm assembly.

4

Where applicable remove the target disc G.

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

Replacement Note: If the power track rod cylinder is to be dismantled, carry out the procedure (see Power Track Rod Cylinders in this section) before replacing/renewing the link arms.

Replacement is the reverse of removal but note the following: 1

Remember to fit the target disc G (where applicable).

2

If the link arms have been renewed, the wheel alignment must be checked.

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.

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). Refer to illustration A.

3

Check the proximity switch setting (where applicable).

See Proximity Switches, Setting Procedure.

Torque Settings Item 9803/9280

Nm

Kgf m

lbf ft Issue 1

Section 4

Hydraulics

Section 4

4-1

4-1

Power Track Rod (cont’d) Cylinder Dismantling and Assembly

A

1 A258580

7 6

8

5

3 4

D

3 S258430

5

8

1 6 7

2

C

A258590 A258590

9803/9280

Issue 1

Section 4

Hydraulics

Section 4

4-2

4-2

Power Track Rod (cont’d)

Assembly

Cylinder (cont’d)

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

Dismantling and Assembly (cont’d) The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling Fix the cylinder assembly on a locally manufactured strip/rebuild bench as shown at A. Remove both end caps, using a special spanner (see Service Tools, Section 1). Pull the piston rod assembly from the cylinder.

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

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

Fit gland seals 6. (Refer to the Gland Seal Fitting Procedure.)

Fit wiper seals 8. Ensure that the seals are pressed in square to the end cap. DO NOT press onto the lip of the seal.

Fit a new seal and wear rings to the piston head.

Position the piston rod assembly on a bench. Remove the seal and wear rings from the piston head.

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 new piston head 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.

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

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.

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

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

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

Note that both end cap assemblies are the same, dismantle as follows: Remove the end cap seal, ‘O’ ring and wiper seal.

The bearing bush 8 can be renewed if necessary. However, time will be saved if a complete end cap and bush assembly is obtained.

Apply Loctite 932 to threads of the end caps, fit new ‘O’ ring 5.

Ensure that there are no burrs at the ends of the piston rod, see Dismantling.

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: 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 times apply at 20°C and are the minimum periods between assembly and filling the ram with oil.

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

Nm 678

Kgf m 69.2

lbf ft 500

Note: 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.

9803/9280

Issue 1

Section 4

Hydraulics

5-1

Section 4 5-1

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 the 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 Drive (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.

9803/9280

Issue 1

Section 4

Hydraulics

6-1

Section 4 6-1

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.

Z

161750- Z

9803/9280

Issue 1

Section 5

Axles

Section 5

i

i

Contents

Page No.

Technical Data SD70/PT Axle - Offset Drive Head (No Brakes) SD70/PT Axle - Central Drive Head (Inboard Brakes)

1-1 1-2

Descriptions Cutaway of SD70/PT Axle - Offset Drive Head Cutaway of SD70/PT Axle - Central Drive Head Cutaway of SD70/PT Axle - Central Drive Head (with Dropbox)

2-3

SD70/PT Axle - Offset Drive Head Removal and Replacement Proximity Switch Setting Procedure Propshafts - Removal and Replacement Renewing the Pinion Oil Seal Hub and Driveshaft - Dismantling Hub and Driveshaft - Assembly Drive Head - Dismantling Drive Head - Assembly

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

2-1 2-2

SD70/PT Axle - Central Drive Head Removal and Replacement (Pad Mounted) 7-1 Removal and Replacement (Trunnion Mounted) 7-3 Proximity Switch Setting Procedure 7-5 Propshafts - Removal and Replacement 7-6 Renewing the Pinion Oil Seal 8-1 Hub and Driveshaft - Dismantling 9-1 Hub and Driveshaft - Assembly 9-1 Drive Head - Dismantling 10 - 1 Drive Head - Assembly 10 - 3 Optional Drop Box (no Park Brake/2-4 WD fitted) Removal and Replacement 10 - 8 Dismantling and Assembly 10 - 10 Optional Drop Box (with Park Brake fitted) Removal and Replacement 10 - 12 Optional Drop Box (with Park Brake/2-4WD fitted) Removal and Replacement 10 - 14 Dismantling and Assembly 10 - 16 Optional Drop Box (with Yokes fitted to Driveshafts) Dismantling and Assembly 10 - 18 Optional Drop Box (2/4 Wheel Disconnect) Dismantling and Assembly 10 - 20 Limited Slip Differential (optional) Dismantling and Assembly

9803/9280

11 - 1

Issue 2

Section 5 1-1

Axles

Section 5

Technical Data

1-1

SD70/PT Axle - Offset Drive Head (No Brakes) Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.

Type

Spiral bevel input with epicyclic hub reduction.

Designation

SD70/PT

Installation

Centre pivot

Number of steer cylinders

1 (Double Rod)

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

385 kg (850 lb) approximately

Ratios Overall Crownwheel and Pinion

OPTION 1 10.46:1 1.937:1

OPTION 2 OPTION 3 12.4875:1 13.7:1 2.313:1 2.538:1

OPTION 4 OPTION 5 OPTION 6 15.78:1 18.16:1 24.975:1 2.923:1 3.363:1 4.625:1

Number of Teeth Crownwheel Pinion

31 16

37 16

38 13

Hub Reduction

5.4:1

Input Type

Yoke

Oscillation

± 5°

Toe-in

0°

Castor Angle

0°

Camber Angle

1°

King - pin inclination

0°

9803/9280

33 13

37 11

37 8

Issue 1

Section 5 1-2

Axles

Section 5

Technical Data

1-2

SD70/PT Axle - Central Drive Head (Inboard Brakes) Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.

Type

3 piece spiral bevel input with epicyclic hub reduction and inboard braking.

Designation

SD70/PT

Installation

Rigid pad mount or trunnion mounted

Number of steer cylinders

1 (Double Rod)

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

410 kg (904 lb) approximately

Half (Axle) Shaft Braking/Type

3 or 5 plate (each half shaft)

Input Type

Yoke

Oscillation

± 5°

Toe-in

0°

Castor Angle

0°

Camber Angle

1°

King - pin inclination

0°

Hub Reduction

5.4:1

Ratios Overall Crownwheel and Pinion

OPTION 1 10.46:1 1.937:1

OPTION 2 OPTION 3 12.4875:1 13.7:1 2.313:1 2.538:1

OPTION 4 OPTION 5 OPTION 6 15.78:1 18.16:1 24.975:1 2.923:1 3.363:1 4.625:1

Number of Teeth Crownwheel Pinion

31 16

37 16

38 13

9803/9280

33 13

37 11

37 8

Issue 2

Section 5 2-1

Axles

Section 5

Descriptions

2-1

Cutaway of SD70/PT Axle - Offset Drive Head (No Brakes)

ITL01060

(Power track rod not shown)

9803/9280

Issue 1

Section 5 2-2

Axles

Section 5

Descriptions

2-2

S258370

Cutaway of SD70/PT Axle - Central Drive Head (Inboard Brakes)

9803/9280

Issue 1

Section 5 2-3

Axles

Section 5

Descriptions

2-3

Cutaway of SD70/PT Axle - Central Drive Head (with Dropbox - Trunnion Mounted)

ITL02920

9803/9200

Issue 1

x

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

3-1

3-1

Removal and Replacement

K

A

C D

B F

H B

E G ITL01550

9803/9280

Issue 1

Section 5

Axles SD70/PT Axle - Offset Drive Head

3-2

Section 5 3-2

Removal and Replacement (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 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 1

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

2

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

3

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

4

Disconnect remote grease nipple hose H.

5

Loosen the road wheel retaining nuts D.

6

Make sure that the wheels are blocked, and raise the front end of the machine.

7

Prop the machine on each side as shown at C.

8

Remove the road wheels.

9

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.

10 Remove nut E and pivot pin retaining bolt F. 11 Remove pivot pin G seals, use puller (tool no.

992/00800) and remove the pivot pin G and axle shims.

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

9803/9280

Issue 1

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

3-3

3-3

Removal and Replacement (cont’d) Replacement

Y

Replacement is the reverse of the removal sequence.

! 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 243 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).

A

Nylon shims must be fitted as follows: 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.

A

X

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.

ITL01560

If the setting of the steering proximity switch has been disturbed, then complete the front axle proximity switch setting procedure (see Proximity Switches, Setting Procedure).

Torque Settings Item A D

9803/9280

Nm 79 680

Kgf m 8 69

lbf ft 58 500

Issue 1

3-4

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

3-4

Proximity Switch Setting Procedure When fitted, the proximity switch setting procedure is the same for both central and off-set drive head axles. The illustration shows a central drive head axle.

1

Align the wheels in the straight ahead position. Check if straight ahead by measuring the steering ram position.

E

Set the steering so that dimension X is equal both sides.

2

Remove the proximity switch cover C.

3

With the starter switch on, loosen the proximity switch lock nut D and slide the switch in line with the target disc A.

4

Loosen the bracket fixing bolts E and adjust the assembly up or down to bring the switch to the centre of the target disc. Tighten the fixing bolts E. Make sure the light emitting diode (L.E.D.) is not illuminated (if it is then screw the switch out).

E

C Y

D

A

Now screw the proximity switch towards the target disc until the light emitting diode (L.E.D.) on the switch illuminates. Add a further 1 to 1.5 turns of the locknut.

Tighten the locknut.

B

A X

A258170

9803/9280

Issue 1

Section 5

Axles

Section 5 3-5

SD70/PT Axle - Offset Drive Head

3-5

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.

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 B

Nm 75 - 85 118

B

A kgf m 7.7 - 8.7 12

lbf ft 55 - 63 87

S157510

C X

A

S232350

Y A

A

Z

S157500 S189610

9803/9280

Issue 1

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

4-1

4-1

Renewing the Pinion Oil Seal The pinion oil seal 3 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.

4

Align the locating marks on the yoke and splined shaft.

Fit the coupling yoke and a new stake nut:

Note: Do not excessively hammer the yoke during assembly or damage to the shaft bearings could occur. If necessary, press fit the parts. Fully support the shaft during assembly.

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

4.1

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

4.2

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

4.3

If necessary, progressively torque tighten nut to achieve correct rolling torque.

GEN-001

1

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

2

Mark the position of the coupling yoke on the splined shaft. Using Service Tool 892/00812, remove the drive yoke together with its stake nut 2.

3

Remove the seal 3 and fit a new one. Pack between the lips of the new seal with grease before fitting. Take care not to damage the housing when removing the old oil seal.

Note: If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in step 1 by 1 Nm (0.74 lbf ft; 0.1 kgf m) or more, then the collapsible spacer mounted on the axle pinion MUST be renewed.

4.4 5

Stake the nut using a square ended staking tool.

Refit the roadwheels and couple the propshaft.

S242140

9803/9280

Issue 1

Section 5

Axles

Section 5 5-1

SD70/PT Axle - Offset Drive Head

5-1

Hub and Driveshaft - Dismantling The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle.

! 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

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

Note: The illustration shows a typical axle.

2

Remove screws A.

3

Lever the planet gear carrier B off the bearing carrier.

Remove ‘O’ ring.

B

A

S258220

4

Remove planet gears only if defective. Note that 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.

5

Pull off the planet gear.

6

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

C

255920

9803/9280

Issue 1

5-2

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

5-2

Hub and Driveshaft - Dismantling (cont’d) 7

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

D 256010

8

9

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

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

F

E

10 Remove the ‘Verbus Ripp’ bolts using a special tool (part number 892/00333). These bolts are very tight andcare 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.

255930

11 Using 2 high grade M14 bolts as jacking screws, remove the annulus carrier.

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.

S258240

9803/9280

Issue 1

Section 5 5-3

Axles

Section 5 5-3

SD70/PT Axle - Offset Drive Head

Hub and Driveshaft - Dismantling (cont’d) 12 Remove circlip G to separate the annulus ring from the annulus carrier.

G

S248910

13 Pull off the bearing carrier together with the outer bearing cone and its bearing cup. Withdraw the inner bearing cup from the inboard side of the carrier.

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.

S248920

X

A258390

9803/9280

Issue 1

Section 5

Axles

Section 5 5-4

SD70/PT Axle - Offset Drive Head

5-4

Hub and Driveshaft - Dismantling (cont’d) 14 Pull off the inner bearing - see Note at step 13.

15 Remove and discard the seal.

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

S258260

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

S248880

17

Mark position of top and bottom trunnions H and remove. Withdraw the hub carrier.

H

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

H 18

S248890

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

S161460

9803/9280

Issue 1

Section 5 5-5

Axles

Section 5 5-5

SD70/PT Axle - Offset Drive Head

Hub and Driveshaft - Dismantling (cont’d) 19 Use a puller to remove the trunnion seal and bearing.

S258270

20 Withdraw drive shaft.

21 Prise out drive shaft inner oil seal J. 22 Remove circlip K. 23 Remove bearing using tool 892/00225.

K J

255990

9803/9280

Issue 1

Section 5 5-6

Axles

Section 5 5-6

SD70/PT Axle - Offset Drive Head

Hub and Driveshaft - Assembly 1

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

2

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

3

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

K J 255990

4

Press new trunnion oil seal into position followed by the bearing. Grease bearing and oil seal before fitting to axle.

S258270

5

Fit driveshaft needle roller bearing to the hub carrier.

Pack the cavity between the oil seal lips with grease and then fit the seal.

S161460

9803/9280

Issue 1

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

5-7

5-7

Hub and Driveshaft - Assembly (cont’d) 6

Locate hub carrier and fit bottom trunnion. Apply Loctite 243 to the bottom trunnion bolt threads, fit and tighten to 98 Nm (72 lbf ft). Fit top trunnion and leave top trunnion bolts finger tight.

S248890

7

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

8

Refit top trunnion. Apply Loctite 243 to the top trunnion bolt threads, 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 fig. 7.

Note: Earlier axles are fitted with shims.

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: On later axles without shims, if, after adjustment the bearing pre-load is unattainable fit new bearings.

9

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

A

10 Fit a new combination oil seal. Do not lubricate before fitting. Using the service tool and spacer drive the seal squarely into the carrier until the locating lip is flush as shown at A.

A272180

9803/9280

Issue 1

Section 5 5-8

Axles

Section 5

SD70 Axle - Offset Drive Head

5-8

Hub and Driveshaft - Assembly (cont’d) 11 Fit the bearing carrier onto the axle arm. Lightly oil the outer wheel bearing race. Fit the bearing onto the axle arm. Rotate the bearing during fitting.

12 Assemble the annulus ring to the annulus carrier. Secure with the circlip G.

G

S248910

13 Fit annulus assembly in the same angular position as removal (see Note, page 5/5-2, step 11) using new ‘Verbus Ripp’ bolts. Do not fully tighten bolts but allow the bearing carrier to rock slightly. measure seal drag rolling force - see step 14.

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

S248540

9803/9200

Issue 1

Section 5

Axles SD70/PT Axle - Offset Drive Head

5-9

Section 5 5-9

Hub and Driveshaft - Assembly (cont’d) 14 To measure drag seal rolling force: -

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.

S248870

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

S248540

16 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).

-

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.

9803/9280

S248870

Issue 1

Section 5 5 - 10

Axles

Section 5 5 - 10

SD70/PT Axle - Offset Drive Head

Hub and Driveshaft - Assembly (cont’d) 17 Press the drive shaft thrust pad C (chamfered side lowermost) into the recess in the planet carrier.

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

(See step 4 in ‘Dismantling’). Secure with circlip.

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.

C

255920

19 Fit spacer and slide the sun wheel onto the driveshaft and secure with circlip D. Fit a new ‘O’ ring in position X.

X

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

D S258230

20 Fit the planet gear carrier onto the bearing carrier, turning it slightly to engage the gear teeth and aligning the two tapped holes 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 butts fully against the bearing carrier.

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

Re-fill hubs with the correct grade oil (See Lubricants and Capacities - Section 3.)

A S258220

9803/9280

Issue 1

Section 5 5 - 11

Axles

Section 5 5 - 11

SD70/PT Axle - Offset Drive Head

Hub and Driveshaft - Assembly (cont’d) 20 Fit the planet carrier onto the bearing carrier, ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and torque tighten the screws A to 56 Nm (41 lbf ft; 5.7 kgf m) after applying Loctite 243 to the threads.

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

Re-fill hubs with the correct grade oil. (See Lubricants and Capacities - Section 3).

A S258220

9803/9280

Issue 1

Section 5 6-1

Axles SD70/PT Axle - Offset Drive Head

Section 5 6-1

Drive Head - Dismantling

S161871

9803/9280

Issue 1

Axles

Section 5 6-2

SD70/PT Axle - Offset Drive Head

Section 5 6-2

Drive head - Dismantling (cont’d) The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

1

Drain the oil from the axle centre casing. Remove the propshaft from the gearbox to the axle.

2

Remove both hub assemblies complete with driveshafts (see Hub and Driveshaft - Dismantling).

3

Mark the installation position of the drive head carrier, item 2.

4

Remove the drive head carrier retaining bolts, item 1, and remove the drive head carrier 2 from the axle casing.

5

Clean the drive head carrier and axle casing mating faces.

6

Pull out tension pins 3 and 4, remove castellated nuts 5 and 6.

7

Remove bearing outer races 7 and 8.

8

Drive off the taper roller bearing cone 9 from the crownwheel differential case half.

9

Remove the differential assembly 10 from the carrier.

10 Remove the differential assembly retaining bolts 11 and separate case halves 12 and 13.

11 Remove the differential side gears and thrust washers 14 and 15 respectively (2 off each).

12 Remove planet gears and thrust washers 16 and 17 respectively (4 off each) from trunnion pins B. 13 Pull off taper roller bearing cone 18 from differential case half 12.

14 Remove ‘Verbus Ripp’ bolts 19 and separate the crownwheel 20 from the differential case half 13.

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

Use service tool 892/00812 to prevent drive yoke 23 from rotating and remove pinion nut 22. Remove the drive yoke.

16 Press the pinion 24 from the drive head carrier 2.

17 Withdraw the pinion oil seal 25 and taper roller bearing cone 26. If necessary, remove bearing outer race 27.

18 If necessary, drive out the pinion bearing outer race 28 and shim(s) 29 from inner side of the drive head carrier.

19 Remove the collapsible spacer 30 and taper roller bearing cone 31 from pinion 24.

9803/9280

Issue 1

Section 5

Axles SD70/PT Axle - Offset Drive Head

6-3

Section 5 6-3

Drive Head - Assembly Pinion Depth Setting Procedure 1

Place new pinion inner bearing 31 and outer race 28 on a flat surface and position bearing cup 892/00174 over the bearing assembly.

2

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.

3

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.

4

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.

5

S184400

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 inner bearing outer race.

Example (all dimensions in millimetres) Cup Depth Gap A Bearing Depth Pinion Deviation (+ 2) Housing Deviation (––1)

30.01 + 0.20 30.21 + 0.02 + 0.01

Total

30.24

Standard Value Less Total From Above

31.19 30.24

Shim Thickness

0.95

Note: In rare instances, it is possible that the setting data stamp may be omitted from the drivehead casing. In these circumstances the following setting procedure should be used: Revise the shim pack size by the difference in setting height marked on the old and new crownwheel and pinion sets.

9803/9280

Issue 1

Section 5 6-4

Axles SD70/PT Axle - Offset Drive Head

Section 5 6-4

Drive Head - Assembly

S161871

9803/9280

Issue 1

Section 5

Axles

Section 5

SD70/PT Axle - Offset Drive Head

6-5

6-5

Drive Head - Assembly (cont’d) Note: The crownwheel 20 and pinion 24 are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential case halves 12 and 13 are also matched as are gears 14 and 16. Do not use unmatched halves or gears.

8

Assemble planet gears 16 and thrust washers 17 (4 off each) onto trunnion pins B. Fit the planet gear assembly and differential side gears 14, thrust washers 15 (2 off each) into case half 13.

9

Position top case half 12 onto bottom half assembly 13 aligning the match mark letters (see Note 1 opposite).

Apply Loctite 243 to the threads of bolts 11 then fit and torque tighten to 56 Nm (42 lbf ft; 6 kgf m). Check the gears for free rotation.

10

Press taper rolling bearing cone 18 onto the spigot of case half 12.

11

Install the differential assembly 10 into the drive head carrier 2.

12

Press taper roller bearing cone 9 onto the spigot of case half 13.

13

Fit bearing outer races 7 and 8, castellated nuts 5 and 6 to the drive head carrier 2.

14

Adjust castellated nuts 5 and 6 to give a bearing preload (see Note 2) of 1.36 to 2.5 Nm (1.0 to 1.84 lbf ft; 0.14 to 0.26 kgf m).

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

1

Fit to the drive head carrier 2 the pinion inner bearing outer race 28 together with the required thickness of shim(s) 29 to give correct pinion depth. (See Pinion Depth Setting Procedure). Fit the shims behind the outer race a shown.

2

Fit new taper roller bearing cone 31 and a new collapsible spacer 30 onto pinion 24.

3

Fit outer race 27 to the drive head carrier 2.

4

Insert the pinion 24 into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same).

5

6

Fit new taper roller bearing cone 26. Pack the cavity between the lips of the new oil seal 25 with grease and fit the seal to the drive head carrier 2.

Align the locating marks on the coupling yoke and splined shaft. Install the drive coupling yoke 23 and secure it with a new combined stake nut and washer 22.

Note 2: Measure the pre-load by taking another rolling torque reading and subtracting the torque figure measured at step 6.3. The difference is the bearing pre-load.

15

Measure the crownwheel backlash which should be 0.13 to 0.2 mm (0.005 to 0.008 in). Adjust castellated nuts 5 and 6 by equal amounts whan altering backlash.

When backlash and per-load are both correct, fit tension pins 3 and 4.

16

Verify crownwheel and pinion are set correctly: use engineers’ marker on three of the pinion teeth and check markings on the crownwheel are as indicated in Crownwheel and Pinion Adjustment. Adjust if necessary.

17

Apply Loctite 243 to the drive head carrier mating face then fit to the axle casing (the carrier assembly locates on two dowels). Make sure the assembly is fitted in the same match marked position (see step 3, Dismantling).

18

Apply Loctite 243 to bolts 1 and torque tighten to 166 Nm (122 lbf ft; 17 kgf m). Use heavy duty socket 892/00817.

6.1 Hold the yoke 23 with Service Tool 892/00812.

Note: Do not excessively hammer the yoke during assembly or damage to the shaft bearings could occur. If necessary, press fit the parts. Fully support the shaft during assembly.

6.2 Tighten the stake nut until end float is almost zero then check seal drag torque is between 0.40 to 0.75 Nm (3.5 to 6.6 lbf in).

6.3 Continue to tighten the stake nut to collapse spacer 30 and give a rolling torque of 1.7 to 2.8 Nm (1.3 to 2.1 lbf ft) excluding seal drag, crownwheel not fitted.

IF THE STAKE NUT IS OVER-TIGHTENED, THE COLLAPSIBLE SPACER MUST BE RENEWED. Make sure that yoke 23 is rotated in both directions to fully seat bearings before measuring rolling torque.

6.4 When the torque is correct, stake the nut to the pinion shaft using a square ended staking tool.

7

Note 3: Verbus Ripp bolts must NOT be re-used.

19

Assemble both hub and driveshafts, refit the propshaft to the gearbox.

20

Fill the axle with recommended oil (see Lubricants and Capacities – Section 3).

Fit crownwheel 20 to case half 13, torque tighten ‘Verbus Ripp’ bolts 19 to 166 Nm (122 lbf ft; 16.9 kgf

m).

9803/9280

Issue 1

Section 5 6-6

Axles

Section 5 6-6

SD70/PT Axle - Offset Drive Head

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

9803/9280

Issue 1

x

Section 5

Axles

Section 5

SD70/PT Axle - Central Drive Head (Pad Mounted)

7-1

7-1

Removal and Replacement

D

C

D

-238.14

B

H

E F J

A

K

9803/9280

ITL01540

G Issue 2

Section 5

Axles

Section 5 7-2

SD70/PT Axle - Central Drive Head (Pad Mounted)

7-2

Removal and Replacement (cont’d) ! WARNING

Replacement Replacement is the reverse of the removal sequence.

! 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.

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.

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

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

2-3-2-8

GEN 1-1

! WARNING

Removal

! WARNING When the propshaft is disconnected the parking brake will no longer function. The machine must be securely chocked to prevent any machine movement before disconnecting the propshaft.

TRAN 1-1

BRAK 1-6

Bleed the brake system. See Brakes, Bleeding Procedure - Section 6.

Apply Loctite 243 to the threads of bolts A.

Removing 1

Using tool 982/00822 remove bolts A to disconnect the drive shaft from the axle.

2

Disconnect the brake pipes from the brake piston housings, shown at H. Remove tee piece B retaining bolt and remove the tee piece. Blank off exposed connections.

3

Bleed the brake system before driving the machine.

When fitted remove the cover C from the proximity switch and then remove the bracket and switch assembly.

If the setting of the steering proximity switch has been disturbed, then complete the axle proximity switch setting procedure, as described in Proximity Switches, Setting Procedure.

Torque Settings Item A E G

Nm 79 680 500

kgf m 8 69 51

lbf ft 58 500 368

4

Label and then disconnect hydraulic pipes D from the steer cylinder, blank off all exposed connections.

5

Loosen the road wheel retaining nuts E.

6

Make sure that the wheels are blocked, and raise the rear end of the machine.

7

Prop the machine on each side as shown at F.

8

Remove the road wheels.

9

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

Note: Attach a ‘cradle’ to the jack that will partially embrace the axle.

10

Remove nuts G, bolts J and washers K.

11

Lower the jack and remove the axle.

9803/9280

Issue 2

Section 5

Axles

Section 5

SD70/PT Axle - Central Drive Head (Trunnion Mounted)

7-3

7-3

Removal and Replacement

B

G B

J

G

J

B J

B

C J

C C

K

D

E H

A F A

ITL02930

9803/9280

Issue 2

Section 5 7-4

Axles

Section 5

SD70/PT Axle - Central Drive Head (Trunnion Mounted) ! 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.

GEN1-1

7-4

Replacing Replacing is generally the reverse of the removal sequence.

Make sure you re-fit dowels J together with any shims in their original positions.

Make sure that the axle oscillates freely before final tightening of the fixing bolts.

Set the proximity switch.

If the boom is raised, make sure the safety support is fitted.

Grease the axle pivot before driving the machine.

Removing

! WARNING When the propshaft is disconnected the parking brake will no longer function. The machine must be securely chocked to prevent any machine movement before disconnecting the propshaft.

TRANS 1-3

1

Disconnect the propshaft coupling from the axle by unscrewing bolts A.

Note: If a drop box is fitted the propshaft coupling is still disconnected in the same manner. The drop box is lifted clear with the axle.

2

Disconnect and plug the hydraulic hoses G to the power track rod.

3

Slacken off the roadwheel retaining nuts then raise and support the front end of the machine on support stands or blocks positioned under the chassis. Remove the front roadwheels.

4

Remove the front mudguards. Undo the bracket retaining nuts F at the steering trunnions.

5

Disconnect the brake hose at the axle. Blank off the exposed connections.

6

Undo bolt D and remove pivot pin E.

7

Undo the sway ram pivot bracket mounting bolts H. Lift away the bracket. Tie the proximity sensor mounting bracket K clear of the axle.

8

Support the axle on a trolley jack.

9

Undo the six trunnion bolts B/nuts C.

Refit the road wheels and carry out the tightness checks as detailed in the Service Manual and Operator Handbook.

Bleed the brake system and steering system before driving the machine.

Torque Settings Item A B/C H F

Nm 78 476 600 98

kgf m 8 48 60 10

lbf ft 57 352 440 72

10 Remove the axle from the machine. Be sure to retrieve dowels J. If shims are fitted record their positions.

9803/9280

Issue 2

Section 5 7-5

Axles SD70/PT Axle - Central Drive Head

Section 5 7-5

Proximity Switch Setting Procedure The switch setting procedure for the Central Drive Head is identical to the Offset Drive Head. Please refer to Proximity Switch Setting Procedure - SD70PT Axle - Offset Drive Head in this section.

9803/9280

Issue 1

Section 5

Axles

Section 5 7-6

SD70/PT Axle - Central Drive Head

7-6

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.

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.

Item A B

Nm 75 - 85 118

B

A

Torque Settings kgf m 7.7 - 8.7 12

lbf ft 55 - 63 87

C

X

A

S232350

Y

A Z A S189610

9803/9280

S157500

Issue 1

Section 5 8-1

Axles SD70/PT Axle - Central Drive Head

Section 5 8-1

Renewing the Pinion Oil Seal The procedure for renewing the Central Drive Head axle pinion oil seal is the same as for the offset axle pinion oil seal. Please refer to Renewing The Pinion Oil Seal - Offset Drive Head for a full description of the procedure.

9803/9280

Issue 1

Section 5 9-1

Axles SD70/PT Axle - Central Drive Head

Section 5 9-1

Hub and Driveshaft Dismantling and Assembly Dismantling and assembly of the Central Drive Head axle hub and driveshaft is the same as for the Offset Drive Head axle hub and driveshaft. Please refer to pages 5/5 - 1 to 5/5 - 10 for a full description of the procedures.

9803/9280

Issue 1

Section 5 10 - 1

Axles SD70/PT Axle - Central Drive Head

Section 5 10 - 1

Drive Head - Dismantling As the drive head cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed.

See Removal and Replacement for axle arm removal precedure.

The crownwheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential case halves are also matched as are the differential side gears and planet gears, do not use unmatched halves or gears.

1

Position the drive head as shown, with the crownwheel at the top. (For coupling removal, see Renewing the Pinion Oil Seal.) Remove capscrews.

2

Match - mark the brake piston housing and drive head.

Pull off the brake piston housing.

3

Drive out the differential side nut locking pin, to allow readjustment on assembly. Remove the other brake piston housing only if damaged, but remove its locking pin regardless (to allow sideload adjustment on assembly).

S256050

S256060

4

Lift out the crownwheel/differential assembly.

Note: If both brake piston housings are to be removed, mark the crownwheel end of the drive head casing to ensure that the assembly is returned to its original position.

S256070

5

Using a soft faced hammer, hit the pinion end shaft until the pinion is free from its front bearing, then withdraw the pinion.

6

Withdraw the pinion seal and outer bearing cone.

7

If necessary, drive out the pinion inner bearing cup and shims. Discard the shims. Repeat for the outer bearing cup if required. Note that there are no shims for the outer bearing cup.

S256080

9803/9280

Issue 1

Section 5 10 - 2

Axles

Section 5 10 - 2

SD70/PT Axle - Central Drive Head

Drive Head - Dismantling (cont’d) 8

Remove and discard the pinion collapsible spacer.

9

Pull off the bearing cone.

9

8 S256090

10 To dismantle the differential assembly, first remove bolts.

11

Lift off the top half housing.

12

Remove the differential gears and spherical washers.

Pull off both differential bearing cones.

0

If required, remove the crownwheel to differential casehalf retaining bolts and remove the crownwheel.

Note: For axles with limites slip differential see Limited Slip Differential.

!

@ @

S256100

9803/9280

Issue 1

Section 5 10 - 3

Axles

Section 5 10 - 3

SD70/PT Axle - Central Drive Head

Drive Head - Assembly Pinion Depth Determine the pinion depth setting as follows: Note: See page 5/6-6 for general guidance on crownwheel and pinion adjustment.

1

Assemble the pinion inner bearing and its cup on a flat surface.

2

Place Service Tool 892/00174 over the bearing assembly. Measure gap A. Add tool depth (30.01 mm) to gap A to give bearing depth.

3

Note the mounting distance figure B etched on the pinion and the deviation figure C on the drive head housing. Both figures are in units of 0.01 mm.

4

If dimension B is positive, add it to the bearing depth.

If dimension B is negative, subtract it from the bearing depth.

5

If dimension C is positive, subtract it from the total. If dimension C is negative, add it to the total.

6

Subtract the result from the standard value of 31.19 mm to give the required shim thickness.

S184400

B

Example (Dimensions in mm) S256110

Dimension A Add tool depth

0.25 +30.01

Total

30.26

Add dimension B if positive.

(Subtract if negative.)

+0.01

Total

30.27

Add dimension C if negative.

(Subtract if positive.)

+0.01

Total

30.28

Standard Value Less calculated total from above SHIM THICKNESS

9803/9280

31.19 -30.28

C

S256120

0.91

Issue 1

Section 5 10 - 4

Axles

Section 5 10 - 4

SD70/PT Axle - Central Drive Head

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

9803/9280

Issue 1

Section 5 10 - 5

Axles

Section 5 10 - 5

SD70/PT Axle - Central Drive Head

Drive Head - Assembly (cont’d) Note: The crown wheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential housing halves are also matched.

Do not use unmatched halves. If required, fit a new crownwheel to the differential case half, torque tighten crownwheel retaining bolts to 166 Nm 122 lbf ft; 17 kgf m).

1

Assemble the differential gears and their spherical washers into the bottom half housing. Fit the differential bearing cones.

2

Position the top half housing onto the differential, aligning the match mark letters (see Note above). Apply Loctite 243 to the threads of bolts, then fit and torque tighten to 56 Nm (42 lbf ft, 6 kgf m). Check the gears for free rotation.

2

2 1 1 S256100

3

Fit the pinion inner bearing cone and a new collapsible spacer.

3

3

S256090

4

5

6

Fit the pinion inner bearing cup, together with the required thickness of shims to give correct pinion dept, see Pinion Depth, steps 1 to 6. To ensure the cup is fitted square, use a suitable puller assembly. Do not use a hammer. Fit the outer bearing cup.

Insert the pinion into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same.

Fit the pinion outer bearing cone and the seal. Pack between the lips of the seal with grease before fitting.

7

Install the drive coupling yoke and secure with a new stake nut and washer. Tighten the stake nut (holding the yoke with Service Tool 892/00812) to achieve the correct rolling torque; see Step 8. If the nut is overtightened, the collapsible spacer must be renewed.

8

Measure the rolling torque, which should be 1.7-2.8 Nm (1.3-2.1 lbf ft; 0.17-0.28 kgf m). When the torque is correct, stake the nut to the pinion shaft using a quareended staking tool.

4

5

4 4 6

S256080

6

S256130

9803/9280

Issue 1

Section 5 10 - 6

Axles

Section 5 10 - 6

SD70/PT Axle - Central Drive Head

Drive Head - Assembly (cont’d) 9

If both brake piston housings were removed, fit the one at the opposite end to the crownwheel, using the procedure in Step 10. Then install the crownwheel /differential assembly into the drive head.

S256070

10

11

Apply Loctite 574 to the drive head mating face, then fit the brake piston housing. Ensure that the match-marks made during dismantling are aligned. Fit capscrews.

Torque - tighten to 56 Nm (42 lbf ft, 5.7 kgf m). (Applies to both piston housings.)

@

!

0

Adjust differential side nuts to give a bearing preload of 1.13-2.26 Nm (0.8-1.6 lbf ft; 0.1-0.2 kgf m). Measure the preload by taking another rolling torque reading and subtracting the torque figure measured at step 8. The difference is the bearing preload.)

S256140

12

Measure the crownwheel backlash, which should be 0.13-0.2 mm (0.005-0.008 in). Adjust the differential side nuts by equal amounts when altering backlash.

When backlash and preload are both correct, fit the sidenut locking pins 12. Verify crownwheel and pinion are set correctly, see Crownwheel and Pinion Adjustment.

Note: To measure the backlash, use a magnet drilled and tapped 6 mm to accept a length of rod threaded 6 mm on one end. Position the magnet in-between the crown wheel locking bolts as shown in the inset.

S256150

9803/9280

Issue 1

Section 5 10 - 7

Axles

Section 5 10 - 7

SD70/PT Axle - Central Drive Head

Drive Head - Assembly (cont’d) 13

Apply Loctite 574 to the mating face of the drive head.

Locate the axle arm onto the drive head, with the embossed word ‘TOP’ on the axle arm uppermost. Fit bolts A and torque tighten to 400 Nm (295 lbf. ft; 41 kgf m).

A

ITL01530 ITL01530

9803/9280

Issue 1

Section 5

Axles

Section 5 10 - 8

SD70/PT Axle - Central Drive Head Drop Box (with no Park Brake - 2/4WD fitted) Removal and Replacement 10 - 8

3

4 5

2

1 7

9803/9280

6

Issue 1

Section 5 10 - 9

Removal

Axles

Section 5 10 - 9

SD70/PT Axle - Central Drive Head Drop Box (with no Park Brake - 2/4WD fitted) Replacement

Carry out General Safety procedures, see Care and Safety, Section 2.

! 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.

1

Replacement is the reversal of the removal procedure.

2

Discard old seals and fit new seals and ‘O’ rings.

3

Take care not to damage ‘O”’ ring seal between axle and drop box during fitting.

4

Use new Verbus Ripp bolts 10.

5

Adjust the parking brake cable.

6

Fill to the correct level with the appropriate grade of oil.

GEN-001

Torque Settings 1

Make sure the wheels are chocked as the parking brake will no longer function when the drop box is removed.

2

Remove drain plug 1 and drain drop box oil into a suitable container.

3

Undo bolts 2 and disconnect bottom drive shaft.

4

Undo bolts 3 and disconnect top drive shaft.

5

Undo bolts 4 and 5, remove support strap.

6

Support the drop box to prevent damage to the oil transfer pipe 6.

7

Release bolts 7, with the weight still supported pull to the rear to release oil transfer pipe 6, remove drop box.

9803/9280

Item 2&3 4 5 7

Nm 78 56 166 156

kgf m 8 6 17 16

lbf ft 57 41 122 115

Issue 1

Section 5 10 - 10

Axles SD70/PT Axle - Central Drive Head Drop Box (with no Park Brake - 2/4WD fitted)

Section 5 10 - 10

Dismantling and Assembly

9803/9280

Issue 1

Section 5 10 - 11

Dismantling

Axles

Remove oil transfer pipe 1, ‘O’ ring 2 and coupling 3 (if fitted).

2

Undo stake nut 4 and remove input drive yoke 5 and seal 6.

3

Undo stake nut 7 and remove output drive yoke 8 and seal 9.

4

Undo bolts 10 and separate casings 11 and 12.

5

Remove bearing 13, input gear 14, bearing 15 and input drive shaft 16. It should not be necessary to disturb blanking plate 17.

7

10 - 11

SD70/PT Axle - Central Drive Head Drop Box (with no Park Brake - 2/4WD fitted) Assembly

1

6

Section 5

1

Replacement is the reversal of the removal procedure.

2

Inspect bearing and bearing housings for wear and damage.

3

Discard old seals and fit new seals and ‘O’ rings, items 2, 6, 9 and 24.

4

Pack cavity in seals 6 and 9 with HP Grease.

5

Bearings to be lightly oiled before assembly.

6

Clean mating faces of the drop box and apply 275 Threadlocker. Ensure mating dowels 25, 26 and 27 are fitted and secure before assembling casings 11 and 12.

Remove bearing 18, input gear 19, bearing 20 and output drive shaft 21.

7

Torque tighten nuts 4 and 7 and stake nut sleeve axially using a square end staking tool as shown at A.

Undo bolts 22 to remove mounting support 23, with ‘O’ ring 24.

Torque Settings Item 4/7 10 22

9803/9280

Nm 300 56 98

kgf m 30.5 5.7 10.0

lbf ft 221.25 41.25 72.25

Issue 1

Section 5

Axles

Section 5 10 - 12

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake fitted)

10 - 12

Removal and Replacement

A N

L K

M

N

A

J

G

H

P

C

B C E

F D ITL01500

9803/9280

Issue 1

Section 5

Axles

Section 5 10 - 13

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake fitted) Removal and Replacement (cont’d) 10 - 13

! WARNING

11

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.

Remove nuts D, bolts E and washers F and ensure the axle pads are free from their mountings.

12

Lower the jack and remove the axle.

13

Locate the axle arms on suitable blocks.

14

Remove drain plug H and drain the Dropbox oil into a suitable container.

15

Undo bolts N, and remove the support strap. Support the Dropbox to prevent damage to oil transfer pipe P.

16

Using a jack to support the Dropbox, release bolts G and pull to the rear to release oil transfer pipe P and remove the Dropbox.

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

GEN-1-1

Removal 1

Using Tool No. 892/00822 remove screws A and disconnect the propshafts from the Dropbox couplings (refer to Propshafts, Removal and Replacement).

2

Disconnect the hydraulic pipes from the swivel hubs and steer cylinder. Blank off al exposed connections and identify for reassembly.

Replacement Replacement is the reverse of the removal sequence.

3

Loosen the wheel retaining nuts B.

4

Ensure the road wheels are blocked. Raise the machine.

5

Prop the machine on each side as shown at C.

7

Remove the road wheels.

8

1

Apply Loctite 242 to the threads of bolts A and new Verbus Ripp mounting bolts G.

2

Renew ‘O’ ring seals to the balance pipe.

3

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

Position a jack underneath the axle and Dropbox at the balance point and support the axle weight.

4

Take care not to damage the ‘O’ ring seal between axle and Dropbox during fitting.

9

Disconnect parking brake return spring J.

5

Adjust the parking brake cable.

10

Remove spring clip K, clevis pin L and circlip M, release parking brake cable from the Dropbox.

6

Fill to the correct level with the appropriate grade of oil.

Note: Because the Dropbox is offset, the balance point is not the centre of the axle. Attach a cradle to the jack which will safely support the axle and Dropbox.

! 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.

! 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

! CAUTION Bleed the brake system before driving the machine.

BRAK 1-6

Bleed the brake system (see Bleeding, Section 6) and steering system (see Steer System, Bleeding Procedure, Section 4).

INT-1-3-7

Note: The weight of the axle and Dropbox is 463 kg (1,021 lb).

9803/9280

Torque Settings Item A B D G

Nm 20.9-23.7 680 476 166

kgf m 2.13-2.42 69 49 16.9

lbf ft 15.4-17.5 500 351 122.5

Issue 1

Section 5

Axles

Section 5 10 - 14

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake - 2/4WD fitted) Removal and Replacement 10 - 14

6

11 7

5

4

2

3

10

9

9803/9280

1

8

S194640

Issue 1

Section 5

Axles

Section 5 10 - 15

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake - 2/4WD fitted) Removal and Replacement 10 - 15

Removal

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

Make sure the wheels are chocked as the parking brake will no longer function when the Dropbox is removed.

Undo bolts 1 and disconnect bottom driveshaft.

Undo bolts 2 and disconnect top driveshaft.

Release spring 3, remove clevis pin 4 and undo bolts 5 to disconnect 2/4 wheel drive (if fitted).

Return spring 11 is fitted on later machines, remove if fitted.

Replacement is the reversal of the removal procedure.

Spacers 10 are fitted to the top front drive ONLY. Discard old seals and fit new seals and ‘O’ rings.

Take care not to damage ‘O’ ring seal between axle and Dropbox during fitting.

Adjust the park brake cable.

Adjust the 2/4 wheel drive disconnect cable.

Fill to the correct level with the appropriate grade of oil (see Lubricants and Capacities, Section 3).

Torque settings Item

Nm

kgf m

lbf ft

1&2 8 9

125 120 110

12.75 12.2 11.2

92.0 88.5 81.0

Remove clevis pin 6 and spring clip 7 to disconnect parking brake.

Remove bolt 8 from oil feed and drain oil into a suitable container. Discard sealing washers.

Support the Dropbox, release bolts 9 and remove Dropbox.

9803/9280

Issue 1

Section 5

Axles

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake - 2/4WD fitted) Dismantling and Assembly

10 - 16

Section 5 10 - 16

S194280

9803/9280

Issue 1

Section 5

Axles

Section 5 10 - 17

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake - 2/4WD fitted) Dismantling and Assembly 10 - 17

Dismantling

Assembly

Remove the parking brake assembly (see Removal and Replacement).

Replacement is the reversal of the removal procedure.

Inspect bearing and bearing housings for wear and damage.

Remove the 2/4 wheel drive disconnect assembly (see Removal and Replacement).

Discard old seals and fit new seals and ‘O’ rings.

Release circlip 3 and remove thrust washer 4.

Clean mating faces of the Dropbox and apply Loctite 574.

Remove lower drive 5.

Use Loctite 262 on bolt 19.

Remove bolts 6 and separate casing 1 and 2.

Torque Settings

Remove gear 8, bearings 7, 10 and drive 9.

Item 6 19

Remove washer 11, release circlip 12 and remove thrust washer 13.

Nm 20 120

kgf m 6.1 12.2

lbf ft 44.25 88.5

Remove upper drive 14.

Remove gear 17, bearings 16 and 18.

To remove mounting support 20 undo bolts 19.

9803/9280

Issue 1

Section 5

Axles

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake fitted) (Yokes fitted to Driveshafts) Dismantling and Assembly 10 - 18

Section 5 10 - 18

S240340

9803/9280

Issue 1

Section 5

Axles

Section 5 10 - 19

SD 70/PT Axles - Central Drive Head Drop Box (with Park Brake fitted) (Yokes fitted to Driveshafts) Dismantling and Assembly (cont’d) 10 - 19

Dismantling

Assembly

Remove the parking brake assembly (see Removal and Replacement).

Replacement is the reversal of the removal procedure.

Undo nut 1 and remove output drive yoke 2.

Inspect bearings and bearing housings for wear and damage.

Undo nut 4 and remove input drive yoke 5.

Discard old seals and fit new seals and ‘O’ rings.

Undo bolts 9 and separate casings 10 and 23.

Bearings to be lightly oiled before assembly.

To remove mounting support 20 undo bolts 19.

Clean mating faces of the Dropbox and apply Loctite 574 sealant.

Pack cavity between seals 3 and 6 with grease (see Lubricants and Capacities, Section 3).

Torque Settings Item 1/4 7 9 19

9803/9280

Nm 300 56 56 98

kgf m 30.5 5.7 5.7 10.0

lbf ft 221.25 41.25 41.25 72.25

Issue 1

Section 5

Axles

Section 5

SD 70/PT Axles - Central Drive Head Drop Box (Optional 2/4WD Disconnect) Dismantling and Assembly

10 - 20

10 - 20

Dismantling

Assembly

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

Replacement is the reversal of the removal procedure.

Discard old seals and fit new seals and ‘O’ rings.

Clean mating faces of the Dropbox and apply Loctite 574 sealant

S194730

9803/9280

Issue 1

Section 5 11 - 1

Axles

Section 5 11 - 1

Limited Slip Differential (Optional)

9803/9280

Issue 1

Section 5

Axles

Section 5 11 - 2

11 - 2

Limited Slip Differential (Optional) (cont’d) Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

! 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

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. Refer to parts information.

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).

7

Fit crownwheel 2 using new Verbus Ripp bolts 1, torque tighten to 166 Nm (122 lbf ft; 16.9 kgf m).

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

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

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

Dismantling Mark the two differential halves before dismantling, for subsequent assembly.

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

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 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 or the second side gear.

5

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

9803/9280

Issue 1

Section 6

Brakes

Section 6

i

i

Contents

Page No.

Technical Data

1-1

SD70/PT Axle - Central Drive Head - Standard Retraction Dismantling 2-1 Assembly 2-2 SD70/PT Axle - Central Drive Head - Positive Retraction Dismantling Assembly

3-1 3-3

SD70/PT Axle - Central Drive Head - Inboard Brakes Axle Breather

3-5

SD70/PT Axle - Central Drive Head Brake Piston Seal Leakage Test

4-1

SD70/PT Axle - Central Drive Head Bleeding Procedure

5-1

* SD70/PT Axle - Parking Brake

Torque Figures Caliper Removal and Replacement Caliper - Dismantling and Inspection Caliper - Assembly Brake Disk - Removal and Replacement

6-1 6-2 6-3 6-5 6-7

* SD70/PT Axle - Service Procedures

Parking Brake - Testing Parking Brake - Adjustment- Type A Parking Brake - Switch Adjustment- Type A Parking Brake - Adjustment- Type B Parking Brake - Renewing the Brake Pads

9803/9280

7-1 7-2 7-3 7-4 7-6

Issue 2*

Section 6 1-1

Brakes

Section 6

Technical Data

1-1

Service Brakes - SD70/PT Axle - Central Drive Head (Inboard Brake) 3 or 5 Plate - Standard or Positive Retraction Type

Oil-immersed Multi-plate Disc

Actuation

Hydraulic

Location

Inboard - Axle Centre Casing (2 brake packs)

Friction Plates Outside diameter Inside diameter Nominal Facing Area/Plate

3 or 5 per pack 220 mm (8.66 in) 180 mm (7.09 in) 12616 mm2 (19.5 in2)

Hydraulic Piston diameter

216 mm (8.5 in)

Piston operation

Standard or positive retraction

Instructions for Dismantling and Assembly are detailed under SD70/PT Axle, Central Drive Head - Standard Retraction, Dismantling and Assembly and SD70/PT Axle, Central Drive Head, Positive Retraction, Dismantling and Assembly.

*

Parking Brake Type

Disc Brake, Manually Adjusted Caliper

Actuation

Cable Operated

Location

Mounted on Rear Axle or transmission output to rear wheels

Disc Diameter

279.4 mm ( 11 in)

9803/9280

Issue 2*

x

Section 6

Brakes

Section 6 2-1

SD70/PT Axle - Central Drive Head - Standard Retraction

2-1

Dismantling

1

7

8

5

6

4

2

2

3 4

9803/9280

Issue 1

Section 6 2-2

Brakes SD70/PT Axle - Central Drive Head - Standard Retraction

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 not rely solely on the machine hydraulics or jacks to support the machine when working under it.

1

Fit new seals 7 and 8. Make sure they seat squarely in their grooves.

2

Carefully press the piston 6 all the way into its housing.

3

Assemble the friction plates and counterplates 2 onto the carrier 3. If the original brake pack is being re-used, return the plates to their original positions (see ‘Dismantling’, Step 4). Soak new friction plates in Mobil 424 Oil before assembly. Fit circlip 4.

4

Locate the three reaction pins 5 into their grooves, securing them with grease. Push the pins fully into their location holes in the housing.

5

Install one counterplate 2 into the housing, then the brake pack, then the counterplate. Ensure that the chamfered end of the brake carrier 3 faces away from the drive head. Return re-used counterplates to their original positions. Push the brake pack fully home.

6

Apply Loctite 574 to the mating face of the drive head, and Loctite 243 to the threads of bolts 1. Locate the axle arm onto the drivehead, with the embossed word ‘TOP’ on the axle arm uppermost.

7

Fit bolts 1 and torque tighten.

GEN 1-1

Note: Although the driveshaft is shown removed in the following pictures, this job can be done without removing the swivel hub or driveshaft.

1

It is recommended that the axle be removed from the machine when dismantling the axle brakes.

2

Remove bolts 1. Use a heavy duty socket to unscrew them.

3

Jack the axle arm off the drive head, using the drive head securing bolts. Remove all traces of gasketing from the mating faces.

4

There are two counterplates 2, one at each end of the brake pack, which are not secured to the plate carrier 3.

If the plates are to be re-used, note their positions and which way round they are then withdraw the brake pack.

2-2

Assembly

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

5

Section 6

Note: Check the grade of bolts fitted. Grade 8.8 should be tightened to 244 Nm (178 lbf ft, 24.9 kgf m), grade 12.9 should be tightened to 400 Nm (295 lbf ft, 40.8 kgf m).

Remove the circlip 4. If the brake pack is to be re-used, note the positions of the plates before removing them.

Note: The plate carrier 3 has an internal chamfer at the end which faces away from the drivehead.

6

Wear limit of friction plates is to the depth of circumferential grooves X. 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.

7

Remove the three reaction pins 5. Inspect for damage.

8

Carefully withdraw the brake piston 6 from its housing, if removal is necessary. A hydraulic hand pump can be used to force the piston out of the housing.

9

Remove and discard seals 7 and 8. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid.

9803/9280

Issue 1

Section 6

Brakes

Section 6 3-1

SD70/PT Axle - Central Drive Head - Positive Retraction

3-1

Dismantling

12 13

9

11

10

8

3

6 1

5 6 4 7

2

A277110

9803/9280

Issue 1

Section 6 3-2

Brakes SD70/PT Axle - Central Drive Head - Positive Retraction

Section 6 3-2

Dismantling (cont'd) Note: This job can be done without removing the planet gear carrier or the driveshaft.

1

Drain the oil from the axle hub.

2

Support axle arm 1. Remove bolts 2.

3

Jack the axle arm off the drive head, using drive head securing bolts 2. Remove all traces of gasketing from the mating faces.

4

There are two counterplates 3, one at each end of the brake pack, which are not secured to the plate carrier 5.

If the plates are to be re-used, note their positions and which way round they are, then withdraw the brake pack.

5

Remove one circlip 6. If the brake pack is to be re-used, note the positions of the plates before removing them.

Note: The plate carrier has an integral chamfer at the end which faces away from the drive head.

6

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

A276990

7

plates.

Remove the three reaction pins 7. Inspect for damage.

8

Remove the piston housing from the drive head (see Drive Head, Dismantling, Section 5).

9

Remove threaded pins 12 and spring 13. Inspect for damage.

10

Carefully withdraw the brake piston 8 from its housing 9, if removal is necessary.

11

Remove and discard seals 10 and 11. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may cause loss of brake fluid.

12

Inspect reaction pins 7 for damage and scoring.

9803/9280

Issue 1

Section 6

Brakes

3-3

Section 6 3-3

SD70/PT Axle - Central Drive Head - Positive Retraction

12 13

9

11

10

8

3

6 1

5 6 4 7

2

A277110

9803/9280

Issue 1

Section 6 3-4

Brakes SD70/PT Axle - Central Drive Head - Positive Retraction

Section 6 3-4

Assembly (cont'd) 1

Fit new seals 10 and 11. Make sure they seat squarely in their grooves.

2

Fit threaded pins 12 and springs 13. Carefully press the piston 8 all the way into its housing 9.

3

Place the housing and piston to the drive head (see Drive Head - Assembly, Section 5).

5

Assemble the friction plates 4 and counterplates 3 onto carrier 5. If the original brake pack is being re-used, return the plates to their original position (see Dismantling, Step 4). Soak new plates in Mobil 424 oil before assembly. Fit circlip 6.

6

Locate the three reaction pins 7 into their grooves, securing them with grease. Push the pins fully into their location holes in the housing.

7

Install one counterplate 3 into the axle arm housing, followed by the brake pack, then the other counterplate 3. Ensure that the chamfered end of brake carrier 5 faces away from the drive head. Return re-used counterplates to their original position. Push the brake pack fully home.

8

Apply Loctite 574 to the mating face of the drive head, and Loctite 243 to the threads of bolts 2. Locate axle arm 1 onto the drive head, with the word ‘TOP’ on the axle uppermost.

9

Fit bolts 2 and torque tighten to 244 Nm (25 kgf m; 180 lbf ft).

10

Refill the differential with the correct grade of oil (see Lubricants and Capacities, Section 3).

9803/9280

Issue 1

Section 6 3-5

Section 6

Brakes

3-5

SD70/PT Axle - Central Drive Head - Inboard Brakes

Axle Breather Later axles, having inboard brakes, are fitted with extended breathers A as shown in the illustration. Original breathers fitted to earlier units should be replaced using the following procedure:

A C

The extended breather A is now available in either metal or plastic construction and is now fitted as standard to all inboard braked axles. Both metal and plastic breathers are fully interchangeable provided the correct fitting procedure is followed.

SERVICE PROCEDURE 1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower all hydraulically operated fittings to the ground.

2

Remove debris and loose material from the top of the axle.

3

Remove existing breathers or degrease breather hole as applicable.

4

Refer to illustration and fit plug B (if not already fitted) and the extended breather after ensuring hole C in the breather is pointing towards the road wheel.

For plastic breathers either a suitable plastic to metal bonding sealant or bonding, part No. 4103/0955 is required, with sufficient preparation and cure time as specified in the manufacturer’s instructions.

For the axle location of the plug B and breather A refer to the Machine Operator Handbook.

Note: Under no circumstances should an axle fitted with oil immersed brakes be operated without an approved breather.

B

ITL01570

9803/9280

Issue 1

Section 6

Brakes

Section 6

SD70/PT Axle - Central Drive Head

4-1

4-1

Brake Piston Seal Leakage Test The following procedure explains how to check if a brake piston seal 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.

5

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

6

Reconnect all brake pipes and bleed the brake system as recommended in Brakes, Bleeding Procedure.

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

BRAK 1-4

! 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.

BRAK 2-1

1

Remove and cap brake piston feed pipe A.

2

Fill the brake piston housing with Light Hydraulic Fluid.

3

Check for severe piston seal damage: 3.1 Install a hand pump (see Note 1) fitted with a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to port B, as shown at X.

Note 1: The hand pump MUST be filled with Light Hydraulic Fluid. DO NOT exceed 69 bar (1000 lbf/in2).

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

3.3 If the pressure falls off rapidly, or if no pressure reading can be obtained, the seal is severely damaged and needs replacing with a new one.

4

Check for small cuts or nicks in the piston seal: 4.1 Install an adapter fitted with a piece of clear tube (approximately 122 mm [4.8 in] long) to the brake piston port B, as shown at Y (see Note 2).

Note 2: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine.

4.2 Fill the tube until approximately three quarters full with Light Hydraulic Fluid.

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 piston seal for slight nicks, cuts or generally for wear.

S159830

9803/9280

Issue 1

Section 6

Brakes

Section 6

SD70/PT Axle - Central Drive Head

5-1

5-1

Bleeding Procedure ! WARNING Before proceeding with the bleeding procedure it is important to ensure that the parking brake is engaged and that one pair of wheels is blocked on both sides.

BRAK 1-2

! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.

BRAK 1-1

Fill the master cylinder reservoir with the correct fluid, and ensure that throughout the bleeding process the level is not allowed to fall below the MINIMUM mark.

Bleed as Follows: Attach a tube to the right hand brake bleed screw A, ensuring that the free end of the tube is immersed in fluid contained in a suitable container.

Open the brake bleed screw and apply full pedal strokes of the brake pedal until all air is expelled.

Close the brake bleed screw with the pedal fully depressed.

Repeat procedure using the left hand bleed screw.

Top up the reservoir to the full mark.

A

S107710/1

9803/9280

Issue 1

Section 6

Brakes

Section 6 6-1

SD70/PT Axle - Parking Brake

6-1

Torque Figures The illustration shows a typical installation.

Where appropriate, the grade of bolt is indicated in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.

Torque Settings Item A B C

Nm 166 13-15 255

lbf ft 122 9-12 188

(12.9) (10.9 Tuflok)

C A

A396540

B

9803/9280

Issue 1

Section 6

Brakes

Section 6 6-3

SD70/PT Axle - Parking Brake

8

14

15

13 13

12

13

13

12

11

10

2

9

1

6-3

5 3

4

Carrier Side Pad Lever Side Pad Bolt Anti-rotation Clip Washer Washer Lever Spring Rotor Ball Spacer Ball Bearings Mounting Bush O-ring Shaft Seal Housing

7

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

6

Component Listing:

228362

9803/9280

Issue 1

Section 6

Brakes

Section 6

SD70/PT Axle - Parking Brake

6-4

6-4

Calliper Dismantling and Assembly Dismantling

Inspection

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

1

Clean and dry all parts. Check all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts.

2

Check rotor 9 for damage or distortion. Renew if necessary.

! WARNING This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

0010

! WARNING Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

! WARNING

Always renew both brake pads if the parking brake has been used in an emergency.

Note: Check the thickness of the friction material on the brake pads. If either pad is worn below 2 mm (0.079 in) fit a new pair of pads.

3

Check the ball pockets in housing 15 for signs of scoring, pitting, damage or corrosion. Renew the housing if damaged.

4

Check spring 8 is not broken or distorted.

5

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

1

Remove the calliper and brake pads, refer to Calliper Removal and Replacement.

2

Bend the tabs on anti-rotation clip 4. Remove bolt 3, anti-rotation clip 4 and washers 5 and 6. Hold lever 7 against the tension of the spring as the bolt is removed.

3

Note the position of lever 7 and the splines of the shaft.

Mark the end of the shaft and lever 7 to aid assembly.

Remove lever 7 and spring 8.

4

Push out rotor 9 and remove ball spacer 10 and ball bearings 11. Take care not to lose the ball bearings.

5

Push out mounting bushes 12 and remove O-rings 13.

Note: Shaft seal 14 will not need to be renewed unless excessively worn or damaged. If removal is necessary, press the seal out from inside the housing using a suitable spacer block and bench press. Clean out any remains of the seal after removal.

9803/9280

Issue 1

Section 6

Section 6

Brakes

6-5

SD70/PT Axle - Parking Brake

3

4

5

7

6

8

14

15

13 13

12

13

13

12

11

10

2

9

1

6-5

228362

9803/9280

Issue 1

Section 6

Brakes

Section 6 6-6

SD70/PT Axle - Parking Brake

6-6

Dismantling and Assembly (cont’d) Assembly Before assembly make sure all parts are clean and serviceable.

1

Fit a new shaft seal 14 if removed. Install the seal as shown. Press the seal into the housing using a suitable spacer block and bench press.

2

Coat the the shaft and ball pockets of rotor 9 and the ball pockets of housing 15 with silicone grease.

3

Insert the three ball bearings 11 into the pockets in the housing 15. Insert ball spacer 10.

4

Slide rotor 9 through the casting and seat the ball pockets against the bearings.

5

Position spring 8 over the shaft of rotor 9. Insert the large diameter end of the spring into hole X in the face of the housing.

6

Locate the small diameter end of spring 8 around the outside edge of lever 7 as shown at Y.

7

Fit lever 7. Align the lever to the mark made during dismantling.

8

Hold the lever against the tension of the spring and fit washers 6 and 5, and new anti-rotation clip 4. Fit bolt 3 and tighten to 13-16 Nm (9-12 lbf ft).

9

Bend up a tab of the anti-rotation clip that aligns with one of the flats on the bolt.

Y

X

A348331

10 Fit the new brake pads, refer to Service Procedures Parking Brake - Renewing the Brake Pads.

11 Lubricate the O-rings 13 and bushes 12 with silicone grease. Fit O-rings into the housing and insert mounting bushes. Wipe off any excess grease.

12 Before fitting the calliper, ensure the lever rotates smoothly and that the lever side pad 2 returns to the off position when the lever is released.

13

Refit the brake calliper. Refer to Calliper - Removal and Replacement.

14

Adjust the parking brake, refer to Service Procedures - Parking Brake - Adjustment.

Torque Settings Item 3

Nm 13-16

9803/9280

lbf ft 9-12

Issue 1

Section 6

Brakes SD70/PT Axle - Parking Brake

6-7

Section 6 6-7

Brake Disc - Removal and Replacement ! WARNING This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

! WARNING Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

Removal 1

Disconnect the propshaft to the rear axle, refer to Section 5 Propshafts - Removal and Replacement.

2

Remove the calliper from the axle mounting bracket F, refer to Calliper Removal and Replacement.

3

Undo the stake nut and withdraw the brake disc from the drive pinion shaft.

Note: If the axle is not mounted to a machine, fit flange spanner (service tool 992/04800) to prevent brake disc and drive pinion shaft turning when loosening or tightening the stake nut. Refer to Section 1 - Service Tools.

Replacement Replacement is the reverse of the removal sequence.

1

Fit a new stake nut and torque tighten to 300 Nm (221 lbf ft), see Torque Settings.

2

Re-stake the nut using a square ended staking tool.

Torque Settings Item 1

Nm 300

9803/9280

kgf m 30.6

lbf ft 221

Issue 1

Section 6

Brakes

Section 6

SD70/PT Axle - Service Procedures

7-1

7-1

Parking Brake - Testing Note: This procedure refers to Backhoe Loaders but the same principles apply to other machines. Refer to the Carrier Service Manual.

SAFETY NOTICE: Ensure all routine health and safety precautions are observed before operating machines.

! WARNING Before testing the parking brake make sure the area around the machine is clear of people.

2-2-4-5

If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB distributor.

! WARNING Do not use a machine with a faulty parking brake.

3-2-3-10

! CAUTION Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

3-2-3-11

1

Enter the machine. Fasten your seat belt and park the machine on a level dry surface.

2

Fully apply the parking brake 1.

3

On machines with two brake pedals ensure they are locked together.

4

Start the engine and raise the attachments to the appropriate travelling position.

5

Select fourth gear, 2 for syncro shuttle machines or 3 for powershift machines.

6

Push down hard on foot brake pedal 4.

7

Select forward drive 5.

6 3

6

P

2

5 1 4

! WARNING If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed.

2-2-5-1

Test the parking brake as follows: 8

Move the parking brake lever fractionally forward until the warning light 6 is just extinguished.

9

Slowly release the foot brake pedal 4.

10

If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500 RPM. The machine should not move.

11

Do not do this test for longer than 20 seconds.

12

Reduce the engine speed to idle and select neutral 5.

13

Return the park brake lever 1 to the fully on position from its partially applied position.

14

Lower attachments and stop the engine.

15

If the machine moved during this test, adjust the parking brake and repeat the test. See Service Procedures, Parking Brake - Adjustment.

9803/9280

A394410

Issue 1

Section 6

Brakes

Section 6 7-2

SD70/PT Axle - Service Procedures

7-2

Parking Brake - Adjustment - Type A Note: Several types of parking brake and brake levers can be fitted, two types are covered here, but reference should always be made to the Carrier Service Manual.

! CAUTION The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced.

Whenever the parking brake has been used in an emergency, always renew both brake pads.

4-2-1-1/2

! WARNING Before working on the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

Cable Adjustment Adjust the cable at the calliper if there is insufficient adjustment at the parking brake lever.

If there is no adjustment at the lever or the calliper, change the brake pads, refer to Parking Brake - Renewing the Brake Pads.

Always renew a worn or damaged cable.

1

Disengage the parking brake (lever horizontal).

2

Turn hand grip E anti-clockwise to centre the pin F in its slot.

3

Release the two locknuts at B and adjust the cable length to give 10 to 15mm (0.40 to 0.60 in) of caliper lever movement at the outer cable fixing hole H. The total clearance between the brake pad to brake disc should be 0.5 to 0.75 mm (0.02 to 0.3 in).

4

Make sure there is adequate freedom of movement of operating lever C to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released.

5

Test the parking brake, refer to Parking Brake Testing. Make final adjustments at the park brake lever if the brake fails the test. Refer to Lever Adjustment.

2-3-2-4/1

The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should light when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN).

! WARNING Over adjustment of the parking brake could result in the parking brake not fully releasing 0011

Lever Adjustment 1

Disengage the parking brake (lever horizontal).

2

Turn handle grip E clockwise, half a turn.

3

Test the parking brake, refer to Parking Brake Testing.

4

If the brake fails the test, repeat steps 1, 2 and 3. If there is no more adjustment and pin F is at the end of its travel adjust the cable.

B

H

B C

E

F

A390850 A396180

9803/9280

Issue 1

Section 6

Brakes

Section 6 7-3

SD70/PT Axle - Service Procedures

7-3

Parking Brake - Switch Adjustment Type A 1

Select the starter key switch to the ON position, do not start the engine.

2

Select either forward or reverse.

3

Raise the handbrake to the ON position.

4

Adjust locknuts B and use feeler gauges to set the proximity switch A so that there is clearance of 2mm MIN - 3mm MAX between the end of the switch and the handbrake lever. The light emitting diode (L.E.D.) on the switch should be illuminated and the audible alarm should sound.

5

Secure the switch in position by tightening locknuts B.

6

Release the parking brake and the audible alarm should cease.

For adjustment of the Parking Brake, refer to Parking Brake - Adjustment.

Torque Settings Item B

Nm 29

kgf m 2.95

lbf ft 21

B

B A

A396440

9803/9280

Issue 1

Section 6

Brakes

Section 6 7-4

SD70/PT Axle - Service Procedures

7-4

Parking Brake Adjustment - Type B

G

B

H

F

A C E

C

A311940

9803/9280

Issue 1

Section 6

Brakes

Section 6

SD70/PT Axle - Service Procedures

7-5

7-5

Parking Brake Adjustment - Type B If the parking brake caliper assembly has been dismantled or the brake pads renewed, then the caliper must be set as follows:

! WARNING Before adjusting the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

! WARNING If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed.

2-2-5-1

c

Slowly release the brake pedals, if the machine has not moved use the accelerator to gradually increase the engine speed to 1500 RPM - the machine should not move. DO NOT test for longer than 20 seconds.

d

If the machine moved inspect the caliper/pads, reset as described above.

BRAK - 008

1

Disengage the parking brake (lever horizontal). Turn handle grip A to bring pin B central to the slot.

2

Adjust the cable’s effective length so that the park brake is fully engaged when the park brake lever is vertical:

3

a

Release and adjust the two locknuts C.

b

Further adjustment, if required, is available at the clevis and cable mounting position at the park brake lever, shown at E.

In the event that there is insufficient adjustment in the cable, remove screw F, anti-rotation clip G and take operation lever H off its mounting spline.

4

Rotate the lever clockwise, one notch of the spline.

Refit anti-rotation clip G and screw F. Torque tighten the screw to 12.5 - 15.5 Nm; (1.3 - 1.6 kgf m; 9.2 - 11.5 lbf ft).

5

After the screw has been torque tightened bend the tabs of clip G to secure the screw.

6

Test the parking brake.

If you have any queries concerning this test procedure or parking brake adjustment, consult your local distributor.

! WARNING Do not use a machine with a faulty parking brake.

3-2-3-10

! CAUTION Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

3-2-3-11

Note: On machines where the parking brake, when fully engaged, electrically disconnects the transmission drive; the machine is prevented from being driven with the park brake ON. Therefore, so that we can complete the test, move the park brake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the park brake will not be fully operational. a

Make sure the parking brake is fully engaged (lever vertical - also see Note above). Select third gear.

b

Make sure the brake pedals are locked together, push down hard on the brake pedals and select forward drive.

9803/9280

Issue 1

Section 6 7-6

Brakes

! WARNING

Pad Replacement 1

Fit the pad 2 to the lever side of the calliper. Position the pad inside housing 15. Locate the plastic clip in the centre of the rotor 9 into the hole X, and press the pad into place.

2

Fit the pad 1 to the carrier sde of the calliper. Add a small amount of silicon sealant to the back outer edge of the backing plate to hold the pad in place within the housing.

3

Replace the calliper, refer to Parking Brake - Calliper Removal and Replacement.

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

! WARNING

Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

7-6

SD70/PT Axle - Service Procedures

Parking Brake - Renewing the Brake Pads

0010

Section 6

Note: If there is insufficient adjustment after fitting new pads change the brake cable.

! WARNING

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

Pad Removal 1

Remove the parking brake calliper from the axle mounting bracket, refer to Parking Brake - Calliper Removal and Replacement.

2

Press carrier side pad 1 into housing 15 and remove.

Ensure any residual silicone used for pad retention during assembly is removed.

3

Carefully lever pad 2 from the rotor inside the housing using a flat blade screwdriver. Take care to prevent damage to the plastic clip in the centre of the rotor 9 (there is no need to remove the rotor from the calliper).

Pad Inspection

! WARNING Oil on the brake disc will reduce brake effectiveness.

Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer’s safety instructions. If the pads are oily, new ones must be fitted.

15

2-3-2-3/3

1

The minimum thickness of the friction material on either pad is 1mm (0.04 in), but it is recommended new pads are fitted as pads worn to this limit may not be able to be adjusted.

2

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn. For brake disc removal, refer to Parking Brake, Brake Disc - Removal and Replacement.

3

X 1 2 9

A390680

Renew the cable if worn or damaged.

9803/9280

Issue 1