comer series s128 axle maintenance manual
Contents
1. 39 40 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Tighten the screws 7 of the top ball knuckle pin to a torque of 15 daNm Check the preload value of the ball knuckle bearings measured as rolling torque with a torquem eter Rolling torque should be between 5 and 8 daNm T08 Accessory for torquemeter If necessary remove and change the number ofshims 8 Mount the lubncators on the top and bottom ball knuckle pins 5 Tighten them to a torque of 1 5 daNm 30 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 3 PLANET GEAR HOLDER HUB 4 3 1 DISASSEMBLY Remove the two screws securing the planet gear holder support subunit to the hub separate the planet gear holder support subunit and lay it on a flat surface Take the Seeger ring 4 off with a pair of pliers 31 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES P Remove the three planet gears 5 with an extractor and separate the needle bearing 3 Check the state of wear of the parts replacing them if necessary lf the axle shaft stopper is damaged replace the whole planet gear holder 1 and 2 32 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 3 2 ASSEMBLY Punch mark the axle shaft stopper 2 in 3 points on the planet gear holder 1 Mount the needle bearing 3 on the planet gear 5 with the special tool T09 Check correct mounting of the needle bearing 3 on the planet ge2. Put the correct number of shims 4 under the internal bearing cap 3 Attention this is fundamental to ensure correct operation of the bevel gear 62 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Put the internal bearing cap 3 in place Put the external bearing cap 6 in place Put the two caps in place with the relative tool 116 The caps can be dnven in with a hammer and dnver but be sure they are both positioned correctly Drive the bearing 3 on the pinion with the tool 117 Insert the collapsible spacer 5 which has to be replaced each time any work is done on the pinion unit 63 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Na S 2 Put the pinion 2 in the central box 1 After having seen to preparnng an adequate support for the pinion drive in the other bearing 6 with the driver T17 Insert the washer 7 in the correct phase with respect to the seat on the pinion Tighten the ring nut 8 with some Loctite 270 and keep the pinion blocked and perfectly still until a rolling torque of 4 to 7 daNcm is reached Measuring the rolling torque with a torqguemeter 118 Accessory for torquemeter 64 66 13 USE AND MAINTENANCE MANUAL SERIES 128 AXLES With a punch driver caulk the nng nut 8 in place on the pinion taking care not to break the edge of the ring nut 65 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES
3. due to their nature when assembling have to be replaced with others in perfect condition gaskets seals wom bearings screws with worn thread ASSEMBLY More than 90 of the bearings break due to dirt which is always abrasive Dirt can get inside the transmission during assembly or be transported by the lubricant dunng operation Dirt can also get inside by way of the seals outlet plugs or even by means of the containers for filling up and changing the oil Prior to assembly each piece must be cleaned thoroughly and those parts that require it oiled The components that need oiling must be lubricated with new oil before being assembled NOTE When reassembling it is essential to replace all the seals Take care NOT to pinch the oil retainers during assembly 9 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES SPECIAL TOOLS Wheel hub tapered roller bearing cup driver Wheel hub cassette seal driver Bearing on wheel spindle driver Accessory for wheel hub bearing rolling torquemeter Wheel driver gear on stud bolts driver 4 2 2 Knuckle housing bush driver 4 2 2 Ss Knuckle housing sealing rings driver TO1 T02 103 T04 TO TO6 TO7 T08 4 2 2 Accessory for knuckle housing bearing rolling torquemeter TO9 2 2 2 2 2 2 3 2 4 2 4 2 4 2 4 2 5 2 5 2 1 2 1 2 1 2 Driver for the needle unit in the planet gear T10 Spring bushing driver T11 Piston insertion driver T12 Piston insertion driver FES Brake assemb
4. holder gear subunit 14 18 19 from the knuckle housing NOTE if the axle is rigid the subunit is installed directly on the lateral beam Retrieve the shims 20 19 66 18 19 20 21 22 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the spring ring 14 retaining the gear holder with the aid of a screwdriver Separate the gear holder 18 from the gear 19 Remove the wheel hub subunit 10 114 12 13 from the knuckle housing 4 with an extractor Separate the hub subunit and retrieve the external bearing 13 Use an extractor to remove the intemal bearing 11 from the knuckle housing 20 66 23 24 25 USE AND MAINTENANCE MANUAL SERIES 128 AXLES mmm Remove the 2 sealing rings 2 from the knuckle housing 4 with a screwdriver Remove the bushing 8 from the knuckle housing 4 with a screwdriver Note Both the sealing rings 2 and bushing 3 must always be replaced Remove the internal and external bearing cups 11 and 13 from the wheel hub 12 with a screwdriver Remove the sealing ring 10 with a screwdriver Note The sealing ring must always be replaced 21 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 2 2 ASSEMBLY Drive in the cup of the external tapered roller bearing 13 on the wheel hub 12 with the special tool T01 Drive in the cup of the internal tapered roller bearing 11 on the wheel hub 12 with t
5. negative brake and before proceeding with the next operations power the negative brake circuit with a pressure of at least 15 bar no more than 30 bar and then with a rubber headed hammer move the positive brake piston 13 back into its initial position against the inner surface 43 66 18 19 20 USE AND MAINTENANCE MANUAL SERIES 128 AXLES seeing as when the securing screws of the brake unit were tightened it was pushed towards the outside by the springs 20 and 21 Alternatively axle assembly can De completed but in this case before installation on the vehicle it will be necessary to proceed as explained in paragraph 4 4 3 but this time tightening the screws right down Put the O ring in its place obtained in the brake unit housing Insert a brake disk 5 in the lateral beam 1 Then insert the steel counter disk 6 Insert the bush 4 as shown in the figure 44 66 21 22 23 24 25 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Insert the second brake disk 5 followed by the second steel counter disk 6 and lastly the third brake disk 5 Pay attention to the brake disks they must be put so the passage holes match Insert the 2 springs 3 in the two blind holes in the housing 1 Position the last counter disk 6 Either using the tool 113 or keeping the counter disk pressed put the spring ring 7 in its place in the housing 1 Check
6. to a torque of 20 daNm with Loctite 270 and repeat but measuring the angle when steering in the opposite direction 15 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 2 KNUCKLE AND WHEEL HUB 4 2 1 DISASSEMBLY ATTENTION fasten the steering wheel reduction assembly to a suitable support Remove the securing screws 7 and extract the bottom knuckle pin 6 Remove the lubricator 5 16 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the secunng screws 7 of the top knuckle pin Extract the top knuckle pin 6 and the shims 8 Retrieve the shims 8 Retrieve the bearing 6 Separate the steering wheel reduction assembly with double joint from the lateral beam 17 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the two screws 29 securnng the planet gear supporting subunit to the hub separate the hub planet gear holder Subunit 26 from the knuckle unit ATTENTION do not let the drive fall Support it with a rope if necessary Retrieve the O ring 25 from the hub Remove the seeger ring 24 Remove the washer 23 lt di KX wees WW i d It j f Fi 18 66 13 14 16 17 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Pull the double joint 1 out from the knuckle 4 Remove the eight nuts 21 from the Stud bolts 9 Remove the closing ring 22 Use two levers to separate the gear
7. 13 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Position the cone of the tie rod 8 in its place on the knuckle Tighten the nut 4 to a torque of 28 daNm Check toe in toe out of the steering system by installing a bar on each nm plane Measure the distance between the two bars at the front steering cylinder side and at the back drive shaft side of the axle ATTENTION the difference between the 2 measurements must not exceed 1 mm Turn the steering tie rod as illustrated in the figure to achieve bar parallelism with one wrench hold the cylinder piston rod perfectly still while with the other wrench tighten loosen the internal thread of the steering tie rod Once parallel tighten the check nut of the steenng tie rode internal thread to a torque of 15 daNm and check adjustment of the end of travel screws on the knuckle housing 14 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES lf a knuckle housing has to be replaced steer the wheels until one of the housing s two stops already adjusted reaches the end of travel Unscrew the stop on the replaced housing until it comes into contact and then tighten the check nut to a torque of 20 daNm using some Loctite 270 Repeat this steering in the opposite direction If both knuckle housings are replaced measure the steering angle and then move the two stops until they come into contact right wheel and left wheel tighten the check nut
8. 3 Extremely intense use fill up to the right level and bearings Change in colour 4 Normal wear change it at the intervals 5 No longer adjusted recommended correctly Adjust them correctly 6 Excessive overheating seals and gaskets 1 Prolonged operation with Replace the seal and Oil leaks from seals and excessive oil temperature coupling surfaces if gaskets 2 Oil seal fitted in a wrong damaged way Use the correct lubricant 3 Edge of the seal is cutor fill up to the right level and Beam corroded change it at the intervals 4 Lubricant is dirty recommended Shaft Extremely intense use oi Replace the shaft Shaft deformed or fracture the vehicle overloaded split Noise 1 Too much clearance between the gear and Noise when dnvng pinion 2 Pinion and gear are wom 3 The pinion beanngs are Adjust Replace Replace Adjust Replace Adjust Replace clearance Top up 5 Differential bearings are Replace worn 10 Replace 6 Differential bearings with 11 Replace clearance 12 Replace 7 Gear notin position 13 Replace 8 Lubricant level low worn 4 Pinion bearings with OND AW N Errore L orig ine rif erimento non stata trovata 7 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 9 Wrong lubricant 10 Shaft is bent 11 Cardan shaft with too much clearance on the Spider 12 Wheel hub bearings worn 13 Wheel unit gears are excessively worn or damaged Nois
9. 5 TESTING AND FINAL INSTRUCTIONS 5 1 TESTINGS Block the input pinion If the axle is installed on the vehicle put it in gear With the helo of another person standing on the other side test correct assembly by turning both wheels as much as possible moving forwards Both wheels should block shortly after With the pinion still blocked release the right wheel and tum the left wheel moving forwards If assembly is correct the left wneel should be turning freely without any effort and the right wheel should be turning also freely in the opposite direction reverse Repeat in the opposite direction IF ONE OF THE WHEELS IS NOT TURNING FREELY check complete assembly of the axle again 5 2 FINAL INSTRUCTIONS Check correct filling up of the lubricating oil in the transmission See paragraph 2 1 Bleed the air from the circuit that feeds the oil bath disk brakes 66 66
10. ANCE MANUAL SERIES 128 AXLES Tighten the screws 8 at a torque of 25 daNm 59 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 7 CENTRAL BOX AND BEVEL PINION 4 7 1 DISASSEMBLY Remove the caulked ring nut 8 Remove the anti rotation washer 7 Remove the tapered roller bearing 6 knocking on the ends of the pinion with a rubber headed hammer 60 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Eh i Retrieve the bevel pinion 2 and Ce E remove the collapsible spacer 5 Ki emm ATTENTION the collapsible spacer must necessarily be replaced Remove the under head tapered roller bearing 3 from the pinion Remove the cup of the pinion under head tapered roller bearing 3 Retrieve the bevel gear set adjustment shims 4 Remove the cup of the external tapered roller bearing 6 61 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 7 2 ASSEMBLY Read measurement AT printed on the head of the bevel pinion 2 To find the nght number of shims to set adjust the bevel gear find measurement A from the centre of the housing to its edge and the height between the two surfaces of the bearing 3 All you need then do is subtract the height of the bearing and the measurement printed on the pinion from measurement A and the result is the height you have to have with the shims d V eg ES E lakia BA BS ek
11. Il oil for the braking system Grease We recommend using Shell Retinax HDX2 grease The maintenance intervals mentioned are for a nomal use of the vehicle intervals should be shorter if the vehicle is used for particularly hard work Job Firstintervention Routine maintenance Changing axle oil 200 hours seasonal every 1000 hours 1 Cleaning the magnetic oil drainage plug at the first oil change at every oil change Checking and topping up the oil 100 hours monthly every 300 hours 1 Cleaning the oil breather 400 hours monthly every 300hours 1 Greasing where envisaged 200 hours 2 weekly every 200 hours 1 2 1 which of the two conditions occurs first 2 50 hours in the case of hard work Errore L orig ine rif erimento non stata trovata 4 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES a e Fy de d LE amp Wheel hub draining filling level plug 2 AR Ei Axle oil filling and breathing plug Axle oil drainage plugs Changing the oil Check the position of the plugs and their function on the axle s dimensional drawing Make sure the vehicle is on a flat surface position the collection trays appropriately and then unscrew the oil drainage plugs Wait for all the oil to drain from the axle Filling the rigid axle The various chambers of the axle are joined together and it is the axle level plug that defines the correct oil level Pour the oil in through the fil
12. USE AND MAINTENANCE MANUAL SERIES 128 AXLES CONTENTS 1 PRELIMINARIES ccscsccccsesssesseessesseessesssessessesseeseeen 2 ES INPRO OG TON EE 2 t2 ID PEATE EE 2 E AFETA NOTE Sana N AE 3 2 PROGRAMMED MANTENANCE 4 2 1 OIL CHANGE AND PERIODIC AL CGONTROU a 4 3 TROUBLESHOOTING o sccsscssscsseessesssesseeseesseeseeeseeeee 6 Sle ROW BEES HOO UN Giibsces ee ee 6 4 EXTRAORDINARY JOBS 9 4 STEERING EISEN Eeer 11 4kali DDASS a eeh 11 AAAs POOP WIDELY EE 13 4 2 KNUCKLE AND WHEEL HUR cccccsceeeeeessseeeeeeesssneeeeeeessseeeeeeeesseeneeees 16 Aes DISASSEMBLE EE 16 ee NS VIE ie EE 22 4 02 PANE T GEAR OLDER EE 31 Ade JDISASSEIMIB US EE 31 EN 2S eal tp EE 33 AA OU BATH DISK BRAKES eege EE EEEER 35 4 4 1 DISASSEMBLY EEN 35 AA AOSE MBEN EE 40 4 4 3 MECHANICALLY DISENGAGING THE NEGATIVE BRAKE 46 ADe EAR E EE 47 4o DIS ASSES EEN 47 E AoE MBEN EE 50 4 6 STANDARD AND LSD DIFFERENTIAL HONG 55 Rn DDASS VOL EE 55 A2 ASF E a EE 57 4 7 CENTRAL BOX AND BEVEL PINION naaoosnnanonnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnenennnnennnnnnn 60 Ge a ALONSO MBL EE 60 Al 2s AOSEMBEYV EE 62 5 TESTING AND FINAL INSTRUCTIONS 00 00000 66 S TESHNGS EE 66 52 FINAL JEE 66 1 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 1 PRELIMINARIES 1 1 INTRODUCTION This manual contains information necessary for carrying out extraordinary maintenance on the differential axle if ever rep
13. airs are required of malfunctions connected to it By always following the instructions given in this manual the number of hours required for disassembly and assembly will be far less and the risk of incorrect maintenance work minimised The certainty of a repair job well done is entrusted to people who do this work It is therefore important that the people assigned to such work receive detailed information about restonng the correct conditions that guarantee operation of the differential axle limited to the purposes for which it has been designed This handbook intends explaining to those who actually carry out the extraordinary maintenance work on the product which are the critena to follow to attain the final result re establish and guarantee functionality of the differential axle over time Hence this manual must be read by persons authonsed to make repairs before they start any such work in order to guarantee the best result 7 2 ID PLATE Axle identification plate SERIAL NO Errore L orig ine rif erimento non stata trovata 2 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 1 3 SAFETY NOTES The observance and respect of all existing safety requirements and laws are absolutely essential to protect people from injury and safeguard the product and environment from damage The repair technicians must have specific skills and expertise to repair these differential axles or similar ones Without such knowledge speci
14. ar 5 with a depth gauge The depth measured in the figure must be equal to 6 0 5 mm 33 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Position the planet gear 6 with preassembled needle bearing on the pin of the planet gearholder 1 taking care to position itin the direction shown in the figure The rounded end of the needle bearing 3 is to go at the bottom Drive in the planet gear with needle bearing 5 3 on the planet gear holder pin 1 with the special tool T09 Fit the retaining Seeger ring 4 on the pin To make doubly sure that mounting is correct check that the surface of the planet gear and the machined surface of the pin are the same height 34 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 4 OIL BATH DISK BRAKES 4 4 1 DISASSEMBLY Once the housing has been removed from the centre of the axle see paragraph 4 5 1 Removing the brake components from Remove the spring ring 7 paying attention to the counter steel disk which is pushed towards the outside by the 2 Springs 3 Remove the first counter disk 6 Attention if the brake disk package does not have to be replaced we Suggest numbernng the position of the counter disks and disks to ensure they are put back in the same position Retrieve the 2 springs 3 35 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the first brake disk 5 the following counter disk 6 and the s
15. ate the lateral beam 5 from the central unit ATTENTION do not let the flange 8 fall that is supporting the differential unit lf the axle has brakes see 4 4 1 Remove the o ring 7 47 66 USE AND MAINTENANCE MANUAL SERIES S128 AXLES Remove the flange 8 R EE k a T D eases V gt KW e Remove the bearing cap 15 Attention if the axle has brakes then this and the next 2 operations are to be done inside the brake unit Retrieve the shims 13 Take the Seeger ring 12 out of its place Retrieve the felt rings 3 48 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Use the extractor to remove the spherical cap 4 from the housing Remove the two oil retaining rings 1 with a screwdhiver n Remove the bush 2 with a screwdriver 49 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 5 2 ASSEMBLY lf the axle is rigid go to phase 4 Drive the bushing 2 with the special tool T06 into the housings 5 Drive 2 sealing rings 1 into the housing 5 with the special tool T07 Grease the oil retainers with Polymer 400 50 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Drive in the spherical cap 4 with the tool 114 Put the Seeger ring 12 in its place Insert the shims 13 Roughly the same number of shims that were there when disassembling must be put back It will later be checked to see if the
16. correct opening of the spring ring The open part of the ring must coincide with the threaded oil drainage hole Mount the housing on the central part see paragraph 4 5 2 45 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 4 3 MECHANICALLY DISENGAGING THE NEGATIVE BRAKE lf there is a failure with the vehicle and it needs to be towed the negative brake where foreseen will need to be mechanically disengaged Attention When mechanically disengaging the negative brake the service brake will be unusable therefore the vehicle must be kept still and safe using suitable methods ropes wedges etc Completely undo the 2 screws 1 on the beam 3 remove the spacer 2 and then retighten the screws 1 on the beam 3 Attention the screws must be tightened alternately turning them 45 at a time do not tighten completely one screw and then the next It is unnecessary to tighten the screws completely stop as soon as the brake is disengaged Proceed in the reverse order to re engage the negative brake 46 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 5 LATERAL BEAM 4 5 1 DISASSEMBLY Put the axle on supports able to withstand the weight of the central body and the two lateral beams even after they have been separated or anchor the three units individually with ropes or belts to a lifting system Undo the screws 11 of the beam and retrieve the washers Separ
17. crease or reduce torque clearance increase or reduce the number of shims to increase or reduce the rolling torque This does mean of course that the lateral beams will have to be disassembled and re assembled if the axle has no brakes If the axle does have brakes simply remove the Seeger 12 leaving the brake units in place Check the goodness of the contacts between the bevel gear teeth disassembling and reassembling the lateral beam on the gear side completely and extracting the differential housing assembly An incorrect contact can give problems of noise and duration of the bevel gear 53 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES CONTATTO OTTIMALE CONTATTOALTO CONTATTO BASSO Use the pinion shims to correct contact a Ba a position bringing clearance back to the E E ie Pe me established values 54 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 6 STANDARD AND LSD DIFFERENTIAL HOUSING 4 6 1 DISASSEMBLY a 3A ZC S WW e 3 1 Remove the two tapered roller bearings 1 from the half housings 10 and 11 using an extractor Retrieve the shims 2 from both sides of the differential housing Undo the securing screws 8 of the bevel crown 9 from the differential housing and separate the crown gear Separate the differential half housings 10 and 11 55 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the planet gears 6 and relative sph
18. e 1 Noise coming from the 1 Adjust or replace see axle above Noise when idling with the vehicle moving are 2 Adjust usually heard when idling 3 Replace even if not very loud 2 Incorrect clearance between pinion and gear the noise heard when decelerating disappears as Speed increases 3 Pinion or inlet flange s grooved coupling is worn Noise 1 Gear damaged 1 Replace the gear 2 The screws closing the 2 Tighten to torque Intermittent noise differential unit housing are loose Noise 1 Differential planet gears 1 Replace worn 2 Replace Noise on a curve 2 Differential housing 3 Replace and or differential pins wom 4 Replace 3 Differential washers worn 4 Grooving on the shaft worn Errore L orig ine rif erimento non stata trovata 8 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 EXTRAORDINARY JOBS DISASSEMBLY Before carrying out any maintenance work the outside of the transmission must be cleaned with a jet of steam Seal all openings before doing this so that water and dirt cannot get inside and damage the fundamental parts To disassemble the axle parts the axle itself has to be taken off the vehicle first This also entails removing the wheels and the hydraulic pipes from the braking circuit as well as draining the oil from the differential and hubs removing the plugs When disassembly is finished carefully remove the dirt from each single piece throwing away all those parts that
19. e gear clearance tooth Bevel gear Pinion and gear teeth are worn or scored Bevel gear Pinion and gear teeth overheated See if altered Bevel gear Pitting of pinion teeth Bevel gear Breakage due to fatigue of the pinion tooth check for characteristic fracture lines Bevel gear Sudden breakage of the pinion and gear teeth Differential unit Extremely intense use Differential planet gear Errore L orig ine rif erimento non stata trovata the 2 Wrong lubricant colour of the gear teeth has 3 Low oil level 3 Pinion ring nut has come loose 1 Insufficient lubrication 2 Lubricant is dirty 3 Wrong lubricant or with impoverished additives 4 Pinion beanngs are wor causing incorrect axial clearance of the pinion and contact between pinion and gear 1 Prolonged operation at excessive temperatures 4 Lubricant is dirty 1 Extremely intense use 2 Insufficient lubrication 1 Excessive use 2 Continuous overload Impact load of the differentials components Replace the bevel gear Follow the steps carefully that are recommended for adjusting gear tooth and pinion clearance and for detecting tooth impression Replace the bevel gear Replace the pinion s bearings making sure the gear pinion and bearing preloads are arranged correctly Use the correct lubncant fill up to the right level and change it at the intervals recommended Replace the bevel gea
20. econd brake disk 5 in this order Remove the bushing 4 Remove the steel counter disk 6 Remove the last brake disk 5 Disassembling the brake unit Remove the screws 25 securing the brake housing 16 to the central box 24 36 66 10 11 12 13 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the brake housing 16 with al the preassembled components inside it from the central box 24 Remove the spring holder ring 22 with all the springs 20 and 21 There are two springs for each hole and can be extracted one ata time Retrieve the O ring 23 from its place in the central box The negative brake piston 19 can be extracted with compressed air Take the O ring 17 off 37 66 14 15 16 17 18 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Take the O ring 18 off Unscrew the nuts 8 Retrieve the washers 9 and spacers 11 Push the piston 13 from the side opposite the brake housing 16 to remove it Take the two O rings 14 and 15 out 38 66 20 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Unscrew the stud bolts 12 Use a punch driver to take the spring bushes 10 out of the piston 13 39 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 4 2 ASSEMBLY Assembling the brake unit Drive with tool T10 the spring bushes 10 in the piston 13 inserting them from the round
21. ed part and pushing them night down to the opposite surface of the flange The surface of the rounded part of the bush must be the same height as the piston surface Mount the stud bolts 12 with some Loctite 270 tightening them to a torque of 1 5 daNm 40 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES H Put the oiled O ring 14 in its place Put the oiled O ring 15 in its place Position the piston 13 in the correct phase determined by the stud bolts and by the two projecting parts of the piston Put the piston 13 in its place taking care not to damage the Orings 111 Driver Put the spacers 11 in place 41 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Fit the washers 9 Put the self locking nuts 8 in and tighten them to a torque of 1 2 daNm Put the adequately oiled O ring 18 in place Put the adequately oiled O ring 17 in place With the appropnate driver T12 put the piston 19 in its place taking care not to damage the Orings 42 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Put the spring holder ring 22 in its place obtained in the central box 24 Put the O ring 23 in its place obtained in the central box Put the springs 20 and 21 in each hole of the flange 22 Drive the pins 26 into the central box Position the brake unit on the central box and tighten the screws 25 to a torque of 4 5 daNm In the presence of a
22. erical washers 5 separating them from the spider 7 Retrieve the friction disk pack 3 of the Limited Slip device from the planet gear 4 Check wear status and if necessary replace the disk pack NOTE keep the disk pack in the right sequence to ensure correct assembly see figure In versions with the STANDARD differential there is a washer on the planet gear 4 instead of the friction disk pack 56 66 2b USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 6 2 ASSEMBLY Pe 10 3 tt SC P Pre assemble the planet gears 6 with their sphencal washers 5 on the Spider 7 Mount the friction disk pack 3 on the planet gears 4 NOTE Observe the sequence of the disks illustrated in the figure In versions with the STANDARD differential the washer must be used instead of the friction disk pack 57 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Install the planet gears 4 in the half housings 10 and 11 Position the pre assembled spider in the differential half housing 10 identified by its threaded holes Couple the half housing 11 to the half housing 10 observing the matching as indicated in the figure Refer to the matching of the two numbers printed on the 2 half housings Mount the bevel crown 9 on the pre assembled differential unit tightening the screws 8 Apply some Loctite 270 on the threads 58 66 USE AND MAINTEN
23. fic training courses must be organised and held by authorised personnel Repair work must only be done after having read and completely understood all what is written in the instruction Manual as regards to repairs Before doing any work on the axles still mounted the vehicle must be made safe Park the vehicle on a flat solid surface Put the work equipment on the ground Engage the parking brake Turn the engine off Take the key out of the ignition Lock the wheels of the vehicle with a wedge Scrupulously observe the indications given on the waming and indication plates that are on the vehicle All auxiliary means and tools must be in perfect condition for use and absolutely safe Errore L orig ine rif erimento non stata trovata 3 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 2 PROGRAMMED MAINTENANCE 2 1 OIL CHANGE AND PERIODICAL CONTROLS Lubricants SAE 85W90 API GL4 with additives for oil bath brakes Examples of usable oils Mobil Super Universal 20W40 Mobil Fluid 422 ELF SF8 AGIP MULTI THT 80W For axles with self locking differential SAE 85W90 API GL5 with additives for oil bath brakes and additives for self locking differential LS Limited Slip Examples of usable oils SHELL SPIRAX HD 85W90 FUCHS TITAN GEAR 85W90 LS CASTROL LSC SAE 90 ELF SF3 In both cases we recommend Shell Donax TD Brake oil Use only Agip ATF Il D mineral oil or altematively ATF Dexron
24. he special tool T01 Fit the cassette seal 10 on the wheel hub 12 with the special tool T02 22 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Drive in the internal tapered roller bearing 11 on the spindle of the Knuckle housing 4 with the appropriate tool T03 Attention if the axle is rigid the operations are to be done from this stage up to point 4 22 on the rigid housing spindle and not on the knuckle housing Mount the preassembled hub subunit on the knuckle housing 4 taking care not to damage the sealing ring 10 Drive in the external tapered roller bearing 13 on the spindle of the Knuckle housing 4 with the appropriate tool T03 With the aid of a rubber headed hammer arrange and adjust the wheel hub bearings to eliminate the preload Use a torquemeter to check drive torque due to just the oil retaining rng 10 T04 Accessory for torquemeter 23 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Place the shims 20 on the gear holder 18 Mount the gear holder with shims on the preassembled knuckle housing Position the closing ring 22 TEMPORARILY tighten eight M12 x 1 25x35 screws to a torque of 10 daNm Attention do not use any LOCTITE Once the bearings have been adjusted again on the hub check the preload value measured as rolling torque with a torquemeter Accessory 104 The rolling torque of only the bearings without the oil retaini
25. l T06 Fit the 2 sealing rings 2 on the knuckle housing 4 using the special Tool T07 Apply some Polymer 400 grease Insert the double cardan joint 1 in the knuckle housing 4 being careful not to damage the sealing rings 2 Fit the washer 23 Fit the Seeger ring 24 27 66 28 29 30 31 32 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Put the O Ring 25 in its place on the hub 12 Position the preassembled satellite gear holder hub subunit 26 on the hub matching the holes with those of the securing screws 29 on the wheel hub Tighten the two securing screws 29 to a torque of 4 5 daNm Fit the oil filling up draining plug 28 with washer 27 tightening to a torque of 5 daNm With the aid of asuitable support insert the knuckle subunit complete with double cardan joint in the housing making sure that the grooving on the differential side of the double cardan joint fits into place correctly in the differential gear WARNING RELEASE THE NEGATIVE BRAKE IF THERE IS ONE 28 66 33 35 36 37 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Fit the ball bearing 6 on the knuckle pin 6 Position the shims 8 on the top ball knuckle pin 6 Mount the top ball knuckle pin 6 on the housing partially tightening the screws 7 Mount the bottom ball knuckle pin 6 Tighten the screws 7 to a torque of 15 daNm 29 66 38
26. ling plugs until it starts coming out of the level plug keep the holes on the hubs open located above the centre line to help the air flow Filling the steering axle The chambers of the steering units are separate from the axle chambers Pour the oil in through the filling up plug located centrally until the level defined by the level plug is reached There is just one plug on the steenng unit that has the function of draining level or filling up depending on the position itis in When it is in the lowest position it acts as the drainage plug when it is on the centre position it acts as the filling up and level plug Caution oil takes time to distribute so you have to wait a few minutes and then add some more oil continue like this until the level stops going down Errore L orig ine rif erimento non stata trovata 5 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 3 TROUBLESHOOTING 3 1 TROUBLESHOOTING PROBLEM CAUSE ACTIONS Replace the bevel gear Follow the steps carefully that are recommended for adjusting gear tooth and pinion clearance and for detecting tooth impression Bevel gear Breakage towards the external end of the gear tooth Bevel gear Breakage towards 1 Gear load is much greater than expected 2 Incorrect gear adjustment too much clearance 3 Pinion ring nut has come loose 1 Knocked bythe load 2 Incorrect gear the adjustment too little internal end of th
27. ly equipment T14 Ball bearing driver T15 Differential beanng cups driver T16 Pinion bearing cups driver equipment T17 Pinion beanng driver T18 Accessory for torquemeter to check pinion torque Note The special tools can be purchased directly from Comer Industries or a drawing can be furnished at the Customer s request 10 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 1 STEERING COMPONENTS 4 1 1 DISASSEMBLY Remove the nut 4 Separate the steering tie rod 3 from the knuckle Unscrew the steering tie rod 8 from the steering cylinder piston rod 1 11 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Remove the securing screws 2 of the Steering cylinder 1 to the central housing and retrieve it 12 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES 4 1 2 ASSEMBLY Before starting to install the steering cylinder 1 on the central housing check that the cylinder piston rod is centred in relation to the mid plane making sure that the piston rod projects equally on both sides lf necessary centre the piston rod by knocking on the end with a hammer Place the steering cylinder 1 on the central housing using the securing Screws 2 Tighten the screws with a torque wrench to a torque of 15 daNm screw the tie rod 3 on to the steering cylinder piston rod 1 with a square head wrench T01 using some Loctite 243 Tighten the tie rod to a torque of 15 daNm
28. ng ring should be between 125 and 155 daNcm If necessary remove the gear holder and change the number ofshims 20 24 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES When the correct preload is reached remove the eight temporary screws the closing ring 22 the gear holder 18 and retrieve the shims 20 Mount the gear holder 18 on the gear 19 Fit the spring ring 14 retaining the gear holder Position the number of shims 20 checked previously on the gear holder 18 Tighten the stud bolts 9 on the knuckle housing 4 using some Loctite 270 Tighten to a torque of 6 daNm Mount the preassembled gear subunit gear holder and shims on the knuckle housing with the appropnate driver TO5 25 66 20 21 22 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Position the closing ring 22 Tighten the nuts 21 on the stud bolts 9 using some Loctite 243 Tighten the nuts 21 to a torque of 10 daNm Screw the pin stud bolts 15 on the hub 12 using some Loctite 270 Tighten to a torque of 20 daNm Note If the axle is rigid simply insert the axle shaft releasing the negative brake if there is one and then go Straight to phase 4 2 2 28 up to 4 2 2 31 26 66 23 24 25 26 27 USE AND MAINTENANCE MANUAL SERIES 128 AXLES a Turn the preassembled knuckle housing subunit upside down and put the bushing 8 in place with the Specific too
29. number is correct Drive in the bearing cap 15 with the tool T15 51 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES Brush some of the gear and pinion teeth with a marking product i e ink to later verify perfect contact of the bevel gear teeth Put the flange 8 in its place Note If itis the flange on the differential gear side you will first need to put the differential unit inside the central box Put the O rings 7 and pins 14 in place in the central box Arrange the housing 5 on the central box turning the flange 8 underneath if necessary depending on the position of the hollow in the housing Tighten the screws 11 with their washers to a torque of 15 daNm 52 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES ADJUSTING ADJUSTING ADJUSTING The number of shims 13 for adjusting the tapered roller bearings 15 must be such to have aclearance of 0 15 to 0 30 mm between the teeth of the bevel gear and bearing 14 pre load measured as an INCREASE of the rolling torque in input to the pinion must be as given in the following table rolling torque INCREASE ratio measured on the pinion with a C C torquemeter daNcm 9 37 oo 12 39 4 7 14 38 4 8 17 38 5 10 Measure the clearance between gear and bevel pinion Measure the rolling torque with a torquemeter Move some of the shims 13 from the bearing on the right to the bearing on the left to either in
30. r Use the correct lubncant fill up to the right level and change it at the intervals recommended Replace the bevel gear Use the correct lubncant fill up to the right level and change it at the intervals recommended Replace the bevel gear Check and or replace other differential components the differential Replace unit Replace the shaft if 6 66 USE AND MAINTENANCE MANUAL SERIES 128 AXLES grooving wom too much necessary clearance Differential unit 1 Insufficient lubrication Replace all the washers Surfaces of the washers of 2 Wrong lubrication marked and those that are the differential gears are 3 Lubricant is dirty 0 1 mm thinner than the worn or marked new ones Use the correct lubncant fill up to the right level and change it at the intervals recommended Pinion unit 1 Extremely intense use Replace the flange Inlet flange s grooved 2 Pinion ring nutor flange Check that the grooving of coupling is worn locking screw has come the pinion is not loose excessively worn 3 Pinion axial clearance Replace the bevel gear if necessary 1 Vehicle overloaded Replace the axles lateral 2 Vehicle involved in an beam and any other The axle s lateral beam is accident damaged components damaged 3 Knocked by the load Bearings 1 Insufficient lubrication Replace the bearings 2 Lubricant is dirty Use the correct lubrncant Wear and pitting of the
Download Pdf Manuals
Related Search