Service Manual S068_rev1.0_eng
Contents
1. SPECIAL TOOLS Ref Code Chapter Description TO 1970 7404 4 1 Square head wrench for tightening the steering tie rod TO2 072 394 01 4 2 External half knuckle sealing ring 55x75x10 driver T03 072 159 4 2 External half knuckle ball bearing 6010 driver T04 3501000050 4 3 M50 hub ring nut commercial wrench head TO5 072 087 08 4 3 Hub external tapered roller bearing cup 32010 driver TOG 072 087 06 4 3 Hub interal tapered roller bearing cup 32012 driver TO7 072 087 05 4 3 Hub sealing ring 145x170x13 driver T08 072 128 4 4 Shaft bushing 35 39 30 driver in the lateral steering housing T09 072 038 4 4 Shaft sealing ring 35x47x7 driver in the lateral steering housing 110 072 040 44 Knuckle pins bushing 35 39 20 driver in the lateral steering housing Differential housing tapered roller bearing cups T11 072 280 4 4 32012 driver T12 3501000030 4 6 4 7 M30 pinion ring nut commercial wrench head T13 072 179 4 6 4 8 Top gearbox body ball bearing 6012 driver Pinion with 1 speed gearbox external tapered roller i CONS oe bearing cup 82210 driver y Pinion with 1 speed gearbox internal tapered roller 1 Oar TBDE Po bearing cup 30308 driver Pinion with drum brake external and internal tapered me Creat E roller bearing cup 32207 driver T17 072 252 4 7 Pinion with drum brake sealing ring 50x72x8 driver T18 072 223 4 8 1 speed gearbox sealing ring 95x120x12 driver N2. e comer industries SERVICE MANUAL STEERING AND RIGID DRIVE AXLES SERIES Date Revision Description Owner 06 10 09 1 0 Document emission PM COMER INDUSTRIES Axles amp Wheel Drive Units Via Magellano 37 42046 Reggiolo RE Italy Tel 39 0522 97411 Fax 39 0522 211601 USER AND MAINTENANCE MANUAL SERIES S068 AXLES TABLE OF CONTENTS ie PRELIMINARIES sapida reisir Ei RA 2 dite INTRODUC TION tl NIE 2 A G ac a gene ree ee R eee ren rer A ree rare 2 1 3 SAFETY NOTES iaiicte ce aka aaa ete ne cai etree dea aos ome teste 3 2 PROGRAMMED MAINTENANCE 4 2 1 OIL CHANGE AND PERIODICAL CONTROLS coccccccccnnnnnnnnncnnnnncconannnnnnnncnnnnncnos 4 3 TROUBLESHOOTING n 5 Sale TROUBLESHOOTING scraps 5 4 EXTRAORDINARY JOBS csssesssessecseeseeeseeseeeseesses 8 4 1 STEERING COMPONENTS lt a ak arate a teen eet romana 10 Ad B Ei ce pe ot WG enc ae REPEC E ee E CE Ee 10 4 12 I A Aah AS SIS ha a SSG ta A le 11 4 2 KNUCKLE AND CARDAN JOINT WITH BRAKEG eeeeeeeeeeeeeeeeeteees 14 2 DISASSENBENG aaa ee le eka ce tel aan ete ae 14 4 2 2i A A AA E Renee ahead 17 4 3 WHEEL REDUCTION ASSEMBLY WITH SERVICE BRAKEG 000 22 4 3 1 O A E 22 432a ASSEMBLY ae ee eo ee es ery ee ne rey eee ee ey eee ae 26 4 4 LATERAL DEAN odds tel ee 32 4 4 1 IDISASSENBE A eta eae eRe he Eke tts es 32 44 2 SPN BY ae a aar Ee AAAren AS venue Geeta vee 35 4 5 STANDAR
3. 23 Remove the guide stud bolts and tighten the screws 6 23 Tighten the screws 6 at 15 daNm EXTRAORDINARY JOBS 53 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 7 BEVEL PINION WITH KNOTT BRAKE 160x40 4 7 1 DISASSEMBLY et 20 19 17 EXTRAORDINARY JOBS Unscrew the ring nut 16 from the bevel pinion 2 with the commercial tool T12 Remove the axial washer 15 from the bevel pinion 2 Separate the flange with drum 12 from the bevel pinion 2 helping with a lever 54 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Remove the 2 brake shoes 20 with the 2 contrast springs 21 from the pin seat 19 and from the brake lever 24 The minimum residual thickness of the friction material must be no less than 1 0 mm in the thinnest point If necessary replace the shoes 20 Remove the Seeger ring 26 recover the shim ring 25 and pull the brake lever 24 out of the pin 17 Unscrew the pin 17 from the pinion housing 5 and recover the shim ring 23 Unscrew the pin 19 from the pinion housing 5 55 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Undo the securing screws 6 of the pinion assembly from the central housing Separate the pinion assembly from the differential axle s central housing using a hammer Recover the bevel gears set adjustment paper shims 1 Remove the seali
4. 19 onto the pinion housing 2 and tighten to a torque of 20 daNm Apply Loctite 270 24 Screw the brake lever s pin 17 onto the pinion housing 2 and tighten to torque 25 Position the shim ring 23 on the brake lever s pin 17 26 Position the brake lever 24 and shim ring 25 on the relative pin 17 EXTRAORDINARY JOBS 63 71 27 28 29 30 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Fit the brake lever s Seeger stop ring 26 on the pin 17 Pre assemble the return springs 21 on the brake shoes 20 Install the brake shoes 20 on the relative pin 19 being careful to keep the springs 21 in their place NOTE check correct operation of the drum brake by means of the control lever Mount the flange with drum 12 on the pinion 2 64 71 31 32 33 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Position the shim ring 15 Tighten the ring nut 16 on the bevel pinion 2 Tighten with a commercial tool T12 at 30 daNm Check for the last time the pre load value of the tapered roller bearings 4 and 10 measured as the rolling torque with a torquemeter The measurement must range between 9 and 20 daNcm without oil retainer 65 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 8 ACCESSORIES 4 8 1 1 SPEED GEARBOX 4 8 1 1 DISASSEMBLY 9 10 Undo the screws 2 re
5. DISASSEMBLY EXTRAORDINARY JOBS Remove the securing screws 6 of the 1 speed gearbox assembly from the central housing Separate the 1 speed gearbox assembly from the differential axle s central housing using a hammer ATTENTION make the 1 speed gearbox assembly safe Recover the set adjustment shims 1 of the bevel gear Unscrew the ring nut 12 with the commercial tool T12 45 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES WS Remove the axial washer 11 Separate the driven gear 10 from the bevel pinion 2 using an extractor Disassemble the tapered roller bearing 8 from the driven gear 10 Remove the O ring 3 from the pinion tang 2 Recover the shims 7 for pre loading the pinion s tapered roller bearings 2 EXTRAORDINARY JOBS 46 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES y 5 Remove the spacer ring 7 Remove the bearing 4 from the bevel pinion 2 with an extractor Remove the bearing cup 4 from the gearbox assembly 5 with an extractor Remove the bearing cup 8 from the gearbox assembly 5 with an extractor Remove the bearing 13 from the gearbox housing 5 EXTRAORDINARY JOBS 47 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 6 2 ASSEMBLY Q Vee a 12 1 Drive the ball bearing 5 on to the gearbox housing 5 using a special tool T13 Use the special tool T14 to drive the cup of the tapered ro
6. NOT ROTATE FREELY then check from the beginning the assembly process 5 2 FINAL INSTRUCTIONS Check the transmission oil level and quantity See paragraph 2 1 Bleed air bubbles from wet discs braking circuit TESTING AND FINAL INSTRUCTIONS 71 71
7. worn 3 The pinion bearings are worn 4 Pinion bearings with clearance 5 Pinion axial clearance is too much 6 Bearings of the differential are worn 7 Bearings of the differential with clearance 8 Gear not in position 9 Lubricant level low 10 Wrong lubricant 11 Shaft is bent 4 Adjust 5 Adjust 6 Replace 7 Adjust 8 Replace 9 Top up 10 Replace 11 Replace Noise when idling 1 Noise coming from the axle with the vehicle moving are usually heard when idling 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 1 Adjust or replace see above 2 Adjust 3 Replace Intermittent noise 1 Ring gear damaged 2 The fixings on the differential housing have come loose 1 Replace the bevel gear 2 Tighten to torque Constant noise 1 Damage to teeth on the ring gear or pinion 2 Bearings worn 1 Replace the bevel gear 2 Replace 3 Replace 4 3 Pinion grooves worn Replace 4 Shaft is bent Noise on a curve 1 Differential planet gears 1 Replace worn 2 Replace 2 Differential housing 3 Replace and or differential pins worn 4 Replace 3 Differential washers worn 4 Grooving on the shaft worn TROUBLESHOOTING 7 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 EXTRAORDINARY JOBS DISASS
8. ANUAL SERIES S068 AXLES Pre mount the needles adhering to the planet gear with grease 11 NOTE grease the needles well Position the planet gear 11 with the two axial washers in its place on the spindle 8 Insert the pin in place on the spindle 8 taking care that the needles and the 2 axial washers remain in place Fit the pins snap ring 7 on the spindle 8 Drive in the stop shot pin 25 of the pins snap ring with a punch driver EXTRAORDINARY JOBS 27 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Drive the tapered roller bearing 13 into the spindle tang 8 with a driver Use the special tool TO5 to drive the cup of the tapered roller bearing 19 in to the wheel hub 15 Use the special tool T06 to drive the cup of the tapered roller bearing 13 in to the wheel hub 15 Fit the sealing ring 14 on the wheel hub 15 with the special tool T07 putting some seal putty on the outside Screw the stud bolts 16 onto the hub 15 using Loctite 270 and tightening at a torque of 13 daNm EXTRAORDINARY JOBS 28 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Mount the hub 15 on the spindle 8 taking care not to damage the sealing ring 14 Drive the tapered roller bearing 19 into the spindle tang 8 with a driver and applying Loctite 603 Fit the washer 20 on the spindle 8 Position the shims 22 Screw the ring nut 21 down with a comme
9. D AND LSD DIFFERENTIAL HOUSING cceeeeeeeeeeeeeeeeteees 41 AD ile DISASSEMBLE Ve tl idas 41 452 O A eS ek A Aree eae 42 4 6 BEVEL PINION WITH 1 SPEED GEARBOX oo eceeeeeeeeeeeeeeteeeeeneeees 45 46t WDISASS EMBL cat da cee cae cece evel Gee eae 45 402s A NN 48 4 7 BEVEL PINION WITH KNOTT BRAKE 160x40 c ooccccccccccccccononccccccccccnnnnnannnnncns 54 47 1 ISA O EMB pit ra tl ld o 54 E A eth tc th ot a 58 Be A eters cee ete esta cette ee cece 66 481 A SPEED GEARBOX edna e A o EUA 66 4 8 1 1 e AA AS 66 A ASSEMB cette ted ie A PEE ett aaaea bec ht de iaiad hha teal 67 5 TESTING AND FINAL INSTRUCTIONS 71 Dade She ING Suter th hth A sh ete 71 52 FINAL INSTRUCTIONS uste ett letal ales 71 1 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 1 PRELIMINARIES 1 1 INTRODUCTION This manual contains information necessary for carrying out extraordinary maintenance on the differential axle if ever repairs 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 lt is therefore important that the people assigned to such work receive detailed information about restoring the correct conditions that guarantee operation of the differential ax
10. EMBLY 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 due to their nature when assembling have to be replaced with others in perfect condition gaskets seals worn 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 during 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 EXTRAORDINARY JOBS 8 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES
11. Gear load is much greater than expected 2 Incorrect gear adjustment too much clearance 3 Pinion nut has come loose Replace the bevel gear Follow the steps carefully that are recommended for adjusting gear tooth and pinion clearance and for detecting tooth impression Breakage towards the internal end of the gear tooth 1 Knocked by the load 2 Incorrect gear adjustment too little clearance 3 Pinion nut has come loose Replace the bevel gear Follow the steps carefully that are recommended for adjusting gear tooth and pinion clearance and for detecting tooth impression Pinion and gear teeth are worn or scored 1 Insufficient lubrication 2 Lubricant is dirty 3 Wrong lubricant or with impoverished additives 4 Pinion bearings are worn causing incorrect axial clearance of the pinion and contact between pinion and gear Replace the bevel gear Replace the pinion s bearings making sure the gear pinion and bearing preloads are arranged correctly Use the correct lubricant fill up to the right level and change it at the intervals recommended Pinion and gear teeth overheated See if the colour of the gear teeth has altered 1 Prolonged operation at excessive temperatures 2 Wrong lubricant 3 Low oil level 4 Lubricant is dirty Replace the bevel gear Use the correct lubricant fill up to the right level and change it at the intervals recommended Pitting o
12. INTENANCE MANUAL SERIES S068 AXLES Fit the bottom knuckle pin 12 with its gasket 13 after having spread grease over it tightening the screws 10 at a torque of 5 5 daNm and applying some Loctite 270 21 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 3 WHEEL REDUCTION ASSEMBLY WITH SERVICE BRAKES 4 3 1 DISASSEMBLY 1 23 5 4 a Remove the securing screws and washers fixing the wheel reduction unit to the lateral beam NOTE if the axle is a steering axle the wheel reduction unit is fixed to the knuckle assembly see paragraph 4 3 1 Remove the brake disc 1 from the shaft s grooved profile NOTE check the state of wear of the brake disc friction material and replace it if necessary Separate the lateral reduction unit from the axle and place it on a flat surface ATTENTION do not let the reduction unit fall support it with a rope if necessary EXTRAORDINARY JOBS 22 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Remove the brake piston 3 To extract the piston use the brake s delivery hole applying the minimum oil or air pressure necessary for expulsion ATTENTION this operation must be done with maximum caution Recover the quad rings 2 and 4 from the brake piston and see whether or not they are worn Replace them if necessary Remove the parallel pins 5 from the spindle 8 with a pair of pliers Remove the cover 24
13. LES Position the shims 8 on the driving gear 7 by the shoulder opposite the grooved profile Install the driving gear 7 in the seat of the ball bearing 6 of the gearbox housing 10 Drive the cylindrical pins 9 into the gearbox housing 10 As shown in the figure spread liquid sealant over the area coupling the housing 10 with the 1 speed gearbox cover 5 Fit the cover 5 on the gearbox housing 10 using a hammer to make it easier 69 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Tighten the screws 2 with washer 3 applying Loctite 270 Tighten at a torque of 12 daNm Put the 3 closing plugs 4 in place tightening at a torque of 3 daNm EXTRAORDINARY JOBS 70 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 5 TESTING AND FINAL INSTRUCTIONS 5 1 TESTINGS Block the input pinion If the axle is mounted on the vehicle engage the gear With the help of another person standing on the opposite side begin the assembly testing by rotating as much as possible both the wheels forward The wheels should get blocked after a while Keeping the pinon blocked free the right wheel and rotate the left one in forward direction Right wheel should rotate in the opposite direction If the assembly procedure has been carried out correctly the left wheel should rotate freely without difficulty and the right wheel should rotate in the opposite direction backward IF ONE OF THE WHEELS DOES
14. Y JOBS Drive the tapered roller bearing 4 on to the bevel pinion 2 with the driver Insert the pre assembled bevel pinion 2 in the pinion housing 5 Fit the spacer ring 7 on the bevel pinion 2 with the shoulder facing towards the head of the pinion NOTE check the correct direction of the spacer Fit shims 8 and 9 on the bevel pinion 2 Drive the tapered roller bearing 10 on to the bevel pinion 2 with the driver 59 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Put the O Ring 3 in place on the pinion 2 Drive the sealing ring 11 onto the pinion housing 5 with the specific tool T17 Grease the inside lip of the oil retainer with Polymer 400 grease Install the flange with drum 12 on the pinion 2 using a hammer Fit the washer 15 on the pinion 2 Tighten the ring nut 16 on the bevel pinion 2 with the commercial tool 112 Tighten the ring nut 16 TEMPORARILY at 30 daNm NOTE DO NOT apply LOCTITE because the flange with drum 12 has to be removed so as to be able to install the pinion holder housing assembly on the central housing 60 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Check the pre load value of the tapered roller bearings 4 and 10 measured as the rolling torque with a torquemeter The measurement must range between 9 and 20 daNcm without oil retainer If n
15. acts between the bevel gear teeth disassembling and reassembling the lateral beam 7 completely and extracting the differential housing assembly Tighten the closing plug 6 at a torque of 3 daNm 39 71 23 24 25 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Tighten the closing plug 6 at a torque of 3 daNm Tighten the breather plug 2 at a torque of 1 5 daNm If the axle is a steering axle go to the next chapter Position the axial washer and insert the shaft in the lateral beams coupling the grooved profile on the shaft differential side with the housing in the differential planet gear 40 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 5 STANDARD AND LSD DIFFERENTIAL HOUSING 4 5 1 DISASSEMBLY 3h EE Peoi 0 a 1 Remove the two tapered roller bearings 1 from the half housings 10 and 11 using an extractor Recover 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 Separate the differential half housings 10 and 11 EXTRAORDINARY JOBS 41 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 5a 5b 4 5 2 ASSEMBLY EXTRAORDINARY JOBS Remove the planet gears 6 and relative spherical washers 5 separating them from the spider 7 Recover the friction disc pack 3 of the Limited Slip devic
16. covering the washers 3 With a lever separate the cover 5 from the body 1 of the 1 speed gearbox taking care to pull out the input gear 7 and shims 8 from their seats in the ball bearings 6 Recover the cylindrical pins 9 from the gearbox housing 10 EXTRAORDINARY JOBS 66 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES n i Y Remove the sealing ring 1 from the y 3 cover with a screwdriver NOTE this operation destroys the sealing ring Remove the ball bearing 6 with an extractor 4 8 1 2 ASSEMBLY 9 10 6 yo Drive the ball bearing 6 into place in the cover of the 1 speed gearbox 5 with the driver EXTRAORDINARY JOBS 67 71 REGISTRAZIONE EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Drive the sealing ring 1 onto the gearbox cover 5 with the special tool T18 Spread the inside lip with Polymer 400 grease Measure value X between the shoulders of the driving gear 7 as shown in the figure Measure value A between the coupling area of the gearbox unit 10 and the end of the ball bearing 6 as shown in the figure Measure value B between the end of the ball bearing 6 and the coupling area of the gearbox cover 5 as shown in the figure Find the Y number of shims 8 according to the following formula Y A B X 68 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AX
17. ction unit with the housing as shown in the figure Assemble the wheel reduction unit on the housing Tighten the screws to 5 daNm NOTE if the axle is a steering axle the wheel reduction unit is fixed to the knuckle assembly see paragraph 4 3 2 31 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 4 LATERAL BEAM 4 4 1 DISASSEMBLY EXTRAORDINARY JOBS Pull out the shaft and perforated washer from the lateral beam NOTE if the axle is a steering axle the double joint was already removed as at paragraph 4 3 1 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 9 and keep the washers 8 of the housing 7 on the bevel gear side NOTE to see which is the bevel crown assembly side please refer to the axle installation drawing 32 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES a Separate the lateral beam 7 from the central body 1 ATTENTION do not let the housing or the differential housing assembly with gear fall Remove the differential housing assembly Remove the two top and bottom bushings 5 from the housing 7 using a screwdriver Remove the top and bottom washers 4 from the housing 7 NOTE the bottom washer has a groove for grease Remove th
18. e 2 sealing rings 13 from the housing 7 NOTE this operation destroys the sealing ring 33 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the bushing 12 from the housing 7 Remove the tapered roller bearing s cup 14 from the differential housing with an extractor Undo the screws 9 and recover the washers 8 of the housing 3 on the side opposite the bevel gear NOTE to see which is the bevel crown assembly side please refer to the axle installation drawing Remove the tapered roller bearings 14 from the differential housing assembly with an extractor Recover the pre load adjustment shims 15 of the tapered roller bearings 14 that support the differential housing assembly 34 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 4 2 ASSEMBLY EXTRAORDINARY JOBS If the axle is rigid go to phase 5 Drive the bushing 12 with the special tool T08 into the housings 3 and 7 Drive 2 sealing rings 13 into each housing 3 and 7 with the special tool TO9 Grease the oil retainers with Polymer 400 Position the bottom and top washers 4 in the housings 3 and 7 making sure the grease grooves are facing outwards NOTE only the bottom washer has a groove for grease 35 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Drive the bottom and top bushings 5 into the housings 3 and 7 wi
19. e from the planet gear 4 Check wear status and if necessary replace the disc pack NOTE keep the disc 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 disc pack 42 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 2a 2b EXTRAORDINARY JOBS Pre assemble the planet gears 6 with their spherical washers 5 on the spider 7 Mount the friction disc pack 3 on the planet gears 4 NOTE Observe the sequence of the discs illustrated in the figure In versions with the STANDARD differential the washer must be used instead of the friction disc pack Install the planet gears 4 in the half housings 10 and 11 Position the pre assembled spider in the differential half housing 1 identified by its threaded holes 43 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS 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 Tighten the screws 8 at a torque of 25 daNm 44 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 6 BEVEL PINION WITH 1 SPEED GEARBOX 4 6 1
20. e wheels of the vehicle with a wedge Scrupulously observe the indications given on the warning and indication plates that are on the vehicle All auxiliary means and tools must be in perfect condition for use and absolutely safe PRELIMINARIES 3 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 2 PROGRAMMED MAINTENANCE 2 1 OIL CHANGE AND PERIODICAL CONTROLS Lubricants SAE 85W90 API GL4 with additives for oil bath brakes SAE 85W90 API GL5 with additives for oil bath brakes and for self locking differential LS Limited Slip The maintenance intervals mentioned are for a normal use of the vehicle intervals should be shorter if the vehicle is used for particularly hard work Job First intervention Routine maintenance Changing axle oil 200 hours seasonal 1000 hours 1 Cleaning the magnetic plug at the first oil change at every oil change Checking and topping up the oil 100 hours monthly 300 hours 1 Cleaning the oil breather 400 hours monthly 300 hours 1 Greasing where envisaged 200 hours 2 weekly 200 hours 1 2 1 which of the two conditions occurs first 2 50 hours in the case of hard work Hub drain and lev gh i Gearbox level plug Gearbox drain plug E PROGRAMMED MAINTENANCE 4 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 3 TROUBLESHOOTING 3 1 TROUBLESHOOTING PROBLEM CAUSE ACTIONS Breakage towards the external end of the gear tooth 1
21. ecessary remove the ring nut 16 the axial washer 15 the O Ring 3 the flange with drum 12 and change the number of shims 8 and 9 Repeat tightening loosening of the ring nut 16 with self locking thread no more than 5 times Remove the ring nut 16 the axial washer 15 and the flange with drum 12 from the pinion assembly Put the central housing on a suitable support Measure value A as illustrated in the figure and in the drawing with a depth caliper In the adjacent figure the value measured is 134 9mm 61 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES REGISTRAZIONE 20 21 EXTRAORDINARY JOBS IMPORTANT this measurement is functional for adjusting the bevel gear Read value X printed on the head of the bevel pinion 2 In the adjacent figure the value given is 107mm Find the Y number of paper shims 1 to adjust the bevel gear according to the following formula Y X A B 0 1 mm For value B refer to phase 2 In the example illustrated Y 107 134 9 34 0 1 6 2mm Fit 2 guide stud bolts in the holes on the central housing and place the shims 1 decided on previously Mount the pinion housing assembly on the central housing using a hammer 62 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the guide stud bolts and tighten the screws 6 22 Tighten the screws 6 to 15 daNm 23 Screw the brake shoes pin
22. eduction unit Spread some liquid sealant inside the area coupling the wheel reduction unit with the knuckle as shown in the figure EXTRAORDINARY JOBS 18 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Mount the brake disc 14 on the grooved profile of the double joint Fix the wheel reduction assembly on the knuckle 8 with the securing screws 2 and washer 2 tighten at a torque of 5 5 daNm Apply some Loctite 270 Tighten the 2 self locking nuts 3 with washer 2 to a torque of 2 daNm m Fit the securing screw 2 with washer i 2 under the knuckle pin housing 12 at a torque of 5 5 daNm and with some Loctite 270 Mount the closing plug 15 and tighten at a torque of 3 daNm EXTRAORDINARY JOBS 19 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Mount the knuckle s breather plug 9 and tighten at a torque of 3 daNm With the aid of a suitable support insert the knuckle assembly complete with double joint in the housing making sure that the grooving on the differential side of the double joint fits into place correctly in the bevel gear Pre assemble the lubricator on the knuckle pin 11 Pre assemble the top knuckle pin 12 with its seal 13 after have spread grease over it Fix the top pin 12 to the knuckle tightening the screws 10 to a torque of 5 5 daNm and applying some Loctite 270 20 71 EXTRAORDINARY JOBS USER AND MA
23. f pinion teeth 1 Extremely intense use 2 Insufficient lubrication Replace the bevel gear Use the correct lubricant fill up to the right level and change it at the intervals recommended Lateral beam of the axle is bent 1 Vehicle overloaded 2 Vehicle involved in an accident 3 Knocked by the load Replace the axle s lateral beam Wear and pitting of the bearings 1 Insufficient lubrication 2 Lubricant is dirty 3 Extremely intense use 4 Normal wear Replace the bearings Use the correct lubricant fill up to the right level and change it at the intervals TROUBLESHOOTING 5 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 5 Pinion nut has come loose recommended Oil leaks from seals and gaskets 1 Prolonged operation with excessive oil temperature 2 Oil seal fitted in a wrong way 3 Edge of the seal is cut or corroded 4 Lubricant is dirty Replace the seal and coupling surfaces if damaged Use the correct lubricant fill up to the right level and change it at the intervals recommended Inlet flange s coupling is worn grooved 1 Intense use 2 Pinion nut has come loose 3 Pinion axial clearance Replace the flange Check that the grooving of the pinion is not excessively worn Replace the bevel gear if necessary Breakage due to fatigue of the pinion tooth check for characteristic fracture lines 1 Intense use 2 C
24. joint Recover the washers 2 8 a NOTE remove the closing plug 15 E SS which is under the top knuckle pin housing 12 to be able to reach the securing screw 2 EXTRAORDINARY JOBS 15 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Separate the wheel reduction unit and recover the two centring pins and two stud bolts 19 Pull the brake disc 14 out from the double joint NOTE check the state of wear of the brake disc friction material and replace it if necessary n Recover the Seeger ring 5 K Pull the double joint 1 out from the knuckle using a hammer to make it easier 13 Use an extractor to remove the bearing 6 from the knuckle 8 EXTRAORDINARY JOBS 16 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the sealing ring 7 from the knuckle 8 with a screwdriver NOTE this operation destroys the sealing ring Fit the sealing ring 7 with the special tool T02 on the knuckle 8 after having spread the lip seal with some Polymer 400 grease Mount the bearing 6 with the specific tool T03 in the knuckle housing 8 applying some Loctite 603 EXTRAORDINARY JOBS 17 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Insert the double joint 1 in the knuckle 8 Fit the Seeger ring 5 Fit the two stud bolts 4 on the wheel reduction unit and tighten at a torque of 2 daNm applying some Loctite 270 Fit the 2 pins on the wheel r
25. k toe in toe out of the steering system by installing a bar on each rim 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 12 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES 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 steering tie rod s internal thread at a torque of 15 daNm 13 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 2 KNUCKLE AND CARDAN JOINT WITH BRAKES 4 2 1 DISASSEMBLY ATTENTION fasten the steering wheel reduction assembly to a suitable support Remove the securing screws 10 and extract the bottom knuckle pin 12 Remove the gasket 13 EXTRAORDINARY JOBS 14 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES dl Remove the securing screws 10 of the top knuckle pin Extract the top knuckle pin 12 and recover the gasket 13 Separate the steering wheel reduction assembly with double joint from the lateral beam Place the assembly on a flat surface Undo the screws 2 and the two nuts 3 securing the wheel reduction unit on the knuckle with double
26. le 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 criteria 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 authorised to make repairs before they start any such work in order to guarantee the best result 7 2 ID PLATE Axle identification plate comer industries axles MADE IN ITALY setae PART NUMBER PRELIMINARIES 2 71 USER AND MAINTENANCE MANUAL SERIES S068 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 specific 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 th
27. ller bearing 8 on to the gearbox housing 5 Use the special tool T15 to drive the cup of the tapered roller bearing 4 on to the gearbox housing 5 EXTRAORDINARY JOBS 48 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES anona 10 1 EXTRAORDINARY JOBS Temporarily position the tapered roller bearing 4 in its cup and measure value B as illustrated in the figure using a depth gauge In the figure beside the value measured is 33 6mm IMPORTANT this measurement is necessary for adjusting the bevel gear Drive the tapered roller bearing 4 on to the bevel pinion 2 with the driver Drive the tapered roller bearing 8 on to the driven gear 10 with the driver Insert the pre assembled bevel pinion 2 in the gearbox housing 5 49 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Fit the spacer ring 9 on the bevel pinion 2 with the shoulder facing towards the head of the pinion NOTE check the correct direction of the spacer Fit adequate shims 7 on the bevel pinion 2 Put the O Ring 3 in place on the pinion 2 Fit the pre assembled driven gear 10 on the pinion 2 using a hammer Install the axial washer 11 on the bevel pinion 2 EXTRAORDINARY JOBS 50 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Screw the ring nut 12 down onto the pinion thread 2 with the specific commercial tool T12 appl
28. making a hole in the middle of it with a screwdriver and exerting leverage Remove the safety Seeger ring 23 23 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Unscrew and remove the M50x1 5 ring nut 21 with the commercial tool T04 Remove the shims 22 Remove the washer 20 Separate the wheel hub 15 from the spindle 8 helping with a hammer NOTE recover the tapered roller bearing 19 Remove the sealing ring 14 from the wheel hub 15 with a screwdriver NOTE this operation destroys the sealing ring 24 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the bearing cups 13 and 19 from both sides of the wheel hub 15 using an extractor Remove the internal cup of the bearing 13 from the spindle tang 8 using an extractor Remove the stop pin 25 of the pins snap ring 7 Remove the pins snap ring 7 Remove the pin with a punch and hammer EXTRAORDINARY JOBS 25 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the planet gear 11 putting the two axial washers and needles to one side Check the state of wear of the parts replacing them if necessary 20 If the shaft stopper is damaged replace the whole spindle 4 3 2 ASSEMBLY 123 54 na al ie 18 18 19 20 21 Punch mark the shaft stopper 25 in 3 points on the spindle 8 EXTRAORDINARY JOBS 26 71 USER AND MAINTENANCE M
29. n must be as given in the following table 37 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES rolling torque INCREASE ratio measured on the pinion with a C C torquemeter daNcm ADJUSTMENT 7 39 2 4 9 37 3 5 12 39 4 7 17 38 5 10 Spread a marking product such as ink over the bevel crown teeth to verify the goodness of the contact impression of the bevel gear teeth Insert the pre assembled differential housing assembly on the side of the central housing that is still accessible NOTE to see which is the bevel crown assembly side please refer to the axle installation drawing Position the three parallel pins 11 on the accessible side of the central housing Apply liquid sealant on the area coupling the beam 7 with the central housing EXTRAORDINARY JOBS 38 71 20 21 22 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Tighten the screws 9 with washer 8 at a torque of 15 daNm Check the pre load value of the tapered roller bearings 14 as the INCREASE of the rolling torque measured in input of the pinion with a torquemeter Please consult the previous table for the value NOTE if necessary disassemble and use a different number of shims 15 Check clearance between the teeth of the bevel gear turning the gear alternatively by means of a shaft NOTE if necessary disassemble and use a different number of shims 15 Check the goodness of the cont
30. ng ring 11 from the pinion housing 5 with a screwdriver NOTE this operation destroys the sealing ring Remove the O ring 3 from the pinion tang 2 Extract the bevel pinion 2 from the pinion housing 5 using a hammer 56 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Recover the tapered roller bearing 10 Remove the tapered roller bearing 4 from the pinion 2 with an extractor Recover the shims 8 and 9 for pre loading the pinion s 2 tapered roller bearings Remove the spacer ring 7 Remove the cups of the tapered roller bearings 4 and 8 from the pinion housing 5 with an extractor EXTRAORDINARY JOBS 57 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 4 7 2 ASSEMBLY 21 20 19 17 e 13 14 oe a A a we A l MN AO 3 EXTRAORDINARY JOBS cd 26 xe Lee ISS 16 15 12 sl 1 19 8 6 Drive the cup of the tapered roller bearing 4 into the pinion housing 5 with the special tool T15 Drive the cup of the tapered roller bearings 10 into the pinion housing 5 with the special tool T16 Temporarily position the tapered roller bearing 4 in its cup and measure value B as illustrated in the figure using a depth caliper In the adjacent figure the value measured is 34mm IMPORTANT this measurement is functional for adjusting the bevel gear 58 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINAR
31. ontinuous overload Replace the bevel gear Breakage of the pinion and gear teeth Impact load of the differential s components Check and or replace other differential components Differential planet gear grooving worn too much clearance Intense use Replace the bevel gear unit Replace the shaft if necessary Surfaces of the washers of the bevel gears are worn or marked 1 Insufficient lubrication 2 Wrong lubrication 3 Lubricant is dirty Replace all the washers marked and those that are 0 1 mm thinner than the new ones Use the correct lubricant fill up to the right level and change it at the intervals recommended Internal cup of the pinion s tapered roller bearing is worn 1 Intense use 2 Pinion axial clearance is too much 3 Inadequate lubrication 4 Lubricant is dirty Replace the bearing Check the pinion s axial clearance Use the correct lubricant fill up to the right level and change it at the intervals recommended Shaft deformed or fracture Intense use of the vehicle Replace the shaft split overloaded Shaft fracture split by the 1 Lateral beam is bent Replace the shaft wheel flange Check deformation of the lateral beam Noise when driving 1 Too much clearance 1 Adjust between the gear and 2 Replace pinion 3 Replace TROUBLESHOOTING 6 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 2 Pinion and gear are
32. ote special tools T04 and T12 could be supplied by Comer Industries Tools drawings are available upon request from customer EXTRAORDINARY JOBS 9 71 USER AND MAINTENANCE MANUAL SERIES S068 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 4 from the steering cylinder piston rod 1 EXTRAORDINARY JOBS 10 71 EXTRAORDINARY JOBS USER AND MAINTENANCE MANUAL SERIES S068 AXLES Remove the securing screws 2 of the steering cylinder 1 to the central housing and recover it 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 If necessary centre the piston rod by knocking on the end with a hammer 11 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES EXTRAORDINARY JOBS Place the steering cylinder 1 on the central housing using the securing screws 2 and some Loctite 270 Tighten the screws with a torque wrench at a torque of 15 daNm Screw the tie rod 3 on to the steering cylinder piston rod 1 with a square head wrench TO1 using some Loctite 243 Tighten the tie rod at a torque of 15 daNm Position the cone of the tie rod in its place on the knuckle and tighten the nut 4 at a torque of 25 daNm Chec
33. rcial tool T04 having applied some Loctite 270 Tighten the ring nut at a torque of 16 daNm EXTRAORDINARY JOBS 29 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 20 21 EXTRAORDINARY JOBS Fit the safety Seeger ring 23 on the spindle 8 and check it is closed Mount the cover 24 on the wheel hub 15 using a hammer to make it easier Put the closing plug 18 in place tightening at a torque of 3 daNm Fit the three cylindrical parallel pins 5 on the spindle 8 applying some Loctite 603 Blow the brake piston 3 and the housing of the quad rings Fit the quad rings 2 and 4 on the brake piston 5 making sure they are positioned correctly Lubricate the rings with mineral oil to facilitate insertion of the brake piston 5 on the spindle 8 30 71 22 23 24 25 26 EXTRAORDINARY JOBS Make a mark with a felt tip pen on the spindle 8 by one of the parallel pins 5 Make a mark on the brake piston 5 with a felt tip pen by the housing of one of the parallel pins Insert the brake piston 3 on the wheel reduction unit making sure it is clocked with the 3 parallel pins 5 NOTE exert just enough pressure to insert the brake piston helping with a plastic headed hammer if needed taking care not to damage the quad rings Insert the brake disk 1 in the shaft s grooved profile Spread liquid sealant over the area coupling the wheel redu
34. th the special tool T10 Drive the cups of the differential housing assembly s bearings into the housings 3 and 7 with the special tool T11 NOTE do not invert the cups if the bearings are not replaced completely Insert the three parallel pins 11 in their seats on the central housing only on the side opposite where the bevel crown is assembled NOTE to see which is the bevel crown assembly side please refer to the axle installation drawing Apply liquid sealant on the area coupling the beam 3 with the central housing Tighten the screws 9 with washer 8 at a torque of 15 daNm 36 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES 9 E a Hs ds ADJUSTMENT EXTRAORDINARY JOBS Place the necessary shims 15 on the side opposite the pre assembled differential housing s bevel crown Drive in the tapered roller bearing 14 on the side opposite the pre assembled differential housing s bevel crown using a driver Place the necessary shims 15 on the pre assembled differential housing s bevel crown side Drive in the tapered roller bearing 14 on the pre assembled differential housing s bevel crown side using a driver The number of shims 15 for adjusting the tapered roller bearings 15 must be such to have a clearance of 0 15 to 0 30 mm between the teeth of the bevel gear Bearing 14 pre load measured as an INCREASE of the rolling torque in input to the pinio
35. ying Loctite 270 Tighten the ring nut 12 at a torque of 30 daNm Check the pre load value of the tapered roller bearings 4 and 9 measured as the rolling torque with a torquemeter The measurement must range between 9 and 20 daNcm without oil retainer If necessary remove the ring nut 12 the axial washer 11 the O Ring 3 the driven gear 10 and change the number of shims 7 Repeat tightening loosening of the ring nut 12 with self locking thread no more than 5 times Put the central housing on a suitable support 51 71 20 21 REGISTRAZIONE EXTRAORDINARY JOBS Measure value A as illustrated in the figure and in the drawing with a depth caliper In the figure beside the value measured is 134 9mm IMPORTANT this measurement is necessary for adjusting the bevel gear Read value X printed on the head of the bevel pinion 2 In the figure beside the value given is 107mm Find the Y number of the bevel gear s set adjustment paper shims 1 according to the following formula Y X A B 0 1 mm For value B refer to phase 4 In the example illustrated Y 107 134 9 33 6 0 1 5 8mm Fit 2 guide stud bolts in the holes on the central housing and place the shims 1 decided on previously 52 71 USER AND MAINTENANCE MANUAL SERIES S068 AXLES Assemble the pre mounted 1 speed gearbox assembly on the central housing using a hammer 22
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