Professional Documents
Culture Documents
Clark 19D Planetary Drive Axle PDF
Clark 19D Planetary Drive Axle PDF
Planetary
Drive Axle
FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with
information and instructions on the maintenance and repair of the DANA SPICER OFF-
HIGHWAY PRODUCTS DIVISION product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of
these units. The slight outlay in personal attention and cost required to provide regular and
proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will
be reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its principle of operation,
troubleshooting, and adjustments, it is urged that the mechanic studies the instructions in this
manual carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only DANA SPICER OFF-
HIGHWAY PRODUCTS DIVISION-approved parts as listed in the applicable parts manual
should be used. Use of "will-fit" or non-approved parts may endanger proper operation and
performance of the equipment. DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION does
not warrant repair or replacement parts, nor failures resulting from the use of parts which are not
supplied by or approved by DANA SPICER OFF-HIGHWAY PRODUCTS DIVISION.
IMPORTANT: Always furnish the Distributor with the serial and model number when
ordering parts.
TABLE OF CONTENTS
1
DESCRIPTION lubrication keeps all moving parts bathed in lubricant to
The axle assembly has a spiral bevel type ring gear and reduce friction, heat, and wear.
pinion with further reduction provided by planetary gear set
within the wheel hub. (LCB) LIQUID COOLED BRAKES
The liquid cooled brake is ideal for use in contaminated or
temperature sensitive environments and in machines
PRIMARY REDUCTION
where extra long maintenance intervals are required.
The spiral bevel pinion and ring gear transmit power
Braking action of the liquid cooled brakes is achieved
through the center differential pinions, side gears, and to
through the application of the hydraulic piston with the
the axle shaft. The spiral bevel differential assembly is rotating graphitic friction surfaces which react with
mounted on tapered roller bearings which are adjusted by stationary stator plates. The stator plates are retained by
positioning of the two threaded adjusting nuts mounted in scalloped tangs at the outside diameter, which in turn
the differential carrier and cap assembly. The tapered roller transfer the reaction torque to the rigid outside housing.
pinion bearing preload is adjusted and maintained by a
hardened and precision ground spacer positioned between Tangs on the O.D. of the friction discs prevent the discs
inner and outer bearings. Spacer is selected at assembly. from dropping out of alignment when the wheel hub is
removed for wheel bearing adjustments. This provides
SECONDARY REDUCTION ease of service reassembly.
In the wheel hub, a self-centering sun gear is spline fitted
Hub splines are long enough to engage all friction discs
to the axle shaft and drives three planetary pinion gears.
before bearings or seals are set. This provides ease of
These gears in turn rnesh with and react against a rigidly
assembly and assures the ability to accurately adjust
mounted internal ring gear. The planet gears rotate on wheel bearings.
needle roller bearings mounted on hardened and ground
pins located in the planet carrier which in turn drives the Wheel bearings can be serviced as in any normal bearing
wheel hub. Positive service procedure.
Initial Fill
Grade 85W140 qualified MIL-L-2105C gear lubricant as specified in Clark MS-8 engineering standard is preferred for initial fill
for most ambient temperatures. (See chart on page 4.) For other ambient temperature ranges use proper viscosities of MIL-L-21
05C.
Other lubricants approved to MIL-L-21 05C specifications are acceptable for initial fill or top off.
Service Fill
Multipurpose gear lubricants approved to the MIL-L-2105C specifications are recommended. MIL-L-2105C
classifies multigrade gear lubricants on the basis of the viscosities at various temperatures.
Listed on page 4 are the recommended multigrade viscosities for use at the prevailing operating temperatures in
Clark Drive Axles.
pound 1 [liter].
Below listed capacities are approximate. Fill to proper level as instructed in this manual. Always fill wheel ends and
axle centers to the bottom of the oil level plug hole.
-3
For proper viscosity lube, refer to fahrenheit or celsius chart
below.
Multigrade Viscosities
MIL-L-2l0SC
Ambient Temperature Ranges See (a) note below.
-40°F to -10°F (-40°C to -23°C) 75W See (b) note below.
-40°F to 0°F (-40°C to -18°C) 75W80
-40°F to + 100°F (-40°C to -38°C) 75W90
-40°F + Above (-40°C + Above) 75W140
-15°F to 100°F (-26°C to 38°C) 80W90
-15°F + Above (-26°C + Above) 80W140
+10°F + Above (-12°C + Above) 85W140
Notes:
(a) The MIL-L-2105C Specification replaced the MIL-L-2105B
Specification.
B. Brake sump cooling oils (when external cooling is used). The following cooling oils are recommended in order of preference. 1 -Organic Esters
2 Hydraulic Oil
3 MIL-L-46152B/MIL-L-2104 C or D.
4 ATF C-3 or oDEXRON@. Not DEXRON II@ (See Note Below).
5 -Motor Oil API SE/CD.
6 -Invert Emulsion
and all of the oils in A above can be used in the brake sump except water/oil invert emulsion must not be used with the LCB 10,000 series shipped from
Clark before 1 June 1984 because of incompatibility with the friction discs.
C. Axle assemblies with Liquid Cooled Brakes having a common brake and gear sump (no brake external cooling used), use 1 -Gear Lubricant meeting
Clark specifications MS-8,
2 MIL-L-2105C.
NOTE: DEXRON "@ is not compatible with graphic friction plate material unless
it meets the approved C-3 specifications. *DEXRON is a
registered trademark of General Motors Corporation.
-4
CHECKING OIL LEVEL IN DRIVE AXLES
For off-highway operation, check Iubricant level after each 250 hours of operation. Always maintain lubricant
level to bottom of filler plug hole. Drain oil every 2,500 hours or one year, whichever comes first.
For highway operation, lubrication should be checked each 5,000 miles [8,000 km]. Maintain lubricant level to
bottom of filler plug hole. Drain oil every 25,000 miles [40,000 km] or one year, whichever comes first.
To check oil level in axles with differential drive and planetary wheel ends, the axle should be run first, then allowed to stand for a minimum
of five minutes on level ground. This procedure will allow oil to drain back to its normal level. After the five minute interval, remove oil filler plug
at axle center and in the planetary wheel ends for oil level inspection. If oil level is not to the bottom of the filler hole, add necessary lubricant.*
The self-contained liquid cooled brake system uses the same lube as the axle center section and wheel ends. There are no seals between
the spindles and wheel hubs. Oil that lubricates the differential and planetary wheel ends also lubricates and cools the brake assembly. The oil
level is the same height as the planet and axle center and the brake may be filled and oil level checked at the planet carrier assembly or planet
carrier cover.
Brake oil changes would be accomplished at the same time the axle lube is changed. Contaminates resulting
from braking will not affect axle within normal oil change periods.
CAUTION: On all axles with liquid cooled brakes, check brake drain plug for presence of axle lube for axles
without forced cooling, or cooling fluid for axles with forced cooling.
To drain the brake housing, remove the bottom drain plug from the brake housing. Remove the inlet plug below the bleeder screw. Allow
enough time for housing to drain completely.
Always check lubricant level in planetary wheel ends, with wheel hub oil level plug in a down position. Remove oil level plug. If lubricant is
below oil level hole, remove filler plug and fill to oil level hole.* Reinstall pipe plugs.
Draining is best accomplished immediately after the vehicle has operated a short time or completed a trip. The lubricant is then warm and
will flow freely, allowing full drainage in minimum time. This is particularly desirable in cold weather.
Remove plug at bottom of axle housing and allow sufficient time for lubricant to drain. With planetary wheel ends, rotate wheel until filler
hole is down. Remove plug and allow sufficient time for draining. Be sure planet cover oil level hole is in proper position when refilling wheel
ends.
* NOTE: When filling the axle housing, planetary wheel ends, and brakes, allow enough time for lubricant to
flow through the various components in the differential, planetary housing, and the brake assembly. After
filling is completed, allow a few minutes for lubricant to attain its level and recheck each wheel end and the
axle center. Add lubricant if necessary.
-5
-6
DRIVE AXLE ASSEMBLY WITH
LIQUID COOLED BRAKES
-8
-22
DRIVE AXLE ASSEMBLY
WITH DRY DISC BRAKES
Item Description Quantity Item Description Quantity
AXLE ASSEMBL Y INSTRUCTION ILLUSTRATION 19D
SERIES (WITH DRY DISC BRAKES)
-24
-33
DRY DISC BRAKE ASSEMBLY
DRY DISC BRAKE HEAD SERVICE INFORMATION
(Service Information Provided By Rockwell International)
INSPECTION OF THE LININGS -FIGURE 2 C. Oil or Grease on Linings -Remove grease or oil
Inspect the lining for: with denatured alcohol or by reburnishing the
linings. If grease or oil cannot be removed, replace
A. Lining Wear -Replace the linings when the the linings.
thickness of the lining is less than 1/8 inch [3 mm].
D. Cracks on Linings -Replace linings that have
B. Linings Wear Not Even -Replace the linings cracks.
when the thickness of the linings is very different
on each lining. Check the pistons for correct NOTE: Cracks on the surface of the linings are
operation. normal when the caliper is used under high
temperature conditions.
Replace pistons that are locked in the bore. Check
that the disc surface is flat and parallel to the CAUTION: Always replace both linings. If only one
linings. lining is replaced, possible disc damage can occur.
-35
INSPECTION OF THE CALIPER HOUSING
Inspect the following areas for fluid leaks:
D. Inlet Fitting -If fluid leaks at the inlet flitting, tighten the
fitting. If the leak continues, the "0" ring must be INSPECTION OF THE DUST COVERS
replaced. FIGURE 3 Inspect to make sure that the dust covers are soft and can bend.
Disassemble the caliper to replace dust covers that are hard or
damaged.
-36
1 .Remove the bolts that fasten the end plates to one side 5. Install the linings in the caliper housing.
of the caliper housing. Remove the end plates.
6. Apply Loctite #271 or equivalent to the threads of
2. Loosen the bleeder screws to release the hydraulic the bolts that fasten the end plates to the housing.
pressure in the caliper.
7. Put the end plates on the housing. Install and tighten the
3. Use a piece of wood against the linings as a pry bar to bolts to 170 Ibf.ft [230 Nom]. Make sure the linings move
push the pistons completely into the housing. Tighten the freely in the housing.
bleeder screws. FIGURE 6
8. Remove the air from the brake system. See Bleeding the
4. Remove the linings from the caliper housing. If Brakes in this manual.
necessary, discard the linings.
9. Apply and release the brakes three times to make sure
CAUTION: Always replace both linings. If only one lining is the caliper operates correctly. Check for fluid leaks. Make
replaced, possible disc damage can occur. sure the linings move freely in the housing.
-37
REMOVAL OF THE CALIPER
1. Disconnect the brake line from the inlet fitting. Put a plug
in the brake line and the inlet fitting to prevent
contamination of the system.
3. Install the brake linings in the caliper housing. Apply 2. Clean the outside of the housing with denatured alcohol.
Loctite #271 or equivalent to the threads of the bolts that Dry the housing with compressed air or a clean cloth.
fasten the end plates to the housing.
3. If installed, remove the bolts that hold the end plates on
4. Put the end plates on the housing. Install and tighten the the housing. Remove the end plates and linings.
bolts to 170 Ibf.ft [230 N.m] .
4. Remove the pistons from the side of the housing
opposite the mounting plate according to the following
5. Make sure the housing is installed correctly on the
procedure :
mounting bracket. The disc must be in the (;enter between
the linings. The linings must move freely in the housing.
A. Use a C-clamp to hold a 1/2 inch [50 mm]
FIGURE 7
block of wood against the two pistons on the
mounting side of the housing. Make sure the
6. Remove the plugs from the brake line and the inlet
C-clamp is not in the area in front
fitting. Connect the brake line to the inlet fitting.
of the piston bore. FIGURE 8
7. Remove the air from the brake system. See Bleeding the
WARNING: Do not put your hand in front of the pistons
Brakes in this manual.
when you force out the pistons. Personal injury may occur.
-38
B. Apply compressed air to the inlet fitting to force the
pistons out of the housing. If one piston comes out
before the other piston, put a piece of wood in front of
the piston that comes out first. Apply compressed lair
to force the other piston out of the housing. FIGURE
9
9. Inspect the "0" rings and the backup rings in the housing for cuts
and damage. Remove and discard the "0" rings and the backup
rings. Inspect the ring grooves in the housing for scratches and
rust. Remove small scratches and rust with emery cloth. Replace
the housing if there are large scratches or large amounts of rust.
FIGURE 12
10. Inspect the pistons and the bores for scratches and rust.
Remove small scratches and rust with emery cloth. Replace the
component if there are large scratches or large amounts of rust.
11. Measure the outer diameter of the piston. Replace the piston if
the outer diameter is less than 2.995 inch [76,073 mm]. FIGURE
13
-39
2. Install a new "0" ring and a new backup ring in the
groove in the middle of the bore. The "0" ring is installed
toward the outboard end of the bore. The backup ring is
installed toward the lining side of the bore.
4. Install the pistons in the housing. Push the pistons in from the
lining side of the housing. Make sure the pistons are straight in the
bores. Push each piston into the bore until the top of the piston is
even with the top of the dust cover. FIGURES 16 AND 17
1. Use the hydraulic fluid that is used in the system and lubricate
the following components:
-40
the specified type of brake fluid and the specified fluid
level,
8. Install the "0" ring and the inlet fitting in the cylinder
head.
You must bleed the brakes to remove air from the brake
system when you remove and replace the caliper or the
linings. If two calipers are used, first bleed the caliper that
is further from the master cylinder. Bleed the brakes as
follows: FIGURES 19 AND 20
-41
NOTE: If an air/hydraulic or mechanical actuator system is
used, pushing the pedal to the down position does not
remove all the air from the system. Tighten the bleeder
screw before returning the pedal to the up position so that
air is not pulled back into the system. After the pedal is in
the up position, loosen the bleeder screw and push the
pedal down until air is removed from the system. Tighten
the bleeder screw before releasing the pedal.
-42
-44
DRIVE AXLE ASSEMBLY
WITHOUT WHEEL BRAKES
Item Description Quantity Item Description Quantity
OVERHAUL OF AXLE ASSEMBLY
(Less Wheel Brakes)
NOTE: Procedure for disassembly and reassembly of axles without brakes are the same as axles with dry disc
If face seal retainer was replaced or removed from the spindle, apply a continuous coat of Loctite sealer #515 to the seal retainer
area on the spindle. It is recommended the seal retainer be heated to 375°F [190,6C] and pressed against shoulder on spindle.
Press inner and outer bearing cups into position in wheel hub. Position inner bearing in bearing cup. Install
face seal in seal retainer and in wheel hub per instruction on face seal installation on page 93. Refer to Figure
-46
DIFFERENTIAL ASSEMBLY SERVICE (LIMITED SLIPI, NoSPIN
AND STANDARD)
The Clark-Hurth POSI TORQ limited slip differential is designed to prevent the severe loss of traction which occurs when one wheel
encounters adverse tractive conditions such as slippery, wet, muddy conditions and the uneven terrain often encountered in off-road vehicle
operations. This terrain can cause the vehicle to become immobile because of the spinning of one wheel.
The Clark-Hurth POSI TORQ differential uses clutch plates (which may optionally be spring loaded) to inhibit spinning and send torque to
the high-traction wheel. With the spring loaded POSI TORQ, the wheel with the best traction can have up to five (5) times the torque of the wheel
with poor traction (5:1 bias ratio) at low torque levels. The use of clutches in the differential provides high torque bias while maintaining a smooth
differential action. This eliminates the drive line shock inherent in locking type differentials.
FEATURES:
.Directs torque away from a slipping wheel to the wheel with the most traction
.Provides Up to five (5) times the torque to the tractive wheel as to the slipping wheel at low torque
levels.
.Uses a quiet four (4)-pinion gear differential with each pinion backed by a replaceable thrust
washer to reduce maintenance costs
.Available in two (2) versions -without springs and with springs depending on application
requirements
-47
LIMITED SLIP DIFFERENTIAL
General Description
The limited slip differential is similar in construction to the torque proportioning or conventional differential. The difference is that the limited
slip differential contains a set of discs, like those used in the Clark-Hurth transmission, which are mounted between the differential side gears
and differential case. These discs limit the amount of "differential" according to the amount of torque transmitted through the differential
assembly.* The purpose of the limited slip differential is to give better traction characteristics than a torque proportioning or conventional
differential and to give better "differential action" when turning than the "nospin" differential. The result is a compromise which provides good
traction and less tire wear.
* Differential action is that function of a differential which allows the outside wheel to rotate faster than the inside wheel when turning a machine.
Operation
In the limited slip differential there is a set of internally splined discs and a set of externally splined discs behind each side gear. The internal
discs are splined to the side gear and must rotate when the side gear rotates. The external discs are splined to the differential case and must
rotate when the differential case rotates. The amount of torque transmitted through the differential assembly determines the force the side gears
exert against the discs. When a small amount of torque is transmitted through the axle assembly, the side gears have little side thrust. When a
high amount of torque is transmitted through the differential assembly, the side gears have a high side thrust and the discs are compressed
together.
When a machine is traveling straight, the side gears and the differential case are rotating at the same speed and there is no slipping action
between the discs When a machine is turning, the side gears must rotate at a different speed than the differential case. The discs must slip. The
amount the discs slip is controlled by the pressure exerted by the side gear and the degree the machine is turned. If the torque transmitted
through the axle is low, the discs are free to slip easily and "differential action" takes place easily. When the torque transmitted through the axle
is high, the discs are compressed together by the force of the side gears and the "differential action" will not take place as easily.
As the discs wear through normal use, the side gears move farther outward. The limited slip differential is self adjusting or self-compensating
for wear -the torque proportioning axle is not.
-48
Lubrication and Service
The limited slip differential uses the same type of lubricant recommended for torque proportioning or conventional axles and the
service interval is the same. For proper lubrication of the discs the oil level in the axle housing had to be raised to the center line
of the housing. Any axle that comes from the factory equipped with the limited slip differential will have an oil level plug properly
located in the center line of the housing.
It is extremely important that the oil level be kept at the level plug. If the oil level becomes too low the discs will not receive
sufficient lubrication and will wear rapidly.
Disc replacement time is determined by the amount of material collected on the magnetic drain plug. When the oil level is
checked, examine the drain plug for metal particles. A considerable increase in the amount of metal particles found on the
magnetic drain pug indicates the necessity for replacing the discs.
The limited slip differential unit is disassembled and assembled like the conventional or torque proportioning differential unit. The
only difference being the removal and installation of the discs. Note the position of the internally and externally splined discs
when disassembling and replace the discs in the same position.
-49
NoSPiN differentials are ideal for vehicles that operate off-road, In bad MAINTENANCE
weather, or under other adverse traction conditions. Lubrication
The NoSPIN differential is designed to operate in those lubricants recommended by
the vehicle/axle manufacturer. No special lubricant is needed For certain cold
PRIME FUNCTIONS
weather applications, use the lightest oil the axle manufacturer will allow.
.Assures "maximum traction" at all time..
.Automatically permIts wheel speed differentiation when Routine Inspection
vehicle turns or operates on uneven surfaces. Follow the recommended lubrication, preventative maintenance
and inspection procedures of the vehicle/axle manufacturer as
part of NoSPIN differential preventative maintenance.
OPERA TION Maintenance, inspection and lubrication requirements of
When a vehicle equipped with a NoSPIN differential is operated in NoSPIN differential equipped vehicles are the same as for
forward or reverse over a smooth surface, the NoSPIN remains locked vehicles with conventional differentials
Both wheels thus turn at the same speed. If one wheel loses traction or
leaves the ground, the opposite wheel, which still has traction, continues Adjustments
to drive the vehicle until traction is regained by both wheels There can No adjustments or alterations should be made to the NoSPIN
be no one-wheel spinout when using NoSPIN differentials (Fig 1)
differential
VEHICLE PERFORMANCE
The performance of a vehicle equipped with a NoSPIN differential will differ from that
of a vehicle equipped with a conventional differential For example
These characteristics are normal because of backlash designed into the NoSPIN
differential
When negotiating a turn under conditions of poor traction, the inside wheel may
receive excessive torque which will cause it to break traction This will cause the
inside wheel to slip until the turn is completed or until the inside wheel catches up
with the outside wheel
When the vehicle turns a corner, or when one wheel passes over an obstruction,
the outside wheel, or the wheel passing over the obstruction, must travel a greater
distance and therefore faster than the other wheel When this occurs, the NoSPIN
differential automatically allows for the necessary difference in wheel speed. (Fig CAUTION
2)
Operator
Turn the engine off and raise all driving wheels of a NoSPIN differential equipped
axle when changing tires to prevent the vehicle from moving Axles equipped with
NoSPIN differentials deliver power to both wheels-even when only one wheel IS on
the ground
Do not operate the vehicle If both wheels of a NoSPIN differential equipped axle are
not driving Power to only one wheel can cause serious steering problems
Distribute the load evenly slde-to-slde do not exceed the vehicles rated payload
capacity keep the diameter of the tires equal Failure to observe these measures can
create a difference in Individual wheel speeds which can cause the NoSPIN
differential to deliver power to only one side of the vehicle and thus cause steering
problems
Operate In low gear when coasting downhill Into a turn Braking capacity IS reduced
when a NoSPIN differential equipped vehicle makes a turn while coasting downhill
Mechanic
NoSPIN differentials have compressed springs Use a retaining bolt or some other
restraining means when separating the differential case halves
A comprehensive NoSPIN differential operation and
maintenance manual is available at a nominal charge.
Contact service publications for Information as to how to
order.
-50
-52
DIFFERENTIAL AND CARRIER ASSEMBLY
LIMITED SLIP
Item Description Quantity Item Description Quantity
-54
DIFFERENTIAL AND CARRIER ASSEMBLY
STANDARD AND NoSPIN
Item Description Quantity Item Description Quantity
1850 DIFFERENTIAL AND CARRIER ASSEMBL Y
-56
Posi- Torq
Limited Slip
Differential
Performance Ranges
POSI TORQ performs in a range dependent upon the size and design variation of the differential. The inclusion of springs
creates pressure on the clutch plates that can increase the tractive effort of the high traction wheel to as much as five (5) times
over the wheel with the poor traction. As operating conditions improve and the torque level in the axle increases, the effect of
the springs diminishes and the bias ratio declines.
In a POSI TORQ without springs the clutch friction is proportional to axle torque, so bias ratio is constant over the axle torque
range. A bias of between 2 2.75 can be achieved in a POSI TORQ without springs.
-75
1850 POSI TORQ
-76
-88
MULTI-DISC LlQUID COOLED BRAKE ASSEMBLY
The self contained liquid cooled brake system uses the same lube as the axle center section and wheel ends. There are no
seals between the spindles and wheel hubs. Oil that lubricates the differential and planetary wheel ends also lubricates and
cools the brake assembly. The oil level is the same height as the planet and axle center and the brake may be filled and oil level
checked at the planet carrier assembly or planet carrier cover. Brake oil changes would be accomplished at the same time the
axle lube is changed. Contaminates resulting from braking will not affect axle within normal oil change periods.
2. Pump porto-power up to about 500 P.S.I. [3447,4 kPa] and bleed brake. After all air is out of
brake, pump porto-power up to 1000 P.S.I, [6894,8 kPa] and lock off. The gauge will show about 100 P.S.I.
[689,5 kPa] drop. At this point the gauge should hold. After three (3) to five (5) mirnutes unlock gauge, let
pressure bleed off so the gauge shows zero, then pump porto-power up to about 100 P.S.I. [689,5 kPa].
Lock off porto-power. Gauge should hold at 100 P.S.I. [689,5 kPa]. Let stand for about five minutes. If
pressure holds, the brake does not leak. If there is a drop in pressure on the gauge the brake is leaking and
will require a complete disassembly to replace the piston inner and/or outer sealing ring.
3. After making a satisfactory test, relieve pressure on the porto-power and remove. Reinstall brake
line arnd bleed brakes in a normal manner.
FACE SEAL BREAK-IN PERIOD
WHEN MACHINE IS IMMEDIATELY DRIVEN FROM PRODUCTION FLOOR OR AFTER FACE SEAL HAS BEEN REBUILT OR REPLACED,
IT IS IMPERATIVE THAT A 15 MINUTE BREAK-IN PERIOD BE CONDUCTED AT NOT MORE THAN 25 RPM WHEEL SPEED, WHICH IS 5
MPH MAX. AND IN 1ST GEAR OPERATION ONLY. THIS IS TO ALLOW THE SEAL RUBBERS AND METAL RINGS TO PROPERLY SEAT.
IT IS RECOMMENDED THAT AXLES WITH EXTERNAL COOLED LIQUID COOLED BRAKES (LCB) USE "TRACTOR HYDRAULIC FLUIDS"
MEETING ALLISON C4 DESIGNATION FOR COOLING OIL. THIS FLUID HAS E.P. ADDITIVE FOR IMPROVED FACE SEAL LIFE AND
-91
SEAL REBUILDING INSTRUCTIONS FOR SPLIT SEAL INSTALLATION
1. The rebuilding kit includes two (2) rubber rings (see Figure 1) and two (2) lint free wiping cloths. Both of the rubber
rings must have barbs as shown in the drawing.
NOTE: In rebuilding the seal do not intermix metal sealing rings. Keep original mated metal sealing rings as a set (see Figure 2).
2. Before rebuilding the seal inspect the two metal sealing rings in the following manner to determine if it is acceptable for rebuilding.
(a) The .sealing band must be within the outer half of the sealing face (see Figures 3 and 4). The sealing band is a
narrow highly polished band on the sealing face.
Seal acceptable for rebuilding Sealing band not within outer half of sealing face.
(b) The sealing band must be uniform in width and must be concentric with the I.D. and O.D. of the sealing face (see Figure 5).
If the metal sealing rings do not meet the proper specifications, do not rebuild the seal-use a completely new seal.
(a) Remove any foreign material from the back of the metal sealing rings with a scraper or wire brush (see Figure 6).
(b) Clean the metal sealing rings with a clear! degreasing solvent then wipe with the lint free wiping cloths
furnished in the rebuilding kit (see Figure 6).
4. Assemble the rubber rings to the metal sealing rings. Be sure the rubber rings are completely seated against the back of sealing faces (see Figure 7).
5. Apply a thin film of light oiI to one of the sealing faces, being careful not to wet other surfaces with oil (see Figure 7).
Cleanliness is critical when handling these seals.
6. See page 93 for face sea I installation instructions, and page 104 for Duo-Cone installation instructions.
-92
FACE SEAL INSTALLATION INSTRUCTIONS
1, Examine the seal carefully and note its four basic parts. It has two rubber members and two lapped metal sealing rings. On new face seals a clear
plastic retainer band is optional and is used only to hold the seals together. Discard plastic band. Note that both rubber members have barbs at the
O.D. The barbs are there to hold the seal halves concentrically in their bores while you are making the assembly; that is their only function.
It is possible to push a rubber member off of the neck of the metal sealing ring. Do not install the seal while it is in this condition-the rubber member
will not go back on the neck of the metal sealing ring by itself. Before installing the seal, you must push the rubber member back on the neck of the
metal sealing ring. When installing the seal you must hold it so that you will not dislodge the rubber members from the metal sealing rings.
One (1) of these bores will be in the wheel hub (a rotating member) and the other bore will be stationary (in the liquid cooled brake housing.)
The function of this seal is to prevent dirt from entering the axle end or axle lube from leaking.
3. An important point to note is that there must be no oil or dirt on the bores, rubber members, or any area of the casting except the lapped face as
explained below. Any oil or dirt in these areas must be removed with a clean degreasing solvent. (A new seal is packaged and shipped clean of oil
and dirt, and need not be re-cleaned unless it has become contaminated.)
4. Seals for split seal assembly may be shipped with their lapped sealing faces (interface) lightly pre-Iubed for installation under clean environmental
conditions. If the seal has not been pre-Iubed or has become contaminated, the lapped face must be wiped clean and a few drops of light oil applied
as a pre-Iube.
5. Seal installation.
(a) Remove oil and dirt from the seal bores using a clean degreasing solvent.
(b) If the seal was shipped with a clear plastic retainer band, remove retainer band.
(c) Install one-half of the seal all the way into one bore, being careful not to get oil or dirt on the O.D. of the rubber
member or dislodge it from its metal sealing ring. (See drawing installation, Step 1.) Repeat the other half of the
seal assembly into the other bore. Note that the barbs hold the seal halves concentrically in the bores.
(8) When the installation is complete (wheel hub to brake), rotate the wheel hub 3 complete revolutions to seat the seal faces.
-93
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONT ACT CHART
ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL RING GEAR THE
FIG. 1
FIG. 2
TOE BEARIING ON BOTH SIDES OF TOOTH -GEAR SET NOISY. TO MOVE BEARING TOWARD
HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH -GEARSET NOISY AND COULD RESULT IN EARLY
GEAR FAILURE. TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY
MOVING GEAR TOWARD PINION,
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT BY PULLING PINION
AWAY FROM GEAR (INCREASE MOUNTING DIST ANCE,
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION, CORRECT BY MOVING PINION IN
TOWARD GEAR (DECREASE MOUNTING DIST ANCE,
BACKLASH
BACKLASH SHOULD BE MEASU RED WITH A DIAL INDI CA TOR RIGIDL Y MOUNTED WITH THE STEM PERPENDICU
LAR TO THE TOOTH SURFACE )AT THE EXTREME HEEL.
-94
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRA RING GEAR -THE
FIG. 1
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH -GEAR SET NOISY. TO MOVE BEARING TOWARD
HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH -GEARSET NOISY AND COULD RESULT IN EARLY
GEAR FAILURE. TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY
MOVING GEAR TOWARD PINION,
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT BY PULLING PINION
AWAY FROM GEAR (INCREASE MOUNTING DIST ANCI.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT BY MOVING PINION IN
TOWARD GEAR (DECREASE MOUNTING DISTANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
-95
CLARK RECOMMENDED WHEEL MOUNTING TORQUE
-96
TORQUE FOR BOLTS, CAPSCREWS, STUDS AND NUTS
-97
AXLE SERIES
19D2641
1. Before wheel bearing adjustment is made, it is imperative all tapered bearing cones and cups be pressed to fully seated position. DO NOT
depend on the wheel bearing adjusting nut to "shoulder" tapered bearing cups and cones. NOTE: If the wheel bearing adjusting nut has an
undercut on the inner diameter, the undercut must go toward the internal gear hub. On axles with LCB brakes, release pressure before
continuing (any brake drag will affect obtaining correct rolling torque value).
2. Coat inner face of nut, spindle threads, and spindle splines with brush-applied lubricant (Anti-Seize or Never-Seez).
3. Install spindle nut and tighten to 800 Ibf.ft [1085 N.m] torque. Shock internal gear hub with heavy bar while
rotating wheel hub two (2) to three (3) times. Recheck nut torque-if nut moves, retorque to 800 Ibf.ft [1085 N.m] and repeat shocking and
tightening as many times as necessary until 800 Ibtft [1085 Nom] does not advance nut. Loosen nut 1/4 to 1/2 turn and shock the wheel
hub until a slight bearing end play is achieved and the wheel hub can rotate freely.
4. Using a torque wrench adaptor bar or other appropriate measuring device, determine the rolling torque of the wheel end with the bearings in
a no-load end play condition. Due to part imbalance, there will be a variation in rolling torque as the wheel hub is rotated. Record
maximum value of rolling torque throughout a revolution. This value will be the "no-load rolling torque" (LCB up to 200 Ibf.ft [271 N.m],
others 25 to 100 Ibf.ft [34-135 N.m]).
5. For field service torque nut to 400 Ibf.ft [542 N.m]. Shock internal gear hub with heavy bar while rotating wheel hub two (2) to three (3) times
while shocking the wheel. Re-check nut torque-if nut moves, re-torque to 400 Ibf.ft [542 N.m] and repeat shocking and tightening as many
times as necessary until 400 Ibtft [542 N.m] does not advance nut. Then advance nut until three (3) holes in lock plate line up with tapped
holes in internal gear hub.
6. Check rolling torque-must be in the specified range as shown on adjustment chart over no-load rolling torque.
7. If over the maximum preload, reduce nut torque as required to obtain the specified range but not less than 300 Ibf.ft [406 N.m] on nut.
8. If under the minimum preload, increase nut torque until preload is in the specified rolling torque range with
lock plate holes aligned, but not more than 900 Ibf.ft [1220 N.m] after rotating the wheel hub five (5) or more times.
9. * Install lock plate and screws, tighten screws 20 to 25 Ibf.ft [27-33 N.m]. See page 101.
*NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING COMPOUND ON THREADS. USE ONL Y ONE
TIME, THEN REPLACE OR THOROUGHL Y CLEAN USED SCREWS AND APPL Y EITHER LOCTITE 262 (HI STRENGTH) OR
LOCTITE 242 (MEDIUM STRENGTH). INTERNAL GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING
SCREWS.
-98
AXLE SERIES
19D2748 -D-37770
1. Before wheel bearing adjustment is made, it is imperative all tapered bearing cones and cups be pressed to fully seated
position. DO NOT depend on the wheel bearing adjusting nut to "shoulder" tapered bearing cups and cones. NOTE: If the
wheel bearing adjusting nut has an undercut on the inner diameter, the undercut must go toward the internal gear hub. On
axles with LCB brakes, release pressure before continuing (any brake drag will affect obtaining correct rolling torque
value).
2. Coat inner face of nut, spindle threads, and spindle splines with brush-applied lubricant (Anti-Seize or Never-Seez).
3. Install spindle nut and tighten to 1000 Ibf.ft [1356 N.m] torque. Shock internal gear hub with heavy bar while
rotating wheel hub two (2) to three (3) times. Recheck nut torque-if nut moves, retorque to 1000 Ibf.ft [1356 N.m] and
repeat shocking and tightening as many times as necessary until1000 Ibf.ft [1356 N.m] does not advance nut. Loosen nut
1/4 to 1/2 turn and shock the wheel hub until a slight bearing end play is achieved
and the wheel hub can rotate freely.
4. Using a torque wrench adaptor bar or other appropriate measuring device, determine the rolling torque of the wheel end with
the bearings in a no-load end play condition. Due to part imbalance, there will be a variation in rolling torque as the wheel
hub is rotated. Record maximum value of rolling torque throughout a revolution. This value will be the "no-load rolling
torque" (LCB up to 200 Ibf.ft [271 N.m], others 25 to 100 Ibf.ft [34-135 N.m]).
5. For field service torque nut to 400 Ibf.ft [542 N.m]. Shock internal gear hub with heavy bar while rotating wheel hub two (2) to
three (3) times while shocking the wheel. Re-check nut torque-if nut moves, re-torque to 400 Ibf.ft [542 N.m] and repeat
shocking and tightening as many times as necessary until 400 Ibf-ft [542 N"m] does not advance nut. Then advance nut
until three (3) holes in lock plate line up with tapped holes in internal gear hub.
6. Check rolling torque-must be in the specified range as shown on adjustment chart over no-load rolling torque.
7. If over the maximum preload, reduce nut torque as required to obtain the specified range but not less than
300 Ibf.ft [406 N.m] on nut.
8. If under the minimum preload, increase nut torque until preload is in the specified rolling torque range with
lock plate holes aligned, but not more than 900 Ibf.ft [1220 N.m] after rotating the wheel hub five (5) or more times.
9. * Install lock plate and screws, tighten screws 35 to 40 Ibf.ft [47-54 N.m]. See page 101.
"NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING COMPOUND ON THREADS. USE ONL Y ONE
TIME, THEN REPLACE OR THOROUGHL Y CLEAN USED SCREWS AND APPL y EITHER LOCTITE 262 (HI STRENGTH) OR
LOCTITE 242 (MEDIUM STRENGTH). INTERNAL GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING
SCREWS.
-99
AXLE SERIES
19D3747 .19D3960 .19D4049 .19D4354
1. Before wheel bearing adjustment is made, it is imperative all tapered bearing cones and cups be pressed to fully seated
position. DO NOT depend on the wheel bearing adjusting nut to "shoulder" tapered bearing cups and cones. NOTE: If the
wheel bearing adjusting nut has an undercut on the inner diameter, the undercut must go toward the internal gear hub. On
axles with LCB brakes, release pressure before continuing (any brake drag will affect obtaining correct rolling torque
value).
2. Coat inner face of nut, spindle threads, and spindle splines with brush-applied lubricant (Anti-Seize or Never-Seez).
3. Install spindle nut and tighten to 1200 Ibf.ft [1627 N.m] torque. Shock internal gear hub with heavy bar while
rotating wheel hub two (2) to three (3) times. Recheck nut torque-if nut moves, retorque to 1200 Ibf.ft [1627 N.m] and
repeat shocking and tightening as many times as necessary until 1200 Ibf'ft [1627 N.m] does not advance nut. Loosen nut
1/4 to 1/2 turn and shock the wheel hub until a slight bearing end play is achieved and the wheel hub can rotate freely.
4. Using a torque wrench adaptor bar or other appropriate measuring device, determine the rolling torque of the wheel end with
the bearings in a no-load end play condition. Due to part imbalance, there will be a variation in rolling torque as the wheel
hub is rotated. Record maximum value of rolling torque throughout a revolution. This value will be the "no-load rolling
torque" (LCB up to 200 Ibf.ft [271 N.m], others 25 to 100 Ibf.ft [34-135 N.m]).
5. For field service torque nut to 600 Ibf.ft [814 N.m]. Shock internal gear hub with heavy bar while rotating wheel hub two (2) to
three (3) times while shocking the wheel. Re-check nut torque-if nut moves, re-torque to 600 Ibf.ft [814 N.m] and repeat
shocking and tightening as many times as necessary until 600 Ibf-ft [814 N.m] does not advance nut. Then advance nut
until three (3) holes in lock plate line up with tapped holes in internal gear hub.
6. Check rolling torque-must be in the specified range as shown on adjustment chart over no-load rolling torque.
7. If over the maximum preload, reduce nut torque as required to obtain the specified range but not less than
400 Ibf.ft [542 N.m] on nut.
8. If under the minimum preload, increase nut torque until preload is in the specified rolling torque range with
lock plate holes aligned, but not more than 1400 Ibf.ft [1898 N.m] after rotating the wheel hub five (5) or more times.
9.* Install lock plate and screws, tighten screws 35 to 40 Ibf.ft [47-54 N.m]. See page 101.
*NOTE: LOCK PLATE SCREWS ARE OF A SELF-LOCKING TYPE (ORANGE) LOCKING COMPOUND ON THREADS. USE ONL Y ONE
TIME, THEN REPLACE OR THOROUGHL Y CLEAN USED SCREWS AND APPL Y EITHER LOCTITE 262 (HI STRENGTH) OR
LOCTITE 242 (MEDIUM STRENGTH). INTERNAL GEAR HUB THREADS MUST ALSO BE CLEANED WHEN REPLACING
SCREWS.
-100
-101
AIR CHECKING THE AXLE WHEEL ENDS AND CENTER
SECTION
Air check the axle center section the same way as the wheel ends
except the checking device is installed in the air breather hole in
the axle center. If an air leak is detected, locate leak and correct.
After air check is made, reinstall air breather in axle center.
-102
CLEANING AND INSPECTION
-103
CORRECT ASSEMBL Y OF DUO-CONE SEALS
STEP -2
1. Oil Leakage
2. Galling
3. Pumping Mud Past The Toric
4. Toric Failure
5. Seal Ring Breakage
Failures are caused by combinations of factors rather than
one single cause, but all have one common denominator
contributing to failure ASSEMBLY ERROR.
-104
STEP -5
STEP -6
STEP -7
FINALLY!
BEFORE ASSEMBLING
BOTH SEALS AND HOUSING TOGETHER...
-105
RESULTS OF INCORRECT ASSEMBLY
-106