1T 8l qbY498zmSUk-zDBJXfZWsKEjcu5 PDF

No
o.: SW‐JS‐22014‐0002
2

HDS300 SERIES DRIV
VE AXLLE SER
RVICE
MANNUAL OOF HA
ANDE AXLE

anDe parts N
Ha No. CCargotec partts No.
HD
DS16T331580 0031 338800377
HD
DS16T331580 0134 338800902
HD
DS16T3315** **** *********

Versions:
V August 2016

HAND
DE produ
ucts

HDS300 R
Rear Rear D
Drive Axle

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588 Email:salees@handeaxle.com
FForeword
d
Th
his manual ccomposed o
of axle assyy. structure of HDS 300 series drivee axles, indications
marks, instaalling and dismantlinng processs and methods, bassic knowle
and m edge of
maintenance, for tthe end use
er’s referencce under service and m
maintenancee.
Th
his manual is applicable to all HD
DS300 serie
es products produced by Shaanxi HanDe
Axle Co
o., Ltd. To be
b sure you
ur interest and axle performance
p e will not bbe affected,, please
read carefully beefore mainttenance, a nd use the original axle assy. or parts for the
maintenance.
W use HanDe products, w
Welcome to u we’ll try the best to servve all users well.
Sh
haanxi HanD
De Axle Co.., Ltd. keepss the right to change on technicaal in future for the
develop
pment.

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Contentt
Specificcations & Idenntifications of Axle Assy. . .............................................................. ................................ 6
1. Specificaations of Axle Assy. ......... .............................................................. ................................ 6
2. Identificcations of Axlle Assy. ........ .............................................................. ................................ 6
Part I W
Wheel End of R.R R Axle ........................... .............................................................. ................................ 8
1.1 Dismantle &Assemble
& Brake Drum ... .............................................................. .............................. 10
1.1.1 Dismmantle Brake Drum
D ............ .............................................................. .............................. 10
1.1.2 Assem mble Brake Drum.............
D .............................................................. .............................. 10
1.2 Dismantle & Assemble End E Cover ..... .............................................................. .............................. 11
1.2.1 Dismmantle End Co over .............. .............................................................. .............................. 11
1.2.2 Assem mble End Cov ver ............... .............................................................. .............................. 11
1.3 Dismantle annd Assemble Sun Gear .... .............................................................. .............................. 12
1.3.1 Dismmantle Sun Geear ................ .............................................................. .............................. 12
1.3.2 Assem mble Sun Geaar ................. .............................................................. .............................. 12
1.44 Dismantle & Assemble Hub H Reducer . .............................................................. .............................. 13
1.4.1 Dismmantle Hub Reeducer .......... .............................................................. .............................. 13
1.4.2 Assem mble Hub Reducer ........... .............................................................. .............................. 14
1.5 Dismantle annd Assemble Hub Assy. ... .............................................................. .............................. 15
1.5.1 Dismmantle Hub Asssy. ............... .............................................................. .............................. 15
1.5.2 Assem mble Hub Assy. ................ .............................................................. .............................. 17
1.6 Dismantle annd assemble wheel hub.... .............................................................. .............................. 19
1.6.1 Dismmantle Wheel Hub ............. .............................................................. .............................. 19
1.6.2 Wheeel Hub Assem mbly .............. .............................................................. .............................. 20
1.7 Dismantle annd assemble brake shoe asssy. ........................................................ .............................. 21
1.7.1 Dismmantle brake shoe .............. .............................................................. .............................. 21
1.7.2 Assem mble brake sh hoe assy........ .............................................................. .............................. 22
1.8 Dismantle annd Assemble the Slack Addjusting arm & Camshaft ..................... . .............................. 23
1.8.1 Dismmantle the Adjusting Arm & Camshaft ............................................ .............................. 23
1.8.2 Assem mble the Adju usting Arm annd Camshaft .......................................... .............................. 24
1.9 Assembling of Adjusting Arm ............ .............................................................. .............................. 25
1.9.1 Assem mbling of Adjjusting Arm . .............................................................. .............................. 25
1.9.2 Adjussting of adjussting arm ...... .............................................................. .............................. 26
1.10 Remove annd Assemble Brake B Floor . .............................................................. .............................. 27
1.10.1 Rem move the Brak ke Floor........ .............................................................. .............................. 27
1.10.2 Asseemble the Camshaft and B Brake Floor ............................................ .............................. 27
Part 2 Fiinal Drive off Rear Axle ......................... .............................................................. .............................. 29
2.1 Disassemblee and assemble final drive assy. ..................................................... .............................. 31
2.1.1 Disasssemble final drive assy.... .............................................................. .............................. 31
2.1.2 Assem mble final driive assy. ....... .............................................................. .............................. 31
2.2 Remove andd mount beariing seat assy. .............................................................. .............................. 32
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2.2.1 Remoove bearing seat assy. ....... .............................................................. .............................. 32
2.2.2 Installl bearing seaat assy. .......... .............................................................. .............................. 32
2.3 Disassemblee and assemble diff assy. .. .............................................................. .............................. 33
2.3.1 Disasssemble diff assy. a ............. .............................................................. .............................. 33
2.3.2 Assem mble diff assy y. .................. .............................................................. .............................. 34
2.44 Disassemblyy and assembly diff assy... .............................................................. .............................. 37
2.4.1 Disasssembly diff assy. a ............. .............................................................. .............................. 37
2.4.2 Assem mbly diff assy y. .................. .............................................................. .............................. 37
2.5 Disassemblee and Assemb ble Bearing S Seat assy. with h Pinion gear .................... .............................. 39
2.5.1 Disasssemble beariing seat assy. with the piniion gear ............................. .............................. 39
2.5.2 Assem mble pinion assy. a .............. .............................................................. .............................. 41
………… ................................................ .............................................................. .............................. 44
Others…
Acccessories Tabble ...................................... .............................................................. .............................. 44
Bollt Tightening Torque to Keey Parts ........ .............................................................. .............................. 44
Toools Table ................................................ .............................................................. .............................. 45
Fit & Adjustmennt of ASA .......................... .............................................................. .............................. 50
D Lock .......................... .............................................................. .............................. 55
Appplication of Diff.
Maaintenance Reegulation ............................ .............................................................. .............................. 56
Typpical Troubleshooting ............................ .............................................................. .............................. 57

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5
Sp
pecifications & Id
dentifica
ations of Axle Asssy.
1. Speccifications o
of Axle Assyy.

HDS300 hub
H R.R Drive Axle
reduction R

Speecifications o
of axle assy.：
No. Ittem RR axle Remarks

Fill tthe oil paralle
el to
1 Oil volume of final drive
e 8.3 L(refere
ence)
thee oil filling ho
ole
2 Oil volum
me of hub 2.8 L each hub
Tightening torque off

3 （550～600
0）Nm
wheel nut
Tightening torque of oil
4 （80±10）Nm
filling or drain plug
2. Identifications o
of Axle Assyy.

Nameplate information
1） Axle number: HDS16
6T3315800331 is axle nu
umber of Ha
anDe.
2） Speed rattio: 11.98 is the total drrive ratio.
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3） Axle load:16000kg is the rated aaxle load.
4） Manufactturing numb
ber: D1406600499, Con
nsists of 1 ca
apital letterr and 9 digitts.
d：Capital letter indicaate the asse
Remarked embly line o
of axle;
Forward
ds 4 letters represent tthe assemblly date of m
month and yyear;
Last 5 le
etters repreesent production serial number.
5）0732‐352:: 38800377 is the axle nnumber of Cargotec.
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Part I W
Wheel End o
of R.R Axle

FFigure 1 Wheel EEnd Explosive Draw
wing of F.R & R.R Axxles
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1.Heexagon bolt 22.ABSS bracket 43.Adjustin ng washer 65.Inner gear rring 87.Circlip for shaft
8
2.Sppring washer 23.Hexxagon bolt 44.Circlip ffor shaft 66.Oil baffle 8
88.End cover pin
3.Oiil shield; 24.Sennsor bush 45.Grease nipple 67.Circlip for hole 8
89.End cover
4.Seeal washer; 25.Sennsor 46.Stud 68.Gear ring brracket 9
90.Seal washer
5.Huub oil seal 26.Hexxagon bolt 47.Plat washer 70.Locknut 9
91.Hexagon bolt
6.Sppacer ring 27.Braake bottom plate 48.I type o
of hexagon nut 71.Thrust wash her 9
92.Plug
7.Seeal ring 28.Add ditional washer 49.Circlip ffor shaft 72.Lock nut 9
93.Brake drum
8.Tapered roller bearin ng; 29.O ring 50.Seal rin
ng 73.Hexagon bo olt 9
94.Screw
9.Huub assy. 30.Bussh 51.Pin 74.Planetary caarrier 9
95.Cross recessed h head screw
10.TTapered roller bearring 31.Circclip for shaft 52.Pressurre switch 75.Sun gear waasher 9
96.Stud
11.WWheel nut 32.Dusst cover of brake 53.O ring 76.Cylindrical ppin 9
97.Locknut
12.RReturn spring 33.Dusst cover of brake 55.Operatiionbar 77.Sun gear 9
98.Cylindrical pin
13.EElastic cylindrical p
pin 34.Sprring washer 56.Fork link 78.Seal ring 9
99.Fixing clip assy.(
(Low)
14.PPin 35.Hexxagon bolt 57.Hexago on nut 79.Plantary waasher 1
100.Fixing clip assy
y.(up)
15.RReturn spring pin 36.Seaal block 58.ES flat ppin 80.Washer 1
101.Plug
16.RRuturn spring 37.Hexxagon bolt 59.Cylindeer 81.Needle bearing 1
102.Hexagon bolt
17.BBrake shoe assy. 38.Braake cam shaft brackket 60.Plug 82.Plantary geaar shaft 1
103.Brake cylinder bracket
18.RRoller 39.Adjjusting washer 61.Stud 83.Plantary geaar 1
104.Axle housing a assy.
19.BBrake cam shaft 40.Bussh 62.Flat washer 84.Steel ball 1
105.Axle shaft
20.HHexagon socket cap screw 41.ASAA 63.Hexago on lock nut 85.Wheel carrier case
21.AABS bracket 42.Washer 64.Ventagee plug 86.Washer

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1.1 Dismaantle &Asssemble B
Brake Dru
um
1.1.1 Dism
mantle Brake Drum
A. Dismanttle the coun
ntersunk he
ead screw w
with the
cross screw
wdriver.

B. Push thee drum outt with M10 jackscrew.

1.1.2 Assemble Brake
e Drum
A. Check tthe surfacee of brake drum , chaange a new
w
one if therre have crack or over wearing onn the drum.
Clean the contact faace betwee en the dru m and thee
hub. Tighteen the drum m with countersunk heead screw.

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1.2 Dismaantle & A
Assemble End Coveer
1.2.1 Dism
mantle End C
Cover
A. Dismanttle the oil d
drain plug from the ennd cover
and drain tthe oil out ffrom the hu
ub.

B. Dismanttle the bolts of the end cover andd take
down the eend cover.

1.2.2 Assemble End C
Cover
he hub redu
A. Clean th ucer case and end Covver. Apply
the sealantt [a] on thee surface off the end coover
equally.
Note: The operation o
of sealant sshall be conntinuously
and closed
d.

e
B. Apply tthe locking agent [c] into the tthread hole
and tighten n the end ccover with hhex bolts.

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1.3 Dismaantle and
d Assemblle Sun Ge ar
1.3.1 Dism
mantle Sun G
Gear
A. Dismanttle and takee out the circlip.

B. Pull the axle shaft aand take ou
ut the sun ggear,
washer of the sun geaar and put out the axl e shaft.

1.3.2 Assemble Sun G
Gear
A. Clean th
he spline off axle shaft and put tthe axle
hub. Put the washer o
shaft into h of sun gear, sun gear,
washer and
d circlip on the spline of the axlee shaft in
order.
Note: circlip shall be put into its groove.

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1.4 Dismaantle & A
Assemble Hub Redu
ucer
1.4.1 Dism
mantle Hub Reducer
A. Screw off the crosss recessed ccountersunnk head
screw.

B. Push thee hub reduccer out from
m the hub reducer
with jacksccrew and taake down th
he hub reduucer assy.
Screw off tthe bolts off the Planetaary carrier;

C. Loose th
he connectiing bolts off the Planetaary carrier.

D. Knock o
out the posiitioning pin
n of the hubb
nd take out the planetary carrier, planet
reducer an
gear and needle bearring.

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1.4.2 Assemble Hub R
Reducer
A. Put the bigger facee of hub red
ducer downnwards.
Press the p
planet gear shaft and ssteel balls iinto
position affter aligningg the steel balls at thee
positioningg groves of the hub reducer case .

B. Overturn the hub rreducer casse and Asseemble the
washer ontto the planet gear shaaft.
Note: put tthe grove o
of the washer downwaards.

one install needle beaaring, washeer, needle
C. One by o
bearing, pllanet gear, washer of p
planet gearr.
Note: The long groove surface o
of planet geear washer
shall be up
p direction. The white or blue pacckaged
needle beaarings shall match the planet geaar. Mixed
assembly is not allow
wed.
D. Press Plaanetary carriier into position with ttool [1]
after aligniing the plan
net gear shaft.
Note: The matching m marks of Planetary carrrier and difff.
Case shall be in one line, and change in pair under
maintenan nce.

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E. Tighten hex bolt.
Note: Applly locking aagent [c] on
nto the boltt.
Tighteningg torque: (1
125±10)Nm. Keep plannet gear
flexible.

F. Check O‐‐ring, replace a new one in case damaged.

G. Apply oil [f] onto the contactiing area be tween
inner cham
mber of the hub reducer case andd hub
ducer with cross
sealing ringg. Tighten tthe hub red
countersun
nk head scrrew after aligning the oil drain
hole and w
wheel bolts..

1.5 Dismaantle and
d Assemblle Hub Asssy.
1.5.1 Dism
mantle Hub Assy.
A. Take dowwn the circclip of the in
nner gear rring and the
e
gear ring w
with screwddriver .

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B. Knock thhe lock platte flat with chisel.

C. Screw offf the outside slotted round nut w with
special too
ol [2]. Take o
out the locking plate aand screw
off the insiide slotted round nut.

D. Take dow wn the geaar ring brackket assy.

E. Dismanttle the hub.. Dismantle
e the inner ring and
space ring of hub beaaring with tool 3.

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1.5.2 Assemble Hub A
Assy.
A. Press sp
pace ring into position with tool [[4].

B. Press inn
ner ring of inner bearing into possition with
tool [4].

C. Assemble the hub assy. and gear ring braacket assy.

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D. Assemble gear ringg bracket. T
Tighten the first
slotted rou
und nut by (500±50)Nm
m with too l [2]. And
turn the hu
ub around b
by 2‐3 roun
nd.

E. Loose th
he first slottted round n ～90°, and
nut by 60°～
put the loccking plate in; Tighten the secondd slotted
round nut with tool [2
2] by (500±
±50)Nm.

F. Measuree the start ppower of th
he hub whicch shall be
(70‐90)N. If not, loosee the secon
nd slotted nnut and
adjust the first slotted
d nut.

G. Lock thee lock platee.
Note: lock the 2 locking nuts botth.

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H. Assemble the inner gear ring and circlip .
Note: put tthe circlip into groove
e.

1.6 Dismaantle and
d assemble wheel h
hub
1.6.1 Dism
mantle Whe
eel Hub
A. Removee the wheel hub oil seaal.

B. Removee the outer ring of both inner andd outer
bearings byy tool [5] to
ogether witth [6] & [7] .

C. Press the wheel bo
olt out.

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D. Removee the inner ring of the outer bearring by tool
[5] togetheer with tool [8].

embly
1.6.2 Wheel Hub Asse
A. Keep thee small endd of wheel h
hub upwardds, press
the ring of inner and outer bearings in placce by tool
[9].

B. Press the seal ring into wheel hub by toool [11],
paint somee lube [e] o
on the lip.

C. Press whheel bolts into the holles.

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D. Align the holes and
d assemble the oil bafffle onto
the hub.

E. Press th
he inner bearing onto the gear rring brackett
by tool [100].

1.7 Dism
mantle an
nd assem
mble brakke shoe

assy.
1.7.1 Dism
mantle brake shoe
A. Press the lower braake shoe do
own, removve the
roller. Pull the brake sshoe up, remove the uupper
roller.

B. Pull the spring pin out，remo
ove the bra ke shoe
assy.

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1.7.2 Assemble brake
e shoe assyy.
A. The brakke lining thickness sho
ould not bee less than
8 mm. Otherwise, rep
place new b
brake liningg;

B. Paint Silver‐base an
nti‐jamming agent [g] on the
stand pin. Install the b
brake shoe onto the sttand pin,
place the sshorter spriing.

Silveer‐base antti‐jammingg agent

C. Assemble the longeer spring to
o the springg pin by a
crowbar.
Note: hookk of spring must be pu
ut into the ggroove of
the pin.

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D. Paint Sillver‐base anti‐jamming agent g] oon the holee
surface bettween the brake shoe e and roller,, pry up the
e
brake shoee and place the roller iinto positioon.

Silver‐base antii‐jamming a
agent

B. Push thee positionin
ng pin into the hole onn axle

housing annd paint geaar oil in the
e thread hoole of springg
bracket. Fixx the springg bracket and bottom bracket byy

bolts.
Note: Tighten the bollts by (570±
±20)Nm.

1.8 Dism
mantle and Assemble thee Slack
Adjustingg arm & C
Camshaft
1.8.1 Dism
mantle the A
Adjusting A
Arm & Cam shaft
A. Removee the circlip by pliers. T
Take off thee adjusting
washer, waasher, remo
ove the adju
usting arm..

B. Removee the circlip on the brake floor, thhen pull outt
the camshaaft.

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C. Loose th
he bolt on ccamshaft brracket and remove
the bracket.

1.8.2 Assemble the A
Adjusting Arm and Cam
mshaft
A. Put thee washer and O ring one by onne onto the
e
camshaft, put the cam
mshaft thro
ough the brrake floor.

B. Assemble another washer and
d circlip.
Note: Circlip should b
be put into the groovee on the
shaft.

C. Assemble the brackket and cho
oose the coorrect
washer, paaint thread locking age
ent [b] on t he bolt and
d
fix the braccket onto the axle hou
using.
Note: tightten torque (160±20)Nm.

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D. Assemble the adjusting arm, washer, corrrect
thickness aadjusting arrm washer and circlip..
Note: a. tthe camshaaft should turn flexibbly withoutt
clamping or stagnaation. Otherwise, reeplace the e
adjusting aarm washeer; b. Slack of the adjjusting arm
m
should bee 0.5~2mm m, if not, change aappropriate e
washer.

1.9 Assem
mbling of Adjustingg Arm
1.9.1 Assembling of A
Adjusting A
Arm
A. Make su ure the brakke chamber bar at freee conditionn
before mounting. Forr the chamb bers with sppring
parking braake, the airr pressure sshould be nnot less
than 0.6Mpa, to keep p the chamb ber at origi nal
location.

B. Assemble the adjusting arm o onto the cam mshaft.
Make sure the arrow on the arm m is in the saame
direction wwith that th
he chamberr bar is pushhed out.

C. Fix adjussting arm oonto the camshaft by w washer andd
circlip, keep the axxis clearance of adjuusting arm
m
between 00.5~2mm.

D. Keep the control arm unlocke
ed and can rotate
n the hex bolt by S12 sspanner (byy hand) to
freely. Turn
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25
align the hole on the adjusting aarm at the aaxle hole off
the chamb
ber U fork, insert the p
pin to the h ole and
lock the co
otter pin.

E. Push thee control arrm to the direction of brake
(follow thee arrow on control armm) till it cannnot move,
fix the control arm byy bolt.

1.9.2 Adjusting of adjjusting arm
m
A. Turn thee hex. bolt by hand spanner in cloockwise tilll

the brake sshoe touches the brakke drum, th en turn

the bolt in anticlockw
wise(can here sound ‘kka,ka,ka’).
The clearance can be adjusted to o the corre ct range
after braking for seveeral times.
Note: Do nnot use auto omatic or ppneumatic w wrench.

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26
1.10 Rem
move and Assemble
e Brake Fl oor
1.10.1 Rem
move the Brake Floor
A. Loosen thhe bolts on bbrake floor annd take downn the brake
floor.
B. Push out the bushing in the brake floor bby special
tool [12].

C. If there is deformattion or dam
mage on thee
dustcover, remove the bolts and
d take off thhe
dustcover.

1.10.2 Asseemble the Camshaft a
and Brake FFloor
A. Push thee new bush
hing into the brakeflooor by
special too
ol [13].

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27
B. Take a n
new dustcovver, fix it byy bolt and sspring
washer.

C. Paint thrread locking agent [b] onto the hholes on
axle housin
ng flange, aand tighten the bolts tto fix the
brake floorr.
que 300±30Nm.
Note: Torq
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28
Part 2 Final Drive off Rear Axle

Picture 2
2 Explosive Draw
wing of Final Drive for Rear Axle
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1. Split pin 13. Pinionn gear 25. shifting fork block 377. Hex. head boltt
2. Flange nutt 14. Adjustting washer 26. Shiftiing fork 388. Spring washerr
3. Flange assy. 15. Final d
drive case 27. Bendding plate 399. Stop plate
4. Dust coverr 16. Ring ggear 28. Tapered slotted screw w 400. Self‐locking nu
ut
5. Ring 17. Differential case‐ left 29. I hex nut 411. Stud bolt
6. Oil seal forr final drive 18. Hex bolt 30. Differential case‐ righ
ht 422. Bearing cap
7. Conical rolller bearing 19. Tapereed roller bearing 31. Adjussting washer 433. Cylindrical pin
8. Adjusting w washer 20. Fixed joggle sleeve 32. Side gear; 444. Hex bolt
9. Hex bolt 21. Lock wwasher 33. Planeetary gear washeer 455. Ring
10. Bearing sseat 22. Round d nut 34. Planeetary gear
11.Seal 23. Differential adjusting nut 35. Bush of planetary gear
12. Conical ro oller bearing 24. Slidingg joggle sleeve 36. Spideer

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2.1 Disasssemble aand assem
mble final drive
assy.
2.1.1 Disasssemble fin
nal drive asssy.
A. Disasseemble self‐locking nutt which coonnect finaal
drive and aaxle housin
ng.
Note: Befo
ore disasseembling finaal drive asssy., be sure
e
that lube should be drained out,
o and puull the axle
e
shaft out.
B. Hang ou
ut final drivve assy., and moothly;
d place it sm

2.1.2 Assemble final drive assy.
A. Paint aa circle of sealant on
n big surfaace of axle
e
housing;
Note: Pain
nt sealant evvenly and ccontinuous ly;

B. Install final drivee assy., th
hen diagonnally fasten
n
self‐lockingg nut;
Note: Tightening torq
que should be (110±100)Nm.

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31
2.2 Remo
ove and m
mount bea
aring seatt assy
2.2.1 Remo
ove bearing seat assyy.
A. Removee connectio
on bolts of the bearinng seat and
d
case;

B. Hang out pinion gear
g with bearing
b seaat assy. and
d
place it steeadily. Remove adjustiing washer and seal.
Note: Cleaan up juncttion surface
e of diff. caase, bearingg
seat, adjussting washeer, check if the seal haas damaged
d
for subsequent assem
mbling.

2.2.2 Instaall bearing sseat assy.
plane sealant[a]on the
A. Apply p e edge of tthe bearingg
seat oil passage, then
n mount seaal ring in thhe spigot；
nt with lesss sealant on
Note: Pain o the oil passage, to
o
avoid block in oil passsage;

B. Apply thread locking agent[b
b] on the tthread hole
e
of the final drive caase after clean

c the diff. case
e
surface. Evvenly applyy sealant[a]on the edgge of the oiil
passage. TTake propeer adjusting washers and applyy
plane sealant[a]on th
he oil passage of eacch adjustingg
washer. Then put th
hem on th
he positivee mountingg
holes of th
he final drivve case installation surrface;

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32
C. Align pinion gear aassy. to the
e position oof hole and
d
steadily hang it to final drive
e case. Appply thread
d
locking aggent[c] in the
t final drive
d case. Diagonallyy
fasten hex bolt.
que should be (120±155)Nm.

2.3 Disasssemble aand assem
mble diff aassy.
2.3.1 Disasssemble difff assy.
A. Removee hex. bolts and take o
off stop platte;

B. Removee the conneection boltts of bearinng cap with
h
wrench and take bearing caps out;
Note: Makke a matchiing mark on
n bearing ccaps in both
h
sides to prrevent instaallation mixxing.

C. Place d
diff assy. smoothly
s after hang it out and
d
remove the outer ringg of tapered roller beaaring.
Note: Cheeck if the tapered
t roller bearingg has been
n
damaged.

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33
2.3.2 Assemble diff aassy.
A. Hoist diff assy. with
h the outerr ring on th e diff. case;
Note : Ap
pply a circcle of lubricating oil [f] on the
e
n position of the taapered rol ler bearingg
installation
outer ring;;

B. Apply th
hread locking agent[b] in the thrread hole of
the case. Mount adjusting nut and bea ring cap in
n
turn. Screw
w hex. bolt on bearingg surface;
Note: asssemble beearing cap
p and casse in pairr.
Tighteningg torque of
o bearing cap bolt should be
e
(120±15) N
Nm.

C. By the tool[20] and tool[2
21] rotate differentiaal
adjusting nuts and adjust the
e differenttial bearingg
preload force;

D. Vibrate bearing caap with copper rod t o eliminate
e
all clearance, and measure differenti al bearingg
preload force with a spring balance along tthe tangent
of the connection bolts of the rinng gear.
direction o
Note : diffferential bearing
b pre
eload forcee should be
e
(14‐28)N. Adjust th
hrough tightening a nd loosingg
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34
e
differential adjusting nuts if it is not qual ified. Make

aligning m
marks on the adjustin
ng nut andd diff. case
e
after adjusstment.
E. First asssemble bearing seaat assy. annd measure

e
clearance of pinion gear
g and riing gear w
with the diaal
gauge, wh
hich is fastened on the final drive case
e.
Vertically press dial gauge he
ead on thhe big side
e
convexity of ring geaar. Measure three pooints evenlyy
through ro
otating pin
nion gear and ring gear alongg

circular dirrection;
uld be 0.20～0.40, thee difference
Note: Cleaarance shou e

should be less than 0.13. Adju
ust clearannce through
h
tightening or loosing differentiaal adjustingg nuts if it is

not qualified.
Note: The two adjustting nuts haave same aangle of the
e
tightening and loosing.
F. Evenly aapply red lead powder on the continuous
3~5 surfacce of ring gear,
g then rotate ringg gear backk
and forth, watch the contact patttern.
Note : con
ntact patterrn position shall be a little more
e
in small en
nd of the to
ooth, take u
up 40%～700% of tooth
h
length and
d take up 55%～75%
% of tooth width. The
e
tooth contact patterrn cannot cross the tooth top
p,
bottom and small end. Adju
ust throughh changingg
adjusting washers and tightening oor loosingg
differential adjusting nuts if it is not qualifiied.

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35
G. Tighten stop pllate with hex boltss and lockk
adjusting n
nut.
Note : Tigh
htening torque should
d be (25±2)N
Nm.

H. Mountt fixed‐messh sleeve and locki ng washerr,
tighten rou
und nut witth special to
ools [22] inn place.
Note : Tigh
d be (200±220)Nm.

I. Bend locck tongue o
of the lock w
washer.
Note : Thee lock tongue shall come into th e groove of
the round nut.

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36
2.4 Disasssembly and assem
mbly diff aassy.
2.4.1 Disasssembly difff assy.
A. Removee bearing inner ringg of the d iff assy. byy
tool[5] and
d tool[23];

B. Removee connection bolts of tthe diff casee;
Note: Wh
hen change the ring gear, reemove the
e
connection
n bolts.

C. Removee the diff caase, then take out sidde gear and
d
side gear w
washer and
d spider.
Note : Cleaan all the p
parts, and ccheck whet her there is
tooth surfaace fracturee and wearr phenomennon, etc.

2.4.2 Assembly diff aassy.
A. Put side gear wassher and side gear innto the difff
case;
Note : Apply a round of lubricating oil[f] in diff case
e
and side ggear and side
s gear washer
w fittting surface
e
before assembly;

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37

B. Take planet gear and plane

et gear wassher in the
e
spider, theen put them
m into the d
diff case.
Note: App d of lubriccating oil[f]] on planet
ply a round
gear and p
planet gear washer after assemblly;

C. Mount tthe other siide gear an
nd side gearr washer;
Note: side gear shall be rotate flexibly.

he two mattching markks of the haalf diff case
D. Align th e
and mount the otherr diff case iin place. Appply thread
d
locking aggent[b]on the bolt screw th read, then
n
diagonally fasten the two diff caases with boolts;
que should be (210±200)Nm;

E. Measurre gear syn

nthetical clearance oof two side
e
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38
gears of diff assy. with tools [24]] respectiveely;

F. After installing ring gear, apply
a enouugh thread
d
locking aggent[b]in thread ho
oles, then diagonallyy
tighten by hex bolt;
Note : Tigh
d be (325±225)Nm.

G. Apply aa circle of lubricatingg oil[f]on tthe bearingg
installation
n position; then press the two beearing inner
rings in plaace with tool[25].

2.5 Disasssemble aand Assem
mble Bearring
Seat assyy. with Pin
nion gear
2.5.1 Disasssemble be
earing seat assy. with the pinion
n
gear
A. Chip cottter pin and
d pull it outt.
Remark: Flange nut ((DZ91129320007) witthout cotter
pin.
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39
B. Loosen the flange nut with to
ool [14] or tool [15] or
tool [16] with respeective torq
que, dismaantle flange
e
and check if oil seal d
damaged.

C. Removee the pinion
n gear with bearing;

D. Take adjusting washer
w and check if the conicaal
roller bearring has beeen damaged.

E. If the cconical rolller bearingg has beenn damaged

d,

with suitabble tool [26]
remove the bearing iinner ring w
or tool [277];

F. Removee the outsside bearin
ng inner r ing on the
e
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40
opposite iinstallation
n direction.. Take outt ring assyy.
Check seall and exchange it if it h
has been daamaged;

G. Removee the beariing outer ring
r with suuitable too
ol
[5] and too
ol [28] or to
ool [29].

2.5.2 Assemble pinio
on assy.
A. Apply aa circle of lubricatingg oil [f]in tthe bearingg
installation
n holes of b
bearing seaat, then preess the two
o
bearing inner rings in
i place with tool [311] and too
ol
[32] or too
ol [33].

B. Apply aa circle of lubricating oil [f]on tthe bearingg
installation
n position of pinion gear, thenn press the
e
bearing inn
ner ring in place with tool [34].

C. Put pinion gear intto the bearing installattion hole of
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41
bearing seeat, then take the suittable adjustting washer
and bush aand press th
hem onto tthe bearingg inner race;

D. Tighten
n flange nutt with S50 sleeve afteer installingg
flange assyy.;
Note: Tigh
htening torq
que of the flange nutt should be
e
(775±25)N
Nm.

E. Measure bearingg preload force withh a springg
balance along thee tangentt directionn of the

e
n holes of tthe bearing seat;
connection
preload forrce shall be (14‐288)N. If not
Note : p
satisfied, aadjust by changing
c the washerrs thickness
after dismaantling flan
nge nut, flange, pinionn gear.
F. Press th
he seal into
o the seal seat with toool [36] and
d
[37].

G. If preloaad force is qualified, rremove thee flange nut
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42
and flangee assy., theen apply a circle of seealant [a]in
n
the spigott of the beearing seatt which maatches with
h
the seal seeat, finally press the seal into tthe bearingg
seat in place with too
ol [35];
Note: sealant must be uniform aand continuuous. Applyy
a circle o
of grease [e]evenly
[ on
o the seaal lip after
pressing;

H. Re‐mou
unt flange aassy. and tighten flangge nut with
h
S50 sleevee, then lock cotter pin.
Note: Tigh
htening torq
que of the fflange nut should be
e
(775±25)N
Nm.

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43

Oth
hers………
……
Acceessories TTable
No. Moddel Rem
mark
[a] Tianshann 1598F Plane s ealant
[b] Tiansha n 1262 Thread lock
T king agent
[c] Tiansha n 1243 Thread lock
T king agent
[d] Tiansha n 1545 Thread ssealant
[e] lithium grrease 2# Greaase
Gear oil for 75WW heavy loaaded
[f] Gearr oil
vehiicle
[g] Silverr‐base anti‐‐jamming aggent Anti‐jamm
ming agent

Boltt Tightening Torque
e to Key P
Parts

1 Tightening torque fo
or flange nuut: 800Nm
Tightening torque fo
or connectinng bolt of rrear axle beearing seat and final drive
2
case: 120Nm
Tightening torque fo
or connectinng bolt of ffinal drive ccase assy. annd axle
3
housing: 120Nm
or connectinng bolt of inter‐wheel diff. case: 210Nm
or connectinng bolt of ccrown whee
el and diff. case: 325N
Nm
or cap bolt oof final drivve case:240
0Nm
or bolt of baackplate:30
00Nm
or bolt of pllanet carrie
er assy.: 220
0Nm
or wheel boolt and nut: 550Nm

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44
Toolls Table
No. Drawing Tooll No. RRemark
Pressure tool for plaanet
[1] S‐781
1‐5250
ccarrier
[2] S‐781
1‐5360 Sleeve foor hub locknut

Dismantlee tool for sppacer
[3] BS‐783‐‐150179 ring and innner ring off hub
bbearing
Pressure ffor inner rin
ng of
[4] BS‐783‐‐150119 hub bear ing and spaacer
ring
[5] XZ‐783‐‐160654 Puller laboor‐saving de

evice
Puller forr outer ringg of
[6] BS‐783‐‐150280
inside hub bearing
[7] BS‐783‐‐150281
outsidee hub bearin ng
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45
Puller fo r inner ringg of
[8] BS‐783‐‐150282
gear ring bbracket beaaring
Pressure tool for ou
uter
[9] BS‐783‐‐150110
ring of hub bearin
ng
Pressure toool for inner ring
[10] BS‐783‐‐150168 of gear ring brackeet
bbearing
Pressure ttool for hub
b oil
[11] BS‐783‐‐150086
seal

Pressure head for back
[12] BS‐783‐‐150301 plate andd bush of brrake
cam shaft seat

Pressuree head of baack
[13] BS‐783‐‐150300 plate andd bush of brrake
cam shaft seat

Dismantlee tool of Φ165
[14] BS‐783‐‐150278
fla nge nut
[15] BS‐783‐‐150279
fla nge nut
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46
[16] BS‐783‐‐150309
fla nge nut
Wrench foor adjustingg nut
[20] BS‐783‐‐150307
oof diff.
Sleeve for adjusting n
nut of
[21] BS‐783‐‐150258
diff.

Sleeve for tthe nut useed for
[22] CQ3‐78
81‐4047 hollow s haft and fixxed
shifft sleeve

Puller foor diff. bearing
[23] BS‐783‐‐150272
332216
Gauge for comprehen nsive

[24] S‐853
3‐015
clearaance of diff..
Pressure head for innner
[25] BS‐783‐‐150295
ring of diff bearing
pinion gea r bearing 32315
[26] BS‐783‐‐150273
（Used foor axle of other
raatio）

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47
pinion gea r bearing 32316
[27] BS‐783‐‐150274
（Used foor axle of ratio
44.8）

BS‐783‐‐150275
[28] (Used ffor axle
bearring 32315
of othe
er ratio)

BS‐783‐‐150276
[29] (Used ffor axle
bearring 32316
of ratio 4.8)

[30] BS‐783‐‐150277
bearring 30312
Pressure head for ouuter
[31] BS‐783‐‐150306
ring of piniion gear be
earing

BS‐783‐‐150289 Pressure head for ouuter
[32] (Used ffor axle ring of piniion gear be
earing
of othe
er ratio) 332315

BS‐783‐‐150290 Pressure head for ouuter
[33] (Used ffor axle ring of piniion gear be
earing
of ratio 4.8) 332316

Pressure head for in
nner
[34] BS‐783‐‐150296 ring of piniion gear be
earing
323115/32316

Pressure toool for inner ring
[35] BS‐783‐‐150293
of pinionn gear bearing

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48
Pressure hhead for carrier
[36] BS‐783‐‐150291
ooil seal
[37] BS‐783‐‐150292 Spacer for ooil seal pre

essure

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49
Fit &
& Adjustm
ment of ASSA
1. Manual slackk adjusterr

A.. Remove brake to enssure chambber push rod
d in initial p
position.
B. Connect manual slack
s adjusster and camshaft to ensuree axial cle
earance
0.5‐1.00mm; presss brake direction annd pull adjjuster, which can reeturn freelyy after
loosingg.
C. Turn adjussting bolt on adjuster w
with S12 w
wrench to co
onnect withh push rod.
D.. Tighten clockwise ad
djusting boolt to brake
e complete
ely and theen loose he
ex. bolt
with th
hree screw pitch.

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50
2. ASA
A
2.1 ASA
A Structure
e

1 rivet 10 oil cup
1 20 O ringg
2 screw
w cap 11 shell
1 21 turbinne
3 bearinng 12 reinforcin
1 ng ring 22 gaskett
4 taper clutch 13 thrust wa
1 asher 23 controol arm coverr
5 clutch
h spring 14 thrust spr
1 ring 24 adaptter ring
6 gear 15 screw cap
1 p on adjust e
end 25 controol arm
7 axis pin sleeve 16 cover
1 26 controol arm comp ponent
8 O ringg 17 Return sp
1 pring (inner) 27 screw
w
9 worm 18 Return sp
1 pring (outer) 28 adaptter sleeve
19 rack
1

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51
2.2 ASA
A Mountingg
A.. Ensure chamber push rod in iniitial positio
on before m
mounting. RRear axle ch
hamber
with sp
pring parkin
ng brake an
nd brake ai r pressure above 0.6M
MPa make cchamber pushrod
in initiaal position.

B. Ensure th
he direction of arrow
w mark and chamberr push rodd consistent after
mounting adjuster on camsh
haft.

C. Fix adjusteer on camsh
haft with w
washer and snap ring a
and ensure axial clearaance of
adjusteer A=0.50‐1
1.00mm.
D.. Adjust hexx. head in aadjuster witth S12 wren
nch (Note: donot use eelectric wre
ench)
to align ng ring hole and pin hoole of U fork on chamb
n reinforcin ber pushrodd. Then insert
round p
pin into U ffork hole an
nd lock cottter pin.

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52

E. Push contrrol arm tow
wards brakee direction ((there is arrow mark ddirection on
n
controll arm) until no move. T
Then fastenn control arrm on bracket with boolt.
Note: aat this time
e, the reticlle on contro
ol arm and
d control arm cover shhall align. T
The
purposse is to makke ASA worrk normallyy without d
damage.
2.3 ASA
A Adjustme
ent
Clearan
nce adjustm
ment:
Ro
otate worm
m hex. head clockwise with
wrench
h until frictiion lining contact brakke drum,
then an
nti‐clockwisse turn worrm hex heaad 3/4
circles ( there is “kaka” sound when
contra‐‐rotation), aafter severaal brakes, bbrake
clearan
nce adjust w
within norm
mal range. uuntil now
mount process fin
nish.
Note: d
do not use electric and pneumattic wrench..
Remark: self‐adju
usting of ad
djuster can be judged by auto‐ro
otation of w
worm hex h
head
when eeach brake finish.

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53
2.4 App
pearance Judgment
The pro
oduct is jud
dged as failure if therre are below
w condition
ns:
A.. There are cracks on tthe shell annd control aarm.
B. The adapter ring can rotate relaatively with control arm
m, which iss called slipping
of conttrol arm.
ntrol arm cllockwise unntil no movve, then rotate anti‐cloockwise, at this
C. Rotate con
time, the worm hex head can’t move.
Parameeter judge
The product is ju
udged as failure if therre are below
w condition
ns:
A.. The worm
m hex. head can’t movee.
B. The turbin
ne can’t mo
ove when tuurning worm
m hex head
d.
er is less thhan 18N.m when turning anti‐cloockwise worm hex.
C. The torque of adjuste
head.
D.. The sound
d is not continuous an d crisp whe
en turn anti‐clockwisee worm hexx.
head.
Testingg tool: One piece of 0‐‐100Nm diaal type torq
que wrench
h. One piecce of 12mm
m
sleeve..
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54

The
T torque shall not le ss than 18N
Nm
when
w turn an
nticlockwisee.

App
plication o
of Diff. Locck
IInter‐wheel diff.: To complete automaticc differentiial betweeen left and
d right
wheeels when veehicle turnin
ng or runni ng on the u
uneven pavvement.
W
When vehicle skid idlin
ng into a m d, lock the differentiaal, vehicle can be
muddy road
forced to run ou
ut of the fau
ult road.
Note:
A.. To avoid damage
d of the intern al gear, vehicle should be stoppped or run at low
speed ((less than 1
10 km/h) when hanginng the diff. lock.
B. The vehiclle can’t turn when hannging diff. llock, and th
he diff. lockk shall be re
elieved
timely when veh
hicle runnin
ng out of ffault road, or else, it will causse parts daamage,
abnorm
mal wear off tyre and roll over.

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55
Maintenance
e Regulation
Item M
Mileage Content Remark
Check if any loose for connecting blots oor nuts on
axle befoore vehicle running.
Check iff any oil le
eakage for axle beforre vehicle
Daily
running..
Maintenanc
M ce
Check bbrake perrformance and brakke return
conditio n before ve ehicle running.
Fill in lubbricating grrease in axle grease fittting. 200 h
Replace lubricatingg grease on drive axle.
Check annd adjust brake clearance.
Initial 2000‐‐4000Km/
Check iff any loose e for the connectingg bolts or
Maintenanc
M ce 250‐500h
nuts andd fasten it.
Fill in lubbricating grrease in axle grease fittting.
Replace lubricatingg grease on drive axle.
Clean annd unchoke air vent.
Regular 15000‐‐18000Km// Lubricatee grease on
o brake shoes pin aand check
friction llining.
Maintenanc
M ce 1875‐2250h
Check iff any loose e for the connectingg bolts or
nuts andd fasten it.
Fill in lubbricating grrease in axle grease fittting.
Note: Th
he convert of KM to H is 8KM/H baseed on port op
peration.

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56
Typiical Troub
bleshootin
ng
1. Brakke overheatt
Item P
Possible failure cause Soluution
Air leakage ffor chambe
er(rear axle)) or
1 Change cchamber
ch
hamber pusshrod can n
not return
2 Sm
mall brake clearance Adjust brake cleara nce
3 Brake camsh
haft jam or can not retturn Lubricate
e camshaft
4 Brake shoes return spriing loose orr break Change rreturn sprinng
5 Im
mproper insstallation of ASA Re‐install and adjusst
Im
mproper ad
djust the cle
earance aftter change
6 Adjust brake clearaance
frriction lining and brake
e drum
7 Brake frequeently Engine exhaust bra ke for long downhill
8 Gas circuit faailure Check ga
as circuit
2. oil leeakage
Item P
Possible failure cause Soluution
1 Air vent blocck Unchoke
e air vent
2 Sh
haft seal rin
ng and O ring age and damage Change sseal ring
3 Co
onnection bolt in joint surface looose Fasten jo
oint bole
4 M
Metallurgicaal defects fo
or casting aand forging Adhesion
n, weld andd replace
O
Open weldin
ng and slag inclusion foor housing
5 Polish an
nd weld agaain
w
welding seam
m
3. Axlee overheat
Acccording to national sttandard andd axle struccture, HanD
De defines aaxle tempe
erature
as belo
ow:
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57
Teemperaturee for final drive shall n ot be highe
er than 120
0℃ and forr wheel end
d shall
not be higher than 90℃. Infrared therm
mometer is available ffrom housinng shell 10‐‐15mm
to meaasure. Final drive is me
easured in tthe input end or rear cover of hoousing; hub
b is
measured in the w
wheel end ccover.
Item P
Possible Failure Reaso
on Solutiion
1 Lack of lubrication Fill lubriccation
2 Excessive lubrication
n Exclude e
excess lubrrication
3 Improper preload off final drivee bearing Readjustt based on aabove standard
4 Improperly adjust prreload of huub bearing Readjustt based on aabove standard
4. Abno
ormal noise
Th
here are so many reasons to causse the axle abnormal n
noise. Usuaally the failure
cause ccan be traceed after dissassemble tthe axle. Th
he typical situations arre as below
w:
Item Field Ph
henomenon
n Failuree Cause
1 Abnorm
mal noise wh
hen vehiclee turning Diff. faailure
Continuous noise when vehhicle running and hig

gh Bearinng pittingg, gear
2
ncreasing.
noise with speed in damagge
3 “Kitkat” noise whe
en vehicle aacceleratingg Big geaar clearance
4 Noise w
when vehicle
e slowing ddown and re
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No. Ittem RR axle Remarks

Tightening torque off

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Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

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Tel:++86-29-8695 7627 Fax:+866-29-869575

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Tel:++86-29-8695 7627 Fax:+866-29-869575

Tel:++86-29-8695 7627 Fax:+866-29-869575

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of the final drive caase after clean

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E. First asssemble bearing seaat assy. annd measure

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B. Take planet gear and plane

E. Measurre gear syn

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E. If the cconical rolller bearingg has beenn damaged

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E. Measure bearingg preload force withh a springg

balance along thee tangentt directionn of the

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[5] XZ‐783‐‐160654 Puller laboor‐saving de

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Gauge for comprehen nsive

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[37] BS‐783‐‐150292 Spacer for ooil seal pre

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