Professional Documents
Culture Documents
Models
G9-43A, G10-43A,
943, 1043, 1055,
1255, TL943,
TL943C, TL1055C,
TL1255C,
JLG - 31200239
Component Manufacturer
ASM-0029E
Revised
May 6, 2015
ASM-0029E
September 2013
CONTENTS
INTRODUCTION ................................................................................................................................ 5
SPECIFICATIONS .............................................................................................................................. 6
DEFINITION OF VIEWPOINTS .................................................................................................................................... 6
DATA PLATE .............................................................................................................................................................. 6
CONVERSION TABLES ................................................................................................................................................... 7
TORQUE SPECIFICATIONS ............................................................................................................................................ 8
COARSE PITCH ......................................................................................................................................................... 8
FINE PITCH ................................................................................................................................................................ 8
WHEEL NUT TIGHTENING TORQUES ...................................................................................................................... 9
MAINTENANCE ................................................................................................................................................................ 10
MAINTENANCE POINTS ............................................................................................................................................ 10
MAINTENANCE INTERVALS ...................................................................................................................................... 11
ADJUSTMENT AND CHECKS .................................................................................................................................... 11
LUBRICANT & SEALANT SPECIFICATIONS ............................................................................................................. 12
SAFETY PRECAUTIONS ................................................................................................................... 13
PLANETARY REDUCTION GEAR .................................................................................................... 15
EXPLODED VIEW ............................................................................................................................................................. 15
DISASSEMBLY ................................................................................................................................................................ 16
ASSEMBLY ...................................................................................................................................................................... 20
SPECIAL TOOLS .............................................................................................................................................................. 24
T1 ............................................................................................................................................................................... 24
T2 ............................................................................................................................................................................... 24
T3 ............................................................................................................................................................................... 25
T4 ............................................................................................................................................................................... 26
T5 ............................................................................................................................................................................... 27
T6 ............................................................................................................................................................................... 28
COMPLETE STEERING CASE .......................................................................................................... 29
EXPLODED VIEW ............................................................................................................................................................. 29
DISASSEMBLY ................................................................................................................................................................ 30
ASSEMBLY ...................................................................................................................................................................... 31
STEERING CYLINDER ...................................................................................................................... 33
EXPLODED VIEW ............................................................................................................................................................. 33
DISASSEMBLY ................................................................................................................................................................ 34
ASSEMBLY ...................................................................................................................................................................... 37
SPECIAL TOOLS .............................................................................................................................................................. 43
T1 ............................................................................................................................................................................... 43
T2 ............................................................................................................................................................................... 43
U-JOINT ............................................................................................................................................. 45
EXPLODED VIEW ............................................................................................................................................................. 45
DISASSEMBLY ................................................................................................................................................................ 46
ASSEMBLY ...................................................................................................................................................................... 47
SPECIAL TOOLS .............................................................................................................................................................. 48
T1 ............................................................................................................................................................................... 48
T2 ............................................................................................................................................................................... 48
BRAKE WEAR CHECK PROCEDURE .............................................................................................. 49
OLD VERSION ................................................................................................................................................................. 49
NEW VERSION ................................................................................................................................................................. 50
SPECIAL TOOLS .............................................................................................................................................................. 51
T1 ............................................................................................................................................................................... 51
SERVICE BRAKE AND NEGATIVE PARKING BRAKE .................................................................... 53
EXPLODED VIEW ............................................................................................................................................................. 53
DISASSEMBLY ................................................................................................................................................................ 54
ASSEMBLY ...................................................................................................................................................................... 57
RELEASE ......................................................................................................................................................................... 63
ADJUST ........................................................................................................................................................................... 63
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use pro-
per equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and
specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly
clean the unit, removing any encrusted or accumulated grease.
INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate
products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly
check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (o-rings,
oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time
a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge.
In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other
one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained.
CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification
is indicated as follows:
= up to the part number
= from the part number on
When no classification is given, disassembly and assembly operations are the same for all versions.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair
work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or
directly from the Service Centers or Authorized Distributors of SPICER.
DEFINITION OF VIEWPOINTS
DATA PLATE
1 2
3
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
CONVERSION TABLES
UNITS OF PRESSURE
1 ATM=1 BAR=105 PA=14.4 PSI
UNIT OF WEIGHT
N daN kN kg lbs
UNITS OF TORQUE
TORQUE SPECIFICATIONS
COARSE PITCH
M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m
M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m
M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m
M12 x 1,75 mm 82 – 91 N·m 90 – 100 N·m 116 – 128 N·m 126 – 139 N·m 139 – 153 N·m 152 – 168 N·m
M14 x 2 mm 129 – 143 N·m 143 – 158 N·m 182 – 202 N·m 200 – 221 N·m 221 – 244 N·m 238 – 263 N·m
M16 x 2 mm 200 – 221 N·m 219 – 242 N·m 283 – 312 N·m 309 – 341 N·m 337 – 373 N·m 371 – 410 N·m
M18 x 2,5 mm 276 – 305 N·m 299 – 331 N·m 390 – 431 N·m 428 – 473 N·m 466 – 515 N·m 509 – 562 N·m
M20 x 2,5 mm 390 – 431 N·m 428 – 473 N·m 553 – 611 N·m 603 – 667 N·m 660 – 730 N·m 722 – 798 N·m
M22 x 2,5 mm 523 – 578 N·m 575 – 635 N·m 746 – 824 N·m 817 – 903 N·m 893 – 987 N·m 974 – 1076 N·m
M24 x 3 mm 675 – 746 N·m 732 – 809 N·m 950 – 1050 N·m 1040 – 1150 N·m 1140 – 1260 N·m 1240 – 1370 N·m
M27 x 3 mm 998 – 1103 N·m 1088 – 1202 N·m 1411 – 1559 N·m 1539 – 1701 N·m 1710 – 1890 N·m 1838 – 2032 N·m
M30 x 3,5 mm 1378 – 1523 N·m 1473 – 1628 N·m 1914 – 2115 N·m 2085 – 2305 N·m 2280 – 2520 N·m 2494 – 2757 N·m
FINE PITCH
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m
M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m
M12 x 1,25 mm 90 – 100 N·m 98 – 109 N·m 128 – 142 N·m 139 – 154 N·m 152 – 168 N·m 166 – 184 N·m
M12 x 1,5 mm 86 – 95 N·m 94 – 104 N·m 120 – 132 N·m 133 – 147 N·m 143 – 158 N·m 159 – 175 N·m
M14 x 1,5 mm 143 – 158 N·m 157 – 173 N·m 200 – 222 N·m 219 – 242 N·m 238 – 263 N·m 261 – 289 N·m
M16 x 1,5 mm 214 – 236 N·m 233 – 257 N·m 302 – 334 N·m 333 – 368 N·m 361 – 399 N·m 394 – 436 N·m
M18 x 1,5 mm 312 – 345 N·m 342 – 378 N·m 442 – 489 N·m 485 – 536 N·m 527 – 583 N·m 580 – 641 N·m
M20 x 1,5 mm 437 – 483 N·m 475 – 525 N·m 613 – 677 N·m 674 – 745 N·m 736 – 814 N·m 808 – 893 N·m
M22 x 1,5 mm 581 – 642 N·m 637 – 704 N·m 822 – 908 N·m 903 – 998 N·m 998 – 1103 N·m 1078 – 1191 N·m
M24 x 2 mm 741 – 819 N·m 808 – 893 N·m 1045 – 1155 N·m 1140 – 1260 N·m 1235 – 1365 N·m 1363 – 1507 N·m
M27 x 2 mm 1083 – 1197 N·m 1178 – 1302 N·m 1520 – 1680 N·m 1672 – 1848 N·m 1834 – 2027 N·m 2000 – 2210 N·m
M30 x 2 mm 1511 – 1670 N·m 1648 – 1822 N·m 2138 – 2363 N·m 2332 – 2577 N·m 2565 – 2835 N·m 2788 – 3082 N·m
ST 37 **ST 52
WHEEL NUTS WITH IN- M18 x 1,5 mm 260 N·m 360 N·m
TEGRATE SEAT
M20 x 1,5 mm 350 N·m 500 N·m
CAPTIVE WASHER
M22 x 1,5 mm 450 N·m 650 N·m
NOTE:
The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant).
NOTE:
The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of
the rim material.
THE DANA OFFICIAL TIGHTENING TORQUE TABLE, THAT IS INCLUDED IN EACH SERVICE MANUAL, SHOWS THE TORQUE FIGURE
RELATED TO THE BOLT CHARACTERISTIC ONLY.
NUT MATERIAL QUALITY 8.8 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE
*THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY
(DANA AXLES ARE 10.9 ONLY).
MAINTENANCE
MAINTENANCE POINTS
4 4
4
1 3 1 3
2 4 2 4 2
1 3
2
1 - Oil filling plug
2 - Oil draining plug
3 - Check level plug
4 - Check brake disc wear
Minimum thickness between counter discs is 5.2 mm.
NOTE:
For details see BRAKE WEAR CHECK PROCEDURE p. 49.
*According to DIN 51825 level KP2K-30 (NLGI #2) or KP3K-20 (NLGI #3); ASTM D4950 NLGI #2 GC-LB
EXPLODED VIEW
15
16 7
8
11
12 9 10
14
4
13
2
1
6
5
17
18 3
19
DISASSEMBLY
1 4
FIGURE 4: Loosen and remove the nuts (4) that lock the gear
safety flange (5).
FIGURE 1: Remove check screws (1) from planetary cover.
7
3
FIGURE 7: Partially extract the wheel hub (7) by using a pla- FIGURE 10: Take out the pins and remove the steering case
stic hammer. (3).
For pin removal details, see PLANETARY REDUCTION GEAR
NOTE: p. 15.
Hammer alternately on several equidistant points.
8
FIGURE 11: Remove the snap rings (9).
FIGURE 8: Remove the external bearing (8).
10
7
FIGURE 12: Using a puller, remove the planetary gears (10).
FIGURE 9: Draw out the wheel hub (7).
NOTE:
Write down direction of installation of planetary gears.
16
12 13
FIGURE 13: Remove the ring gear (13) snap ring (12). FIGURE 16: Remove inner bearing (16).
14
8
7
NOTE:
Hammer alternately to avoid thrust block clamping and
deformation.
15
17
17
15
FIGURE 15: Remove seal ring (15) from wheel hub (7).
NOTE:
Mark the seal ring position.
FIGURE 18: Using a puller, remove seal ring (17) from stee-
ring case (3).
NOTE:
Write down seal ring orientation.
T1
18
ASSEMBLY
16 15
15
T2
16
18
CAUTION
17
T3 Check ring orientation carefully.
15
17
T5
15
FIGURE 21: Apply a coat of AREXONS rubber cement to the
outer metal surface of the snap ring (17).
Position the seal ring and, using tool T3 (See drawing T3
p. 25), fit it in the appropriate seat.
7
7
T4 8
16
T4
7
7
FIGURE 25: Turn the hub over (7), lubricate bearing seat and,
FIGURE 22: Position the wheel hub (7) under a press; lubri-
using tool T4 (See drawing T4 p. 26) install the bearing thrust
cate the outer seat of bearing and, using tool T4 (See drawing
block (8).
T4 p. 26), install the thrust block of bearing (16).
14
12 9
10
13
FIGURE 26: Fit the flange (14) in the ring gear (13) and lock FIGURE 28: Lock gears (10) into position by installing the
into position with snap ring (12). snap rings (9).
NOTE:
Check that snap ring (12) is fully inserted in the slot of ring
gear (13).
3
T6
2
10
9
FIGURE 29: Oil the seal ring and bushing. Slip the steering
2 case (3) onto the twin u-joint and fit the pivot pins and con-
nect the steering bar.
10 For details, see PLANETARY REDUCTION GEAR p. 15.
FIGURE 27: Mount gears (10) onto the pins of the planetary
cover (2).
To insert gears, use tool T6 (See drawing T6 p. 28).
FIGURE 31: Install the wheel hub (7) onto the steering case FIGURE 34: Ensure that faces are thoroughly cleaned, and
(3). then mount the safety flange (6).
FIGURE 32: Install the outer bearing (8). FIGURE 35: Apply Loctite 242 to the studs and tighten nuts
(4).
NOTE: Tighten nuts (4) in two stages using the criss-cross method.
Initial tightening torque: 250 N·m.
Push the bearing as far as it will go by tapping with a pla-
Final tightening torque: 460 - 465 N·m.
stic hammer all around the rim.
2
5
FIGURE 36: Fit the planetary cover (2) on the wheel hub (7).
FIGURE 33: Install the complete ring gear flange (5).
NOTE:
To engage the flange (5), use a plastic hammer and ham-
CAUTION
mer alternately on several equidistant points. Check state and position of o-ring (11).
2 1
FIGURE 37: Lock the planetary cover (2) with screws (1).
Tightening torque for screws: 40 - 50 N·m.
SPECIAL TOOLS
T1
P/N: 2364
260
25 27 205
30
45
Ø61. 8
Ø2 5
Ø5 9
Ø4 6
R7 120 3 x45°
.5
2 x 45 °
2 x 45 °
R1.5
T2
P/N: 3348
35
0. 8
120 30
Ø6 5 ---- 0.0. 64
Ø6 0 ---- 0.08
0.12
Ø2 5
Ø7 5
Ø4 5
R1
0
0. 8
3 x15°
0. 8
1. 5 0
-- 0. 2 3 x15°
40 200
250
P/N: 2365
32 32
0
R1
120 30
-- 0. 1
-- 0. 2
-- 0. 2
+0
Ø7 4 ---- 0.0. 64
Ø60. 3
Ø58. 5
Ø2 5
Ø9 0
3x15 °
3x15 °
32
6 3. 5 +-- 0,0 2
21 14 215
250
D1240330
T4
P/N: 3265
Ø184
Ø4 0 Ø3 5
12. 5
25
45
32
0
R1
20°
176
131
5x15 °
32
-- 0. 1
Ø5 0 -- 0. 3
Ø178 27. 5
20°
Ø4 5
0. 8
0. 8
0. 8
20
60
5x15 °
47.631
126
166
0. 8
Ø50 H7
141
R3
Ø60 H7-p 6
0. 8
Ø165
0. 8
Ø184
± 0.03
Ø200
P/N: 2366
Ø180
Ø4 0
30
140
90
0
R1
0. 8
R3
15
10
48
0. 8
28
14
0. 8
6. 5
0. 8 Ø140
0. 8
+ 0. 1
Ø154 -- 0. 2
Ø178
Ø189
Ø205
T6
P/N: 2378
2 x15 ° 0.8
R3 100 30
Ø51
Ø59
Ø30
3 x45 °
10 15
25
0.8
175
EXPLODED VIEW
8 5
9 4
3
10
2
1
18
12
13
10
14
15
16
17
DISASSEMBLY
8
3
15 FIGURE 3: Using two levers, remove the top articulation pin
(4) complete with front seal (9) and shims (3) .
FIGURE 1: Loosen and remove the capscrews (15, 8) from Pay attention not to damage the surfaces.
the articulation pin (19, 4).
10
3
19
4
ASSEMBLY
19
under articulation pin
FIGURE 9: Fit the unit (19) in the steering case (1). Position
the screws (15) and tighten securely.
Check for the correct assembly side of the seal (10).
3
FIGURE 6: Prepare a series of shims (3) of 0,85 mm to be as-
sembled under the upper pin (4).
140 N·m
3 15
140 N·m
4
upper articulation pin FIGURE 10: Tighten the new capscrews (15) of the top and
bottom articulation pins in sequence using the criss-cross
method.
Torque wrench setting: 140 N·m
FIGURE 7: Fit a new seal (3) onto the top articulation pin (4).
Lubricate and install the unit in the steering case.
Position the screws (8) and tighten to 140 N·m.
Check the correct assembly side of the seal (3).
30 - 60 N·m
EXPLODED VIEW
10
11
12A
12
2 8
6
12A
7
12
11
1 4
13
16
3 14
9 17
5
15
14
2
12
11
10
7 9
2
1
4
6
DISASSEMBLY
1
3
5
3 4
2
8
CAUTION 7
The self-locking nuts (2) must be replaced once every 5 di-
sassemblies.
8
T1
3
5
FIGURE 6: Extract the steering cylinder (8) using a plastic FIGURE 9: Using a punch, force the stop ring (4) located in-
hammer. side the cylinder (3) and extract ring using a screwdriver.
12
12 10
10 99
11
11 55
FIGURE 7: Before attempting to disassemble the unit, drain FIGURE 10: Using a plastic hammer, hammer the piston (5)
the oil in the cylinder chambers completely. so it strikes against the head (2).
Using a screwdriver, remove the snap ring (1) of the cylinder Continue until the head (2) is ejected from the cylinder (3).
head (2).
12
12 10
10 99 T1
11
11 55
5
FIGURE 11: Take the cylinder unit (3) apart by extracting the
FIGURE 8: Lightly tap the cylinder head (2) with a plastic head (2) first, followed by the piston (5).
hammer to push it inside the cylinder (3).
NOTE: CAUTION
Insert the cylinder head so it is flush with the cylinder.
Write down direction of installation of piston whose seal ring
"A" is oriented towards cylinder head (2).
3
2
NOTE:
1 - All seals must be replaced at each disassembly.
2 - Pay particular attention not to damage seal seats and
piston beds.
ASSEMBLY
T1
3
5
5
FIGURE 14: Grease and install the piston rod seal ring (6) and
scraper ring (7) into the head (2).
FIGURE 17: Introduce the piston (5) into the cylinder by ap-
proximately 150 mm using a plastic hammer.
2
T1
FIGURE 15: Prepare piston (5) by fitting it with guide ring (9), 5
magnetic ring (10), o-ring (11), and seal (12).
CAUTION FIGURE 18: Remove tool T1 (See drawing T1 p. 43) and ap-
ply it to the opposite side of the piston (5).
1 - To ease installation, lubricate with grease.
2 - If a centering sensor is not required, the magnetic ring
(10) can be replaced with an additional guide ring (9).
3 2
2
FIGURE 19: Grease the seals of the head (2), slip the head FIGURE 22: Fit the snap ring (1) of head (2).
onto the piston and, using a plastic hammer, introduce head If necessary, force it into the seat with a punch and hammer.
into cylinder (3).
NOTE: CAUTION
Introduce the head so it is flush with the cylinder.
Make sure that the snap ring (1) fits snugly in its seat.
8
3
FIGURE 20: Introduce the stop ring (4) and ensure that it sets
FIGURE 23: Check the condition of the axle unit's o-rings (9).
in the seat of cylinder (3).
Grease piston seats with Tecnolube Seal 101 and install
cylinder using a plastic hammer.
7 8
4
19
FIGURE 25: Apply Loctite to the threaded portion of the ste- FIGURE 27: If required, install the steering piston stroke cen-
ering bars and connect the bars by tightening the ends in the tering sensor (1) for checking piston centering and tighten
piston rod. screws (13). Tightening torque: 5 - 6 N·m
Tightening torque: 430 - 470 N·m.
CAUTION
CAUTION
If required, eliminate the action of the negative brake.
Accurately remove grease from the threads using an activa-
tor before applying the thread locking compound.
3 B
B
T2
5
2
FIGURE 29: Connect the sensor (1) to the control device ac-
cording to either of the following diagrams.
I max=0,80 A
NERO
BLACK C
CONNETTORE
CONNECTOR
2 BLU
1 3
BLUE
--
4
BATTERIA
BATTERY
MARRONE
BROWN
+
2A
FIGURE 30: Sensor wiring diagram for STANDARD version. FIGURE 33: Check distance "C" of piston on either of the two
sides and write down distance dimension to check subse-
I max=0,80 A quent adjustments.
NERO
BLACK NOTE:
CONNETOR For cylinders without sensors, piston must be centered
CONNECTOR BATTERIA based on maximum stroke.
2 BATTERY
BLU
1 3
BLUE
--
4
LL
MARRONE
BROWN
+ LL
2A
== =
= T2
T2
FIGURE 34: Lay level "L" on two upper studs and line them
up. Apply tools T2 (See drawing T2 p. 43) to the two horizon-
tal studs; hold them in position with two nuts, level them, and
finally lock into position.
T2
FIGURE 32: Center by slowly moving the piston first in one
direction, then in the opposite one, position the piston in the
middle point of the stroke, which is determined by the control
device signalling lamp turning on and switching off in the re-
verse stage.
T2 T2
FIGURE 35: Without moving the piston, check front and rear
stud between the edges of tools T2 (See drawing T2 p. 43)
maximum allowed difference: 1 - 1.5 mm.
12 Pos. 2 Pos. 4
11
Pos. 3 Pos. 1
STEERING CYLINDER
CILINDRO STERZO
LENKZYLINDER
CILINDRO DE DESVIO
CYLINDRE DE DIRECTION
NOTE:
12 Perform the same operations on both sides (see dia-
gram).
12A
B
FIGURE 37: Hold joints (12A) tight and rotate the ball pins (12)
until tools T2 (See drawing T2 p. 43) become parallel to each
other.
15 14
NOTE: FIGURE 40: Adjust the jutting portion of the screw (15) accor-
1 - Loosen the nuts by a few turns. ding to data shown in the table.
2 - Half a turn of the pin will reduce the front stud by about Lock into position with nut (14) tightened to 145 - 148 N·m.
3 mm and increase the rear one by about 3 mm.
12
11
15
14
FIGURE 41: Perform one full steering operation until the adju-
FIGURE 38: Once toe-in has been adjusted, lock nuts (11). sted screw (15) leans against the arm stop.
Tightening torque for nuts: 328 - 363 N·m.
16
17
14
FIGURE 42: While holding the adjustment screw in position
against the arm stop, adjust the screw opposite (16), on non-
cylinder side, until it leans against the arm stop.
CAUTION
The screws (15) and (16) must lean against the respective
arm stops all at the same time.
SPECIAL TOOLS
T1
P/N: 2368
Ø5 0 ---- 0.05
0.10
0. 4
M8 x1.2 5
R2 5°
.5
15
30
44
14
75
6
7
1
1 x45
28 °
Ø6.5
0
Ø28. 3 -- 0.05
Ø48. 1 + 0.05
0
T2
P/N: 2367
5
R1
23
R 11 0
100
50
5 x45°
22 40
55 500
555
17 ±0. 1
63
125
125
EXPLODED VIEW
4 6
7
9
5
8
1
3
2
DISASSEMBLY
1 2 5
6
7
8
3
FIGURE 5: Remove the bearing (7) snap ring (6).
Remove the o-ring (8) and, using a puller for inner parts, re-
FIGURE 2: Extract the whole twin u-joint (3). move the bearing (7) and seal ring (9).
NOTE: NOTE:
If necessary, use a plastic hammer or lever to ease ex- Write down direction of installation of seal ring.
traction of the twin u-joint.
FIGURE 3: Remove the snap ring (4) of the bushing kit (5).
ASSEMBLY
CAUTION
Tap around the whole rim.
T1 T2
5 4
NOTE: FIGURE 9: Install the bushing (5) snap ring (4); position the o-
ring (8) as well.
Check direction of installation of seal (9) carefully.
6
7
3
FIGURE 7: Install the bearing (7) snap ring (6). FIGURE 10: Introduce the twin U-joint (3) into the arm and
lock into position with stud (2) coated with Loctite 242.
Tighten stud to a maximum torque of 15 N·m.
1
1 22
1 2
5
SPECIAL TOOLS
T1
P/N: 3342
100 30
0.8 0.8
0. 8
Ø54, 5 -- 0.0 1
Ø9 0 -- 0.15
Ø5 4 + 0.0 1
Ø7 9
Ø3 0
3 x45°
R1
0. 8
3 x15°
0. 8
7
2,5 -- 0.0 2
14 10 120
T2
P/N: 2301
10
1. 5 x45°
R1
0. 8
100 30
49. 5
Ø3 0
89
3 x45°
R1
0
0. 8
130
155
OLD VERSION
CAUTION
Perform all operations on both arms.
35 - 50 N·m
FIGURE 4: Install the oil drain plug.
Torque wrench setting for screws: 35 - 50 N·m.
Fill with oil.
T1
CAUTION
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE AND NEGA-
TIVE PARKING BRAKE p. 53.
NEW VERSION
CAUTION
Perform all operations on both arms.
35 - 50 N·m
FIGURE 4: Install the inspection plug.
Torque wrench setting for screws: 35 - 50 N·m.
T1
CAUTION
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE AND NEGA-
TIVE PARKING BRAKE p. 53.
SPECIAL TOOLS
T1
5.2
°
45
1
25
32
32
160
110
8
32
32
25
1
°
45
10
5.4
EXPLODED VIEW
1
2
3 6
5
7
4 8
26
9 10
11
25
12
13
24
14
15
23
17 16
18
27 22 19
21
20
28
29
30
31
DISASSEMBLY
21-35 Bar
13
13
12
12
13
13
31
31
21
Down
FIGURE 6: Write down their order of assembly and remove
the counterwasher (23).
1
1
11
26
26
Service Brake
CAUTION
Hold the piston (11) back, as it may be suddenly ejected and
damaged.
24
16
14
3 Down 15
17 16
18
19
20
CAUTION
Hold the piston (3) back, as it may be suddenly ejected and
27
27
damaged.
14
15
28
28
NOTE:
16
16 Build a stack of washers and check the measurement.
FIGURE 15: Remove braking discs (14, 15, 16), noting down
direction of assembly.
NOTE:
If disks are not being replaced, avoid changing their position.
ASSEMBLY
11
11
24
24
CAUTION
The o-rings always have to be assembled from the pressure
facing side.
Down
FIGURE 20: Fit o-ring (9) and anti-extrusion ring (10) onto the
piston (11).
Lubricate the piston and the o-rings and install the unit into
the cylinder (24).
23
23 Down
11
11
10
10
9
FIGURE 21: ATTENTION: The o-rings always have to be as-
sembled from the pressure facing side.
33
11
11
FIGURE 19: Using a plastic hammer, install the piston (3) into
the cylinder (24).
NOTE: 24
24
Lightly hammer all around the edge in an alternate se-
quence.
FIGURE 22: Using a plastic hammer, install the piston (11)
into the cylinder (24).
NOTE:
Lightly hammer all around the edge in an alternate se-
quence.
24
24
1
DOWN
24
24
FIGURE 23: Position the Belleville washers (1) and engage FIGURE 26: Engage the cylinder (24).
the cylinder (24).
NOTE:
NOTE: Check the sense of direction of washers (1) and relative
Check the sense of direction of Belleville washers (1) and centering.
relative centering.
Loctite 242
26
26
30-35 N·m
2
FIGURE 25: Check integrity and position of the cylinder's o- FIGURE 28: Tightening the studs to a torque of 30 - 35 N·m.
ring (2).
23
23
21-35 Bar
FIGURE 29: Connect an external pump to the negative brake FIGURE 31: Insert the intermediate disk (23).
and introduce pressure to 21 -35 bar.
12
12
Negative Brake 13
13
Service Brake
23
23
FIGURE 32: Fit the reversal springs (12, 13) on the interme-
diate disk (23).
22
22
10-15 N·m
Loctite 242
23
23
1000Kg
Y V
Y 21
V
Y = BRAKE GAP
FIGURE 34: Y=brake gap FIGURE 37: Put the brake disc pack including the shim under
0,75mm 1,00mm 1,25mm 1,50mm a press, load with 1000 kg and take the measure “V”.
depending on axle configuration. EXAMPLE: V = 42,33 mm
5 - 7 N·m
Loctite 270
74 mm
X S 28
X
X
S = 74mm - (x + y + v)
FIGURE 39: S = 74 mm - ( x + y + v ) = Thickness of shims to
insert under the shim washer.
FIGURE 36: Take the measurement from the surface of the EXAMPLE: 74 mm -(29 + 42,33 + 1,25) = S = 1,42 mm
intermediate disk to the cover sealing surface with 30 bar of
pressure introduced.
EXAMPLE: 29 mm
18
18 20
20
19
19
S 28
17
17
20
20
3° Disc
18
18
FIGURE 40: Insert under the shim washer a thickness of FIGURE 43: Install the friction disc (18) on the flange (17) from
shims (28). arm side and insert the group on the u-joint.
18
18
16
16
First Disc
4° Disc
18
18
16
16
FIGURE 41: Install the friction disc (18) on the flange (17) from
arm side. FIGURE 44: Insert on the flange the discs (16, 15, 14).
19
19
2° Disc
19
19
FIGURE 42: Install the metal disc (19 ) on the flange (17) from
arm side. FIGURE 45: Check the alignment of last disc (14) and flange
(17).
NOTE:
To assist axle shaft centering, slightly move the wheel
hub.
RELEASE ADJUST
29
30
31
34 mm
FIGURE 51: Tighten screws (31) to fasten them onto the pres- FIGURE 54: Adjust screws (31) to obtain a distance of 34 ± 0.5
sure plate (23). mm between axle machined surface and screw underhead.
30 31
CAUTION
CAUTION Hold screws (31) into position while locking the nuts (30); af-
Tighten maximum by one turn. ter locking, check the distance of screws (31) once more.
EXPLODED VIEW
1 2
3 4
7
42 8 9
5 10
19
39 6 17 20
18
38
22
12
40 24
13
14
28 29 30 15 21
41
23 27
37
25 26
31
32
33
34
36
35
DISASSEMBLY
2 26
T1
FIGURE 5: Loosen the stud bolts (35, 41) and remove two of
FIGURE 2: Only if removing or adjusting, remove the screw them.
(27).
80C°
38 33
29
FIGURE 7: Remove the cover and studs. FIGURE 10: Remove the cap (29).
3 25
37 36
33 38
FIGURE 8: Extract the whole differential unit. FIGURE 11: If the bearings need replacing, extract the exter-
nal thrust blocks of the bearings (3) and (25) from middle co-
ver (33, 38).
NOTE:
30 Accurately check the o-ring (37, 36).
3
FIGURE 9: Remove the snap ring (30).
24
25
23
FIGURE 13: If the bearing need replacing, extract the bearing FIGURE 16: Remove the screws (24) joining the differential
(25) from the differential carrier (23). unit half box.
4
23
FIGURE 14: Remove the ring gear (6) capscrews (4). FIGURE 17: Using a plastic hammer, take the half box (23, 5)
to pieces.
NOTE:
42
Write down the coupling marks.
23
FIGURE 15: Remove the spacer (42) and the ring gear (6).
22
8
21
FIGURE 19: Remove shoulder (22) and first planetary gear FIGURE 22: Remove the 2nd planetary gear (8) and shoulder
(21). ring (7).
15 19 18 23 5
14 20 P
SR
Sw
Sh
S
FIGURE 20: Remove shafts (18), complete with planetary ge- FIGURE 23: The differential unit.
ars (15, 19) and spherical shoulder washers (14, 20).
Sh = Shafts (18)(17)
ASSEMBLY
22
8
21
5 FIGURE 27: Install the planetary gear (21) and shoulder ring
(22).
FIGURE 24: Install the shoulder ring (7) and planetary gear (8)
into the halfbox (5).
23
9 13 17
10 12
FIGURE 28: Mount the locking half-box (5) onto the half-box
(23)
FIGURE 25: Install the planetary gears (10, 12) and spherical
shoulder washers (9, 13) onto the shafts (17).
Install the planetary set. Loctite 270
15 19 18
24
14 20
FIGURE 29: Lock the half box with screws (24) coated with
Loctite 270.
FIGURE 26: Install the planetary gears (15, 19) and spherical
shoulder washers (14, 20) onto the shafts (18). CAUTION
Install the planetary set.
1 - The match marks on the two half-boxes must corre-
spond.
2 - Use only new screws.
24
FIGURE 30: Fit the complete differential unit in a vice and FIGURE 33: Lock the ring gear (6) by tightening the screws (4)
tighten the screws (24) holding the two half boxes together to to a torque of 150 N·m using the criss-cross method.
a torque of 80 N·m.
CAUTION
100°
Tighten screws using the criss-cross method.
42 3
FIGURE 31: Install the spacer (42) and the ring gear (6).
100°
Loctite 270
25
FIGURE 35: Turn the unit upside down and install the second
bearing (25).
FIGURE 32: Mount the ring gear (6) and fasten it to the diffe-
rential box with screws (4).
CAUTION
Pay particular attention; position a shim with adequate dia-
CAUTION meter in order to engage the internal ring of bearing without
engaging the cage.
Use only new screws.
FIGURE 36: Only if bearings are replaced, insert the thrust FIGURE 39: Position the differential unit in the central body
blocks of the bearings into the intermediate covers. with the help of a bar and fit the middle cover.
36 37 C
38
FIGURE 37: Thoroughly check the condition of the o-ring (36, FIGURE 40: Tighten the two safety screws “C” into the main
37). body (28) and install the intermediate cover (38).
33
FIGURE 38: Fit the intermediate cover (33) on opposite side FIGURE 41: Tighten screws to a torque of 140 N·m.
of ring gears: lock cover with screws (35) coated with Loctite
242.
Tighten screws to a torque of 140 N·m.
1/4 turn
T1 2
FIGURE 42: Only if ring nuts have been removed, tighten the FIGURE 45: Introduce a gauge “A” with long tracer through
ring nut (2) on ring gear side until clearances between pinion the hole provided for the cap. Position the tracer on the side of
and ring gear are zeroed. Then, loosen by about 1/4 turn. a tooth of the ring gear, approximately 5 mm from the outer
rim; preload by about 1 mm and zero the gauge.
T1 26
FIGURE 43: Only if ring nuts have been removed, preload be-
arings with ring nut (26) on non-ring gear side in order to in-
crease the torque of the pinion. FIGURE 46: As you hold the pinion in position, move the ring
gear manually in both directions to check clearance between
pinion and ring gear. Standard clearance: 0,25 - 0,33 mm
CAUTION
In the case of used bearings, check thrust torque; in the
case of new bearings, check continuous torque.
2 26
1 27
TM
T1
FIGURE 48: Adjusting clearance between pinion and ring gear. FIGURE 51: Install the complete arm.
To INCREASE: loosen the ring nut on ring gear side and tighten
the ring nut on non-ring gear side by the same measure.
To DECREASE: perform the same operations inversely. To ro- 283 - 312 N·m
tate ring nuts, use special wrench T1 (See drawing T1 p. 75).
Loctite 242
24 - 26 N·m
NOTE:
Tighten using the criss-cross method.
FIGURE 49: Engage screw (27) in the slot next to the holes
provided for the check screws.
Coat screws (27) with Loctite 242 and tighten to a torque of
24 - 26 N·m.
SPECIAL TOOLS
T1
P/N: 2379
¯ 166
10 x15
¯ 40.5 ---- 0.1
0.2
0.8
¯ 15H7-n6
100
¯ 14
2 x15
8
0.8
24
17
20
238
0
R1 ¯ 25
¯ 10
¯ 35
123
125
33
36
¯ 37H7-n6
¯ 47
¯ 143 0.1
R 30
25
EXPLODED VIEW
3 6
2
14 15
17
7
1
8
13
10 16
11
12
DISASSEMBLY
2
1
10
11 10
80C°
10
NOTE:
Heat will loosen the setting of Loctite on the nut (1).
9
T1 FIGURE 5: Remove the sealing ring (9).
T2
FIGURE 6: Apply blocks T2 (See drawing T2 p. 87) and, with FIGURE 9: Remove the thrust block of the external bearing
the help of a puller, extract the pinion (5) complete with the in- (3).
ternal bearing (6), the spacer (8), and calibrated spacer (4, 7).
NOTE:
The thrust blocks of the bearings remain in the central
body (12).
17
7
5
4
6
6
FIGURE 11: Remove the thrust block of the internal bearing
(6) as well as the shim washers (4).
15
14
ASSEMBLY
I = 135
M5
- 0,1 = Y
42 mm
FIGURE 16: Check nominal dimension “I” as marked on the
pinion. Add up to or subtract from “I” the variation indicated
FIGURE 14: CALCULATING PINION CENTER stud as “Y” to obtain the actual center stud “I”.
Using a faceplate, reset a dial indicator “DG” on a calibrated EXAMPLE: I = 135 - 0.1 = 134.9
block (whose known thickness is 42 mm.).
Preload the gauge by about 3 mm. NOTE:
M5 = Match part number
D
9
T3
A
DDG
A
6
4
T4 T4
3
FIGURE 18: Using special tool T3 (See drawing T3 p. 87) par- FIGURE 21: Introduce the tracer of a depth gauge “DDG” into
tially insert the thrust block of the bearings (3, 6) and shims (4). either side hole of tool T4 (See drawing T4 p. 88). Reset the
gauge with a preload of about 3 mm.
3
FIGURE 19: Connect the tension rod to the press and move
the thrust block of bearings (3, 6) into the seats. FIGURE 22: Remove the gauge and take out tool and bearing
Disconnect the press and remove the tension rod. kits from the main body.
Reinstall every part, also introducing a spacer between bea-
NOTE: rings (3) and (6). Tighten the entire pack by hand.
Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
T4
12
H = A - B = 1,8 mm
FIGURE 23: Introduce depth gauge “DDG” in tool T4 (See
3 T4 drawing T4 p. 88) and measure deviation “H” from the pre-
vious reset.
FIGURE 20: CALCULATING PINION BEARINGS ROLLING
EXAMPLE: H = A - B = 1,8 mm.
TORQUE
Introduce tool T4 (See drawing T4 p. 88) complete with bea-
rings (3) and (6) into the main body (12); tighten by hand until
a rolling torque is definitely obtained.
17
7
S1 7
FIGURE 24: Deviation “H” must be added to a set value of FIGURE 27: Refer and keep to the positions marked during
0.12--0.13 mm (X) to obtain calibrated spacer “S1” (7) for in- disassembly.
sertion between inner bearing (6) and spacer (8).
Dimension “S1” must be rounded off to the higher 5/100.
EXAMPLE: S1 = H + X = 1,8 + (0.12 - 0.13) = 1,92 - 1,93 mm.
5 5
100°
FIGURE 28: Fit the pinion (5), calibrated spacer “S1” (7) and
6 spacer (8) in the main body (12).
FIGURE 25: Heat the inner bearing (6) to about 212 °F [100
°C] and fit it onto the pinion (5).
NOTE:
Once the bearing has cooled down, lightly lubricate bea- 5
ring (6) with SAE85W90 oil.
NOTE:
Lightly lubricate bearing (3) with SAE85W90 oil.
FIGURE 26: Make sure that the bearing (6) is well set.
CAUTION
If torque exceeds the maximum value, then the size of cali-
brated spacer “S1” (7) between the bearing (6) and the spa-
cer (8) needs to be increased. If torque does not reach the
set value, increase the torque setting of the ring nut (1) in dif-
ferent stages to obtain a maximum value of 800 - 1000 N·m.
If torque does not reach the minimum value, then the size of
calibrated spacer “S1” (7) needs to be reduced.
5 When calculating the increase or decrease in size of calibra-
terd spacer “S1”, bear in mind that a variation of calibrated
10 spacer (4) of 0.01 mm corresponds to a variation of 60 N·cm
in the torque of the pinion (5).
FIGURE 30: Install the flange (10) onto the pinion (5) without
the sealing ring.
10
Loctite 242
800 - 1000 N·m
5
T1 FIGURE 33: Make positional marks across nut (1) and pinion
(5) tang; then remove nut and flange (10)
FIGURE 31: Apply wrench to the ring nut (1) and bar-hold T1
(See drawing T1 p. 86) to the pinion (5). Lock the wrench T1
(See drawing T1 p. 86) and rotate the pinion using a torque 12
wrench, up to a minimum required torque setting of 800 -
1000 N·m.
9 T5
FIGURE 34: Apply Arexons rubber cement to the outer surfa-
ce of the new seal ring (9) and fit ring in the main body (12)
using driver T5 (See drawing T5 p. 89).
FIGURE 32: Apply onto the pinion (5) the bar-hold and with
the help of a torque meter, check the torque of the pinion (5).
Torque: 120 - 180 N·cm
Loctite 242
10 11
FIGURE 36: Oil seal ring lips and install flange (10).
Mount o-ring (11) and apply Loctite 242 to pinion tang; tighten
nut (1).
T1
FIGURE 37: Tighten the nut until the match marks line up.
SPECIAL TOOLS
T1
P/N: 2308
¯ 185 0.2
0.2
120
80
¯ 105
25 ¯ 105 0.2
125
10
15
25
125
97
73
61.5
61.5
85
126 12
¯ 32 150
10
15
100
¯ 45
P/N: 2381
90
¯17
25
131
20
T3
P/N: 2377
38
122
8
R 10 5
0.8
R2
25
0 .8
21.5 19.5
0 .8
¯ 104
¯ 109
¯ 55
¯ 69
¯ 85
¯ 89
¯ 35
¯ 70
¯ 80
R3
0.8
¯ 19.5
M18 x 1.5
R2
0.8
27 25
28
10 85
30 3 x 15
0.8
¯ 35
0.8
450 80 ¯ 25
¯ 19.5
M18 x 1.5
550
Cylinder
Thrust block
Thrust block
Differential box
T4
P/N: 2374
¯ 60
30
¯ 6
1/4"
0.8
12
70
0.8
128
3 x 15
38
0.8
M16 x 1.5
20
¯ 20
-0.2
¯ 50 -0.4
-0.2
¯ 40 -0.4
0.8
¯ 20
3 x 15
M16 x 1.5
0.8
40
65
67
119
¯ 5
163
3 x 15
0.8
-0.02
¯ 50 -0.04
37
0.8
10
44
0.8
A-A
10
¯ 70
P/N: 2375
¯ 50
30
3x45
110
158
195
125
1 x 45
R5
28.5
R3
6
16.5 +-- 0.0 2
3 x 15
12
0.8
¯ 39.5
0.8
¯ 61.5 + 00.1
¯ 85
¯ 98
¯ 125
EXPLODED VIEW
14
13
12
9
6
11
12
10
13
14
15 8
7
5
4
3
6
DISASSEMBLY
6
1
7
5
2 FIGURE 4: Remove the upper half box (5) and pull out shims
(6) and clutch pack (7).
FIGURE 1: Remove the whole differential unit (2) from the
main body (1). (For details, see DIFFERENTIAL UNIT p. 65).
CAUTION
If the clutch pack does not need replacing, avoid swapping
CAUTION discs position.
The following section includes clutch replacement procedu-
res only; for ring gear replacement, see DIFFERENTIAL
UNIT p. 65.
8
10
4
11
FIGURE 7: Remove the 2nd clutch pack (11) and shim set (6).
CAUTION
If the clutch pack does not need replacing, avoid swapping
discs position.
ASSEMBLY
14
14 12
12 10
88 10
6
6
13
13 FIGURE 10: Install planetary gear (10).
CAUTION 9
Add shims (6) until a total size of 17.6 - 0.05 mm is obtained.
11
6 FIGURE 11: Fit the planetary gear set (9) and install second
planetary gear (8).
NOTE:
Make sure that spherical thrust washers (15) are present.
6
FIGURE 9: Fit shims (6) and clutch pack (11) sequentially.
CAUTION 7
When installing the increased shim, place shim so that it le-
ans against the ring gear (8, 10). 5
FIGURE 12: Fit increased shim (12), clutch pack (7) and shims
(6) onto the planetary gear (8).
Fit the upper half box (5) and make sure that the match marks
line up.
Complete the assembling operation and install the differential
unit following the procedures described in the first part of the
manual under section DIFFERENTIAL UNIT p. 65.
EXPLODED VIEW
3
1
DISASSEMBLY
44
FIGURE 2: Remove the swinging support (4) on the side op-
posite the drive.
ASSEMBLY
A 33
4
4
reference direction A
4
4
4
4
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
www.jlg.com
31200239
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
www.jlg.com