214 Section 4.

POWER TRAIN
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4.7.6. Possible failures of “dry” brakes and instructions for their troubleshooting

Failure, Troubleshooting
external manifestations, cause
Inefficient braking
Increased brake pedal travel Adjust brakes according to the section “Service
brakes adjustment”
Oiling or wear of brake disks pads Rinse the discs with petrol or replace the discs if
they are worn out
Uneven braking of left and right wheels
Faulty adjustment of brake pedal travel Make adjustments
Frictional brake discs wear or oiling Replace the discs or rinse them with petrol
Sticking of brakes
Wear of tapered surfaces of ball cross-sectional Replace the pressure disks
grooves in pressure disks
Insufficient brake pedal travel Make adjustments
Spontaneous locking of brake levers on the shaft
Corrosion of the mounting seat on the brake shaft Remove the right lever from the brake shaft,
for the right lever clean the mounting seat, grease it with “Lithol-
24” and place the lever back
215 REAR AXLE
_________________________________________________________________________________

4.7.7. Possible rear axle failures and instructions for their troubleshooting

Failure, Troubleshooting
external manifestations, cause
Increased noise of the main gear
Improper main gear gear meshing Adjust gear teeth meshing of the main gear
according to the tooth contact. Adjust the side
clearance in the main pair meshing. It shall be
within 0,25...0,55 mm.
Improper adjustment of the main gear conic Adjust bearing preload
roller bearings
Insufficient oil level in transmission Refill oil to the oil level mark
Gear teeth damage Check. Chipping, pitting corrosion and damage
are not allowed.
Differential lock (of dry-type) fails to operate
Oiling of lockup clutch disks Eliminate oil leakage
Worn-out friction disks of lockup clutch Replace the disks
Damaged lockup clutch diaphragm Replace the diaphragm
Low oil pressure at the entry to the differential Check. It shall be within 90… 100 MPa (9 … 10
lock clutch kgf/cm2)
Electro-hydraulic valve fails to operate (tractors Check the fuses, relays and other elements of
with the hydraulic lift) electrical network operability. Check the ease of
spool movement.
216 Section 4. POWER TRAIN
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4.7.8. Rear axle disassembly (Fig. 4.135)

Fig. 4.135. Rear axle:

1 – differential assembly; 2 – bearing sleeve; 3 – sleeve cover; 4 – final drive drive gear, right; 5 –
semi-axle; 6 – semi-axle tube; 7 – final drive driven gear; 8 – PTO planetary reduction unit; 9 –
outside bearing cover; 10 - final drive drive gear, left.

A. Semi-axle tube dismounting

1. Unscrew four bolts 4 and remove hub 3 after removing bushing 7 (Fig. 4.136).

Fig. 4.136
 4

Fig. 4.137

For further semi-axle tube assembly it is required to tighten up bolts 4 with the torque from 300 to
330 Nm.
2. Unscrew four bolts 1 and remove cover 2 together with the gasket and the collar after knocking out
the key from the semi-axle groove.
For further semi-axle tube assembly, tighten up bolts 1 with the torque from 44 to 56 Nm.
3. Unscrew bolts 5 and screw two disassembly bolts 6 into threaded openings of tube 8. Dismount the
tube assembled. Remove the gasket. For further assembly, tighten up bolts 5 with the torque from 120
to 140 Nm.
4. Remove the collar from cover 2.
If the collar is damaged, sort it out. Squeeze a new collar into the cover against the stop.
5. Remove locking ring 1 from semi-axle 4 (Fig. 4.137).
6. Knock out semi-axle 4 from tube 3 together with bearing 2.
7. Squeeze out the bearing from the semi-axle. For further assembly, the bearings shall be squeezed
in the rear axle housing and semi-axle tube 3 against the stop.

B. Lockup mechanism and power cylinder dismounting

Tractors with canopy tent (fig. 4.138)
1. Unsplint, remove pins and uncouple link 1, spring 7 and lever 6.
2. Unsplint and remove pin 3 releasing the links of lockup mechanism from bracket 4 of power
cylinder 5.

1 7 6 5 4 3
Fig. 4.138

3. Remove the lockup mechanism 2 assembled.

4. Unsplint and remove pin 8. Dismount power cylinder 5.

Tractors with a cabin (fig. 4.139)

1. Unsplint and remove pins, uncouple link 3. Remove spring 4.

2. Unsplint, remove pins, then lever mechanism 5.
3. Unsplint and remove pin 1. Remove lockup mechanism 7 assembled.
4. Unsplint, remove pin 6 and uncouple the hydraulic cylinder rod from the cover.
5. Dismount power cylinder 2.

Fig. 4.139

C. Hatch cover and rear axle cover dismounting

1. Unscrew four bolts 2 (M8x16) and remove access hatch cover 1

and the gasket (fig. 4.140).
2. Unscrew nineteen bolts 3 (M12x30), remove rear axle housing
cover 4 and the gasket.

Fig. 4.140

D. Dismounting of PTO planetary reduction unit

1. Unscrew adjusting bolt 1. Loosen the coupling screw and remove lever 2 from control shaft 3
(fig. 4.141)
2. Unsplint (spline 8) and remove locking device 7. Unscrew adjusting screws 4 from nuts 5.
Remove screw axles 6.
3. Remove control shaft 3 from the rear axle housing in the direction inside the housing.
4. Unscrew bolts 4 and remove cap 3 (fig.4.142).
5. Unscrew nuts 1 and remove housing 2.
 6. Unscrew six bolts 5 (M10x35 – 5 pieces, M10x40 – 1 piece).
Screw in two disassembly bolts into the rear PTO cover 6 and
dismount PTO planetary reduction unit from the rear axle
housing. Remove the gasket.

Fig. 4.141

7
Fig. 4.142

For further assembly:

 Tighten up adjusting nuts 4, fig. 4.141, with the torque from 10 Nm and then loosen them by
2,0 – 2,5 turns. Mount and splint locking device 7.
 Tighten up bolts 5, fig. 4.142, with the torque from 30 to 35 Nm.
 Check the ease of the PTO shaft rotation with the PTO control handle in the middle position.
If the rotation of PTO shaft is hindered, loosen adjusting nuts 4 by 0,5-1,0 turns.

E. Control shaft and shifting clutch dismounting

1. Remove locking wire and unscrew locking bolt 2 (fig. 4.143).

Remove shifter arm 3 and control shaft 1.
1. Remove the shift collar 4. 2. Remove shifting clutch 4.

For further assembly, tighten up the locking screw and

lock it carefully with the help of wire.

Fig. 4.143
 4.7.8.1. Differential lock clutch (of dry-type)

1. Unscrew bolts 12 and remove housing 10 together with the adapter (fig. 4.144). Remove the
lockup clutch assembled.
2. Unscrew bolts 9 and remove cover 7, diaphragm 6 and pressure disk 5.
3. Remove shaft 4 and disks 2, 3. Unscrew fitting 16. Remove ring 13 and sealant 14.
For further assembly, discs 2 shall shift along locking shaft 4 splines under the influence of their
own weight.
There shall not be oil or lubricant on the disks pads.
Bolts 9 shall be tightened up with the torque from 14 to 18 Nm.

20 19 18

17 16 15

11 12
Fig. 4.144. Clutch of differential lock:
1 – clutch housing; 2 – disk; 3 – throw-out disk; 4 – locking shaft; 5 – pressure disk; 6 – diaphragm; 7
– diaphragm cover; 8 – washer; 9, 12 – bolt; 10 – housing; 11 – washer; 13, 17, 20 – ring; 14 –
sealant; 15 – adapter; 16 – fitting; 18 – spring; 19 – bushing; 21 – adjusting pin.

4.7.8.2. Final drive differential, sleeves, gears

1. Screw in disassembly bolts 3 into the threaded openings of cover 1 and remove the cover
together with collars 4 assembled (fig. 4.145).

1 2 3
Fig. 4.145

2. Unscrew bolts 2 fastening the sleeve to the rear axle housing.

For further assembly, tighten up bolts 2 with the torque from 85 to 105 Nm.
3. Squeeze out collars 4 from sleeve 1 cover.

Fig. 4.146

For further assembly it is required to put a thin layer of lubricant onto the sealing edges of collars.

4. Screw disassembly bolts 1 into the threaded openings of sleeve 2 and remove the sleeve
assembled from the rear axle housing (fig. 4.146).
5. Remove adjusting gaskets 3.
6. Dismount the differential assembled from the rear axle housing.
7. Squeeze gear 5 and roller bearings 3, 6 out of sleeve 1 (fig. 4.147).
8. Squeeze out ring 7 and outer cage 8 from the sleeve. Remove sealing ring 2.
9. Remove sealing rings 4 from drive gear 5.
For further assembly drive gear 5 shall rotate in bearings 3, 6 smoothly, without jamming.

Fig. 4.147
6

Fig. 4.148
 10. Fix the differential assembled in the jaws.
11. With the help of a marker put marks on cover 2 and differential housing 9 to provide proper
differential assembly (fig. 4.148). Mark crosspiece 11 trunnions and mating surfaces of
differential housing 9.
Remove locking wire, unscrew bolts 1 and remove cover 2, washer 3, semi-axle gears 4,
crosspiece 11 with satellite gears 5 and washers 6. Remove satellite gears and washers from
crosspiece trunnions.
12. Squeeze bearings 7 out of cover trunnion 2 and housing 9.
13. Unbend locking plate 13, unscrew nuts 12, remove bolts 8 and squeeze gear 10 out of the
differential housing.

IMPORTANT! Gear 10 shall be dismounted only if it is necessary to replace the main pair of gears.

For further assembly it is required to oil mating surfaces of gears, washers, crosspiece and semi-
axle gears with transmission oil.
Mount spherical washers 6 of satellite gears with bumps out. Semi-axle gears in the cover and
housing, satellite gears on crosspiece trunnions shall rotate smoothly, without jamming.
Tighten up nuts 12 and bolts 1 with the torque from 75 to 80 Nm.
IMPORTANT! Replace gear 10 with the main drive drive gear as a unit only.
Replace housing 9 and cover 2 as a unit only. The specified parts shall be handled in assembly and
they shall not be torn down.

4.7.8.3 . Checking operations

Semi-axle (fig. 4.149)

Fig. 4.149

1. Measure the journal diameter for bearings.

2. In case the diameter of bearings journal is less than the permissible limit set below, replace
the semi-axle.

Nominal value, mm ……………………. 85.003 … 85.025

84.989 … 85.011
Limiting value, mm ……………………. 84.98
84.95
 Differential cover and housing (fig. 4.150)

1. Measure the trunnion diameters of the

differential cover and housing.

Fig. 4.150

2. Nominal value shall be from 75.043 to 75.062 mm. Permissible limit shall be 74.96. If the
diameter is under the specified limit, the parts shall be replaced.

IMPORTANT! Replace the differential cover and housing as a

unit only.

Clearance gap between the satellite gear and crosspiece

trunnion (fig.4.151)

1. Measure the satellite gear bushing inner diameter.

Fig. 4.151
 2. Measure the crosspiece trunnion outer diameter.
3. Calculate the clearance gap between the satellite gear and the crosspiece.
4. If the clearance gap exceeds the limits set in the table below, replace the mating parts.

Value, mm
Parameter
Nominal Limiting

Clearance gap between the

0.086 – 0.117 1.200
satellite gear and the crosspiece
Satellite gear bushing inner
25.065 – 25.117 25.800
diameter
Crosspiece diameter 24.979 – 25.000 24.600

Spherical washer of satellite gear. Retainer washer of semi-axle gear (fig. 4.152)

Fig. 4.152

1. Measure the thickness of washers.

2. If the thickness of washer is under the limits set in the table below, replace it.

Value, mm
Thickness of washer
Nominal Limiting
Satellite gear 1.60 – 2.00 1.40
Semi-axle gear 1.45 – 1.55 1.20

Bearing sleeve (fig. 4.153)

1. Measure the counterbore diameter for roller bearings (radial).

2. Measure the counterbore diameter for conic roller bearings.
3. If the diameter exceeds the permissible limit, it is required to repair or replace the sleeve.

(Fig.)
Fig. 4.153
Value, mm
Counterbore diameter
Nominal Limiting
For radial roller bearings 109.975 – 110.050 110.050
For conic roller bearings 129.948 – 129.988 130.010
 Final drive drive gear (fig. 4.154)

1. Measure the journal diameters for roller bearings. The

nominal value shall be 60.002 – 60.021 mm. Permissible
limit shall be 59.98 mm.
2. If the diameter is under the permissible limit, replace the
gear.

Fig. 4.154
Differential lockup clutch disk (fig. 4.155)

Fig. 4.155

1. Measure the thickness of disk with pads assembled using a beam caliper. The nominal value
shall be 12 mm. Permissible limit shall be 11 mm.
2. If the thickness is under the permissible limit, replace the
disk.

Diaphragm of differential lockup clutch (fig. 4.156)

Inspect the condition of the diaphragm. If there are cracks, tears
and other damages, replace the diaphragm.
 Fig. 4.156

4.7.8.4. PTO planetary reduction unit. Assembling and disassembling.

Fig. 4.157
Fig. 4.158. Planet reducing gear of PTO:
1, 38 – bolts; 2, 37 – washers; 3 – cover; 4 – gasket; 5 – shaft; 6 – collar; 7 – bearing; 8, 11, 12, 13 –
locking ring; 9, 10 – bands; 14 – drum; 15 – sun gear; 16 – satellite gear shaft; 17, 30 – adjusting
pinl; 18 – carrier; 19 – satellite gear; 20 – bearing; 21, 24 – ball bearing; 22 – nut; 23, 34 – bushing;
25, 28 – pin; 26, 29 – lever; 27 – bracket; 31 – eccentric axle; 32, 33, 35 – ring; 36, 39 – plate; 40 –
exchangeable shaft end (8, 6 or 21 splines); 41 – axle.

9, 10

Fig. 4.159

1. Unscrew nut 22 (fig. 4.157, 4.158).

2. Squeeze out bearing 21, carrier 18 together with satellite gears 19 (fig. 4.158, 4.159).
For further assembly, bearing 21 shall be squeezed in carrier 18 against the stop at the
ledge.
3. Remove locking ring 35, eccentric axle 31 and brake bands 9, 10, as well as levers with axle
31 and axle 41 (fig. 4.158, 4.160).
 9, 10
Fig. 4.160

Fig. 4.161

ATTENTION! While mounting the PTO planetary reduction unit with extended brake band on the
drive drum (sun drum) on the tractor, it is required to fix the more extended band (B=56mm) from the
PTO cover side.

4. Remove powering drum 14 and sun gear 15 (fig. 4.161).

5. Remove shaft 5, bearing 7 and collar 6 from cover 3 (fig. 4.158, 4.161)
For further assembly, oil the collar with solid lubricant.

Carrier
1. Knock out adjusting pins 17 and axles 16. Remove satellite gears 19 with bearings 20
assembled (fig. 4.158, 4.162).
Fig. 4.162

For further assembly, apply solid lubricant in the openings matching with satellite gear bearings.
To squeeze in adjusting pins, the openings in the shafts of satellite gears shall be matched with the
openings in the carrier. Radial lubricant openings shall be directed outward from the center.
Squeeze in adjusting pins flush with the carrier surface.
Satellite gears shall rotate smoothly, without jamming.

Sun gear with the drum

1. Remove locking ring 12 from the drum (fig. 4.163).

2. Squeeze out bearing 24 out of drum 14 using the innertial hammer (fig. 4.164).

Fig. 4.163

Fig. 4.164
Fig. 4.165

Fig. 4.166

Fig. 4.167

For further assembly squeeze in the bearings so as to mount locking rings.

3. Remove locking ring 13 and disconnect sun gear 15 and drum 14 (fig. 4.165).
4. Remove locking ring 8. Squeeze out bearing 7 and the collar of cover 3 (fig. 4.166).
5. Unscrew six bolts 1 (M10x18). Remove plate 39 and disconnect exchangable shaft end 40 and
shaft 5 (fig. 4.167).