Vf TADANO YORAULIC GRAN SERVICE MANUAL DRIVING AXLE MODEL SHP=S21.0 SERIES P-EAV=a7 I RS4EYSTIZW Bist : SHP-S21.0 YU -—X INFORMATION No RAS O1 TADANO LTD.INTRODUCTION This service manual gives the disassem- bly and reassembly procedures for axles used in Tadano rough terrain cranes. The models covered are listed below. Before starting to repair these units, check the model code given on the model plate on the unit. Use this manual in conjunction with the relevant parts catalog, crane service manual and other reference materials and make proper preparations. Applicable models : SHP-S21.0FU SHP-S21.0R (no-spin differential) BEBE KYW ERLET ML, IIB IAI LW TiCeR ENTOS TI ANOS 5, FROWRICO TAM + HL ATH RBHLE LOTT. TER MEW 5 CHEM CHIH, PREZ LTE 8 U6 EA, AME FICS BHF O, PoE TVEORN HRD D2, BUM DROS LTR, SHP~S21.0FU SHP-S210R( 7 -%UYF7) sams The contents of this manual are sub- ject to change without notice due to modification. AAG Lick ARR SHABdS ETO Te CTRL RE563-2101 663-2101 DRIVING AXLE RIFE YIP IAW © CONSTRUCTION AND FUNCTION The axle serves to transmit the drive force of the engine to the right and left axle shafts, and to support the weight of the vehicle. Designed as a steering drive axle, it is equipped with ball joints, tie rod and other steering units. Differential section (Model: SHP-S21.0FU] 50:+5 ke-m Taeateen-y) © ie ane FO ANALY 25 OMG) BEEOMMMICEA BLE SIC, MMOMME TA SMHSLTOET. BET VLZIR GATT D AWD, ATTY LTBMRTIMABL II, HWY af Yh, F404 FROAFT > TURBAN TORT. FJ pb yyy NB (Mt : SHP-S21.0FU) f U1+2 kgm (r96E14 6-1) @ 942 Kg+m (65.1 141) 2 _— 158 hem 2 _— Orage 2148 Kem (152422%e- 15) osi2m-m We aaa, iat ; © TE ~ 1052%0-m _/ “d/(C (Q) (7594141 Ib © (aa ha fe-1b) eG » Ti95= 207 iby SE Fig. 1RS63-Z101 563-7101 DRIVING AXLE (Model: SuP-$21.0R] 10.5: 2 ke- m 59 14t= 16) 105-2 ke-m (is.9+14fi-16) (WK: SHP-S21.0R) ty (862:436%t-1b) _@ S22 Ce5.1= 14418) ea @ 15:8 kam ——= OTs LaLTN TS : ® 218 ke m (135 29Ft- Ib)563-2101 563-2101 DRIVING AXLE Housing, reducer, brake sections NII TR, BBB. TFB Bot1 kes 55455 lem 14 0.2ke-m (398404015) 4ii-Tb) M2 hem, Ca) wer \ 14.5f-1b) GD 2 BD @ E 2 @ is oi asi @® ‘5am sae 360-18) 11) bb bo & a @® Dap @ @ @ B4kAte- 55:E5.5 ke m Teas E291) (984041) at Qe Disk brake ass'y FRITH FAB Fig. 3563-2101 563-2101 DRIVING AXLE 5405-m Go f GBT PADI : a 7 OO pa) edt 3 Tsim TSEERETETY 1, Carrier case 2. Ring nut 3. Lock pin 4. Thrust plug 5. Thrust bolt 6. Lock nut 7. Shim 8. Differential case 9. Spider 10. Differential pinion 11, Thrust washer 12. Side gear 13. Thrust washer 14, Tapered roller bearing 15. Tapered roller bearing 16. Drive pinion 17. Bolt 18. Companion flange 19. Companion yoke 20. Ring gear 21. Bearing cage 22. Spacer 23. 24, 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. al. 42. 43, 44, 45. 9.51.5 ke+m L a TeTLnsnty 8D & OG & Nut i Packing 2. oil seal 3. Roller bearing 4 Tapered roller 6. bearing 6. Tapered roller 7. bearing 8 Bolt 8 Bolt 10, Washer Washer nL. Snap ring 12, Axle shaft 18. Differential case 14 Bolt Washer 16 Bearing cap Bolt 16 Bolt 1. Washer 18, Bolt 18. Bolt 20. Flange slinger 21 Cover 22, 4 View B BRB FDP THR 23. Yorba b 24, Bypey 25. RGANISS 26, RIA RHE 2, Bortab eh 28. FI pV BAH 29, FI pve 20. vane 31 BORN Ye 82. RY 33, ROAM Ue 34 Fok oH 86. Arye 36. Foon 3. Arye 38. Ko47ea4y 39 Bh 40. a 42, 43, ATVI Ae 44 Bano 45, toh Ny ky AAwEw e-9Nr Ie AvIUe Are vb wk Dove Dove Py TILT FORME Th FIV HR ov Dove ATIVE aT563-2101 563-2101 DRIVING AXLE 46. No-spin diff. 105. Bolt ass'y 46 2-AEYFPAwy 0 BAF ass'y 106. Bolt (2 eee (LEFI-ZVNT) 47. 107. Cap seal 48. hy tY 108, Vb Assy 48. Packing 108. Dust seal 49-745 T—b 1068, KK 49. Disk plate 109. Piston seal 0. THAWADYYF 107. Fae FU— 50. Axle housing «110, Backup ring = 51. #Y4EYFy va 108, 51. King pin bush 111. Disk plate m= —— 108, 52. ——— 112, Bolt 5. ——— MO yar AIL 53. 113. Washer BA RTT WL F429 7U=b 54. Air breather 114, Grease nipple 55. 737 12 avy b 55. Plug 115. Plug 5 1B Dove 56. 116. Nut 8. 797 Ma FY ASy Fh 57. Plug 117. Stopper bolt 88. VF—ayYIVY 1. 58, Retaining ring 118. Bolt 8 ANH 116. Fob 59. Spacer 110, Washer 60. At vE— LL Abort h 60. 011 seal 122. Ball bearing 61. +70 118. 0k 61. Knuckle 123. Collar 62 At 19. Dobe 62. Spacer 124, Ball joint 68. Fy HWA EM 1B K-WAT IY 63. Knuckle spindle ass'y 6 Jove 128, 29- 64. Bush 125, Sun gear 65. Hb 124, KW ody bAssly 65. Bolt 126. Planetary gear 6% + %Uy 125, 9H 67. King pin spider 68 tyr eD 126, F5as VERA 68. King pin 127. Planetary gear 69. %YYELAFAR 18. FARE 69. King pin thrust 128. Planetary pin Dove 18. Faz VEY washer 129. Thrust washer 70. 44.07—w 12, ADARDI Ys 70. Oi1 seal 130. Internal gear 71. 180, 4 9-H vee 71. Shim 131, Internal gear 72. 1B, ARP ATHY 72. Spacer hub ae 182, Aho FIA 73. Bolt 132. Stop wire 1, 188. AF IY 7H ob 74. Boot 133. Bearing nut 75. 18 89 7U—b 75. Band 134. Lock plate 16. 188. a= 76. Plate 135. Cover 1. 186. Ye 7 hab 77. Bolt 136. Shaft stopper 78. 1st OD 78. Washer 137. O-ring , 188. ODF 79. Bolt 138. O-ring 80, 189. =— Kar yyy 80. Washer 139, Needle bearing 81. #4048 M0 Fo + 81. Tierod 140. Washer 82 24 ey KVR WML RK 82. Tie rod end 141, Bolt BBA Oy KF oy — M2 Hh 83. Tie rod bush 142. Bolt Bde REY REY 18 KE 84. Tie rod end 143. Bolt 85. oy 2 7L-b MA Doe pin 144. Washer 86 AAW M5. Fy be 85. Lock plate 145. Washer 88, Vb 6. 797 86. O11 seal 146. Plug 88. Fab M799 ea MPD 88. Bolt 147. Plug 9 ove M8, kA AT 89. Nut (with magnet) 95. hv 77h 19 AZARD Ee 91. Washer 148. Wheel hub 96. ty KAss'y 150. FY FEL ATAb 95. Torque plate 149. Thrust washer 97. KAssy Dove 96. Pad ass'y 150. King pin thrust 98, hwo ey 1. ey 97. Pad ass'y washer (our rH) 182 A7A0Y 98. Torque pin 151. Pin 99. kaon 158. A744 b (with O-ring) 152. Hub bolt 100. 28—FU-b 1868. F—K-0 99. Torque pin 153. Hub nut 10, VARY TOY AT IEE 100. Cover plate 156. Tapered roller 102. vary 152 101. Piston plug bearing 108. FY - FF ATI 102. Piston 157. Tapered roller (LAIRD H) 188 ALL 103. Bleeder valve bearing (or connector) 159. Oi1 seal 104. Connector (or bleeder valve)663-7101 563-2101 DRIVING AXLE (1) Differential a 1 1 Reduction gearing The reduction gearing consists of the drive pinion and the ring gear mounted to the differential case. The drive force of the propeller shaft is turned 90° around into the axle shaft direction, and is re~ duced in speed to increase force, by this unit. Differential The differential allows the right and left wheels to be driven at different speeds to prevent tire slip when the two drive wheels must run at different speeds for driving along a curve. There are two types of differential; one is the ordinary type used in ordinary vehicles and the other is the no-spin type which adjusts the torques distributed to the right and left drive wheels. 1. Ordinary differential rive pinion Roseets Thrust washer BORN ne ‘Thrust washer FI pvp yeh YI9D ee MDA TEAAYEFD pL we RICE NEIL TE COMME, FORTY 7 BIEL CHE S ABDI SITY 72 Ave DT (iy) Ae EAB EE GICAL CHIT HBA TORT FI bye eR HMFICL > THOM MICOS 5B AIC MMe SES CLICED, 24 DOSS IOR EDLY SETS, 133, AICO SCG NS—MIT Ly vent Fk, REBDRADEE KV? 2A BIGHT 57 ALL FD LYE het ID 2 HBR ORT. L RFD pL Ea Ring spider es Differential pinion yoy eeste ste _-Side gear Spee T__Axle shaft Py sn ee ak Fig. 5 In the differential case, four dif- ferential pinions, rotatably mounted on a spider, are in mesh with two side gears splined to the ends of the right and left axle shafts. The spider is fixed to the differential case, but the differential pinions are free to turn on the spider. Differential case FI Vey Wem AB, FI ey er HRICKA BME ANA FICE TOE AMOI 7 VEL eWERAYE, TI AWY 7 RIMICA TS AY CRIBS TOS 2 MOH KE DIME It HAGICBIETS SEG ICo TORT.563-2101 563-2101 DRIVING AXLE _ [DESCRIPTION OF OPERATION] The principle of operation of a dif- ferential for straight travel and curve travel is illustrated below. Drive pinion voryeate Ring gear yea Side gear ree [Straight travel] Catto 9 Difterential case Ponto n gird Anle shaft aes Differential pinion Po peseeneore CHempaeos ie OGL FO PRY AR A FB outside Inside {curve travel] itn 9 Fig. 6 As shown above, when the vehicle trav- els along a curve, the differential pinions turn on their own axes to absorbe the speed difference between the right and left axles, for slipfree driving. When however, the road surface condi~ tions differ between the right and left tires, such as on muddy or frozen roads, the straight driving performance is reduced, and in extreme cases, one of the tires slips to make the vehicle propulsion altogether impossible. When one of the tires is bounced free from the road as when driving on bumpy road, the lifted tire is driven at a high speeds, and when it lands on the ground, it momentarily drives the vehicle impulsively to cause the vehicle to veer. 2. No-spin differential The no-spin differential has been invented to overcome the defects of the ordinary differential given above. With this differential, even when one of the tires slips, the other tire retains sufficient drive torque to propell the vehicle, and even when one tire bumps free from the ground, its speed remains equal to the ground-gripping tire, so that the bouncing tire has no veer— ing effect. COL SCHMID yy eves AOR HEC E 9, FEAR ORME ORL CARICA AMICK TOE TS Lip, GD 2 4 IC CHING DRM & TE HICH Beds HET. PICA A, DRE GICH IDM Ao ABE OTERO AY y AULD ATT RABIES 9D LET. Ey MAOS OGM EET L, Mek CRE SARC LN U1 NCAA IC BLT REL CR DRG RC UBC ORT. BJ AREL ED LY BAT MOB F7ORAL HED BICBA BNO JA RELFIC. HWMDSAY 9 FL BUSES (Av KES 6 MO MOM NICL OTT CEMTEET. EI, BURMA MD bRNT 6 LOIRE SOONER 2 IL CH Ba TED MORE HIE CED ET.eee 563-2101 DRIVING AXLE ray bing gor Drive pinton Be Foneate No-spin differential oas'\ h fa | se ent c \ \ ay \ notdoue ving | 771%. cin sianroh ibs | 7 San stog feta ls Gisicn,seetm) : oS a rns Driven clutch ae Liwle shaft TS Side gear <= oem) Fig. 7 1) Spider center cam ass'y This assembly consists of a spider, a-center cam, and a snap ring. The spider is provided with radial clutch teeth on both sides, and four trunnions on the periphery, as shown. The bore of the spider is provided with a key for limiting the rotation of the center cam and the holdout ring. The center cam has grooves on the periphery, with one narrow groove accepting the spider key, and three or more wide grooves accepting the projections of the holdout ring. (The center cam shown below has three grooves.) The center cam has cam teeth on both sides, the number cf which is equal to the number of clutch teeth on the spider. ‘The cam teeth have slanted sides. The center cam and the spider are held together by the snap ring. Between the spider key and the center cam groove, slight relative rotation is allowed, but axial motion is not allowed. Spider Bee (cam teeth) (cane (Clutch, teeth) LOEB eek » Differential case RSAB eat hAssy CNBR, BYE HA AH oA ILT LOBMEN TORT, 2104 FIELD 3 FMA HKICD DEF. NABICIEMD E5104 DOhI=AAY BHO THEFT, AISA AEMBICKL, BLA LER ET DAY Y FOR EMT 5 1: DO+— Ad OE Fo EUR AAS IIICIMASD D LODE MIC, 24 FE“ HAD, BIEN LOUIE IV ETO bY FO RIEA DRG. (MCI B OCT) eye Lid, HBC FOF 2 7 FALE MURO 4 A BH TORT. WAMAMIC TORT. CORY E-HLEARAH I APO TILT TRESNTOET. ELT, AA FDH-E ELF— LOWE THF OMIT SEF, ATR NEI TOE TS center com Sens i \ Berrie ¢ -563-2101 563-2101 DRIVING 2) Driven clutch ass'y The driven clutch ass'y consists of a driven clutch and a holdout ring, and is mounted on both sides of the spider. The driven clutch is provided with clutch teeth the number of which is equal to the number of clutch teeth on the spider, and they are in en gagement. The cam teeth are in en- gagement with the cam teeth on the center cam. The spline on the bore of the driven clutch is in engage ment with the external spline on the side gear. The clutch teeth have a groove in which the holdout ring is inserted. twech,eeech (assaiee? am, eee) Gaen 3) Spring ‘The spring is installed between the outside face of the driven clutch and the side gear flange, and ensures the engagement between the spider and the driven clutch. 4) Side gear The outside spline on the side gear is in engagement with the inside spline in the driven clutch, and its inside spline is in engagement with the axle shaft spline. (PRINCIPLE OF OPERATION] Straight travelling The right and left driven clutches are in engagement with the spider by their clutch teeth, and with the center cam by the cam teeth. In this state, the drive force is transmitted from the drive pinion through the ring gear, differential case, spider, driven clutch, side gear to the axle shafts to drive the right and left wheels. The sketch below shows the engine drive forward run state. AXLE 2) KIT Y DF oF Assy KIFLI So FER ETO RU Oth RIN, 284 FOMMIEMATET. EVIL DS 9 Fld, ANA EMMOD Fy F WERE ARA YO) Fy FHLMATT, F Ky DAMIER YY LOH AEMEVET. FU FY 2 Fy POMERAT TA IR, 14 RE HONBR TIAL EMAOET, 77 o Fil HCNREDS DECIR ETD RIL TBA bet. Driven eluteh Deere Holdout, ring Sup ee Fig. 9 a) ary ey RIVA hy IIL 2 Fy POMBE HAF FL IIL VMHLOMELA TORT. TUT BARLEY ILD Fy FONE ERE L, CHET. 4) a Ree MYAPI ALLE ITY Fo FOWEAT I AVENE, BEAT IAAT DALY 7 hemes t. C resin) tes KBOKY SLID 7 FDI Io FBANRATOD Do FMLMAR TBD, HAIG EY eH AD DLBLMARS THEF. TORMTIL, BITE ROA FERAL AVY TER OFT LY FAARIA YOY ILY Dy FAA REL AT PAVE 47 hOB CRB OMMICEE SNES. BBLS YOY R91 FCMMO RMT LET.R563—Z101 DRIVING Backlash yd ae a Rung in the sanespeed avascer Spider driving the driven clutches. ANA YEE SIZ 97 FMT Se Fig. 10 When the engine brake is applied, the force transmission relationship is reversed, and when driving rearward, the running direction is reversed. In both these cases, the clutch teeth in engagement make contact on the opposite tooth flanks. Forward curving by engine drive For curve travelling, the run dis- tance differs between the outside and inside tires, and for this, the right and the left axle shafts must run at different speeds. While the spider is driving the driven clutch, the driven clutch can not run slower than the spider because of the structural design of these members, but it can run faster than the spider in the direction of backlash. When the vehicle steers towards right during forward run, the spider trans— mits torque to the driven clutch on the right (inside) through the driven clutch with which the clutch teeth of the spider are in full engagement. In this state, the right axle is driven at the same speed as the ring gear. However the left (outside) tire is driven by the road through fric- tion faster than the spider, to push the driven clutch to disengage the clutch, allowing the driven clutch to run faster than the spider for smooth curve travelling. The left holdout ring comes in con- tact with the spider key when the clutch teeth are disengaged, and at the same time, the projections are lifted off the grooves in the center 10 663-2101 AXLE Driven clutch Risa Se 2827 center cam Sea Center cam {s in engagement with driven clutches on both sides. SPA LAID EI 23 2 PICHIA Ty BY DUT UH FOE NORROROBICTE DEI Ki CROMEAMDIC KD. OFNGD FROM RITHM ORI DET. piety 54 7H EIR CLAP AOU HAD He FTAALA He 3, BROT? 20Vo » 7 ROBERT 6 MEU EAE DRtA. ARABI TLD Dy FMB TOS BEI ROWE KI I LY Fy FASE ED BEC BC EAOMETIAN 7 Fy Ya DHS GMI BCMACLUTAET, ite BEI, 284 OOO CAB) EZ Dy FOP Fy FBEREICMS > LEE THM CA MY) RYT L2 Io FICK UD RRAETS COMETH, BM (PHD ICY re 2 MU eA THM eM SET. LiL etl a) Tid, Bhi OMI NICL DY ab ADM ET FUFY9S oF RARAYDGRY LG EUEOT (23 y FROME LBANS BML OH COMEL Raney, EMOR- VET OKITA, 99 9 FLOM DANIEL RS 284 OHI YRC Bie Bn AOMBED HY bdo CHES, K YILY Dy FRAN HE DRE BEY ID Fo FOMANEGRET. HeMasteD ), ABO BMA Cte Te BEE CRB G ED RT.563-2101 563-2101 DRIVING AXLE cam and held, to prevent the engage- nent of the driven clutch while the driven clutch runs faster than the spider. When the vehicle stops curving, and the right and the left tires no more require differential drive, the straight driving state is restored. vam cee Runs faster, sos cme For engine-braking in forward curving In this case, the torque applied by the road surface to the ring gear is opposite to the torque in driving by the engine. During braking by the engine, neither vheel can run faster than the ring gear. (Because the clutch teeth are in engagement as shown.) While steer- ing to the right in forward run, the left (outside) driven clutch is in full engagement with the spider teeth to transmit torque to the spider. In this state, the left (out- side) clutch is running at the same speed as the ring gear. However, since the right (inside) center cam slope pushes the driven clutch out of engagement with the spider, the clutch teeth disengage, and the right clutch can run slower than the left for smooth curving. ‘The holdout ring operates in the same way as when the vehicle is driven by the engine while steering right. Running at the sane speed Acamect: Running at slower speed moane-cibe Runs in the same speed clutch Fig. 12 " The left clutch teeth are dis~ engaged by center cam. EG ulee nny 95 FROMAL IANS faite = COMER D> G DMEM ICL 9 TY 7H CoM Bhwa Pian 2 KIA Fis MEK DET. ELVYF UF, EBSOMBE IY TEL DCMS CETERA. (BIOL TIED I oF amas THE) UAE ASMEEN Na, EL HW) DEY Td Fy Fae BRAYOD Fy FEF ENME 9 ELE TAN PICbUS BRALT, COWIE TRAE (EB) 16 yy 7 El CME TEL TET. Libby ER) C PUB) LEER 6 OMRIBAICA DEF — DMMT EY ID Fy FRARAY >GRO LVS BEDUT( FF 7 FROMAVMAINS ) HME D EC MEL RET DN T. WET ORY HR, BRM Y EY KIL ID IBA SARC HDD UE Te (Center can disengages the right clutch teeth) Corp nick DBD 9 FBOmaLH wn)663-2101 563-2101 DRIVING AXLE 2) Planetary reduction gearing The planetary reduction gearing con- sists of a sun gear, planetary gears, an internal gear, and a planetary gear spider. The planetary gears are in mesh with the sun gear and the internal gear, and are installed to the planetary gear spider by planetary pins. The planetary gear spider is bolted to the wheel hub. The internal gear is integrally built in the axle housing. In this state, the sun gear on the input shaft drives the planetary gears, but since planetary gears are in mesh with the stationary internal gear, they can not rotate with the positions unchanged. They revolve around the sun gear along the inter- nal gear while rotating. In this way, the driving force of the sun gear is transmitted to the planetary spider (wheel hub) which in turn drives the tire. The turning direction of the tire is the same as that of the sun gear. Planetary gear spider FIA EM AAT Plonetary gear IRD Planetary pin SE Sun gear eS 2) eae ERA DEY, 79a Ue 4 BAP WERROT IAD IER ANA YCBLEN TBD TFAR VERE ENN 1 > LEP PICMEU, TIAA VEY CT IAT IE ANTOET. Bh, SIRE IE PARA Ki NA WANT ICAL ROBE STO EG, Aa TERI, TO AINE Hic 3 TH OMEN TORT. COMM CAIMMED YY ¥ FDINET SAFE Vics NETH, F949 FRB SN PERI UEYE bo TO CR OME CHET REUA. Mo TF IAB DEK Ae TE PIC THLE YOR ELD AL ET. AUTH ER OMBNIR, TIAZIELART CRA WT) OBR UTR EN, BAL NTKMOBV SHES 4 YMRS. ZOO BHM, HH POMMEBME MELO ET. Whee? hub Benny Fig. 13 RFRS63-Z101 563-2101 DRIVING AXLE a a) Ball joint ass'y @) RNS atv b Assy The ball joint is composed of an HOW at REAR AB T- K-TH inner ring, an outer ring, a cage, RENTED, MMEL 2 atv bAHET Se and balls. When this ball joint ro- By TRAC TRB SN — LAR OO tates with the two shafts intersect- OM LEH. 7- TRA AMOBIEMLL Sty ing at an angle, the balls, retained OHV RHLOWMCREL TORT. by the cage, roll along the grooves RUTAFT V7 PREF L 3 TE 9 1 HOTA in the outer ring and the inner ring, BED ES ICHAEL C8. FEICRARHAAIC RST 5 EMH and the cage retains the balls while REN LORS MAORI EES 2 Baw HS sliding on the guiding surfaces of DIY at heT the two rings. This joint is capable of transmitting the drive force and torque at uniform speeds, irrespective of the angular displacement between the input and output shafts, caused by steering. outer ring _p Balt ne x dul shaft Poaeeoy 1x Fig. 14 Brake @ 7U-* The brake is an opposed piston type FUR BEDE SIF 4 ADT L— hOABLICH disk brake using one each pad ass'y on F Assy 1 oC. F429 TU = HERERO S both sides of a disk plate to pinch it EDIE oTHBHMER RY MOT 1 AI FL—* between them, as shown here. ct. ‘The disk plate turns together with the RAW ESICENET AF 4 ADT U- bEF IH wheel, and pads are incorporated in a ee & tuts hay FL CH RENTOR Ts torque plate which is fixed to the hwo Fe= KEE bh ABENTHO, FL knuckle. -HIE LTE LEMON y FAasy BF 4% The torque plate incorporates pistons DAU bCBifid> © FER L THEME SFT 5 3 to force the pad ass'ies onto the Kote. disk plate to brake its motion. 13563-2101 563-2101 DRIVING AXLE ‘Torque plate haart epneeen’ cap seal The clearances between the pad ass'ies and the disk plate are maintained at a constant size by means of the piston seals. When hydraulic pressure is applied The pistons apply force ass'ies by deforming the (Fig. 16) When hydraulic pressure to the pad piston seals. is removed The seals recover the original shape to push the pistons back, creating clear- ance between the disk plate and the pad ass'ies. (Fig. 17) When pad ass'y wears The piston displacement distance in- creases beyond the seal deformation limit, and the pistons slip relative to the seals, but when the hydraulic pres sure is removed, the pistons are pulled back by the seals through the same dis- tance as before the occurance of wear, giving the same clearances. Backup ring aT oF Y Piston seat eae ‘Torque plate eset _— Piston ext Piston dleplacenent Pahokee Fig. 16 Piston ploy exroys ee Bolt Fig. 15 AIFL TOE TS My ty BAsty 25 hope A he PIC 2 CHEN MEE ASHER Le & & CARI, — WV RBRIE BEMIS Gy K Andy (CIE NEMAZ (Fig 16) ME ASHER Uae & AEA (MAL, Y— LAORRICE EM, BAK VUAOAVEE BESNTH4 ADT hE K Asc’y EDMNC— EOF EMOTES. (Fig 17) PoE Aas’y £801 L ERY OBMMES (in, - ORM EMA, COBY EAT EY VEOM EM Rik, BIAS OLREMUES IGA GESH, TAB BeREN Be Piston seal Torque plate bag7vee IN Fieron Bane Fig. 17 “563-2101 63-2101 DRIVING AXLE © DISASSEMBLY AND REASSEMBLY OR, BAUT NOTE ae vein this section, the descriptions for WARMEST, TDA Asly REFIT 7b the axle ass’y and for the differential DE Ib Assy CRO THAL TORT. ‘ass'y are given separately. BALTHSER, —BEMERRS OOM The photo in this manual may HOST HRABEL TRACTS. sometimes be slightly different from your crane components, but the descriptions are valid. () AXLE ASs'Y @) TOA Assy © DISASSEMBLY O sR NOTE =e se When disassembling the planetary WT SRI VEVBREIL—FMEDRTS gear unit or the brake unit, the axle WA, 7IALEIL—YHDERONTOR need not be removed from the crane. tar, veThe right and left members can be RAMBO RTT I, ARICA isassembled in the same way. When FEBS BAMRCSAOESCRETS isassembling right and left members ce imultaneously, take care not to mix the right and left parts. 1, Draining gear oil 1, #PALNORSMO 1. Unplug plug, and remove the gear 1 P9PORNL ENDL TBOEY AA VEE oil completely from the housing. BS. (9260) (Fig. 18) Capprox. 26 lit. (6.87gal.)] (Fig. 18) 2. Unplug plug@@D, and remove the gear 2 F5¥CGDEMLTRA-UATHOH TAL oil completely from the wheel hub. BRSMS. (HORA E ) CFig. 19) approx. 4 lit. (1,06gal.) per side] (Fig. 19) Fig. 18 2. Removing disk brake ass’y 2, F4ADTL—* Ass'y OROHL 1. Unscrew bolts CID and remove the disk L -# KID SHU TH 4 APT L— + Assy HRD brake ass'y. AF 6563-2101 563-7101 DRIVING AXLE ~ 3. Removing planetary gear spider ass'y 1, Mark match marks on planetary gear 1 spider G2 and wheel hubCH®, unscrew boltsC4@>, and take out the plane- tary gear spider ass'y utilizing extraction bolts. 4. Disassembling planetary spider assy 1. Mark cover G@ and planetary gear 1 spider G2>with match marks, un~ screw boltsCH#, and renove cover CD. (Fig. 21) 2. Remove planetary pins GD by push- 2 ing the end without a recess, with a press. (Fig. 22) 3. Remove planetary gears (2, thrust 8. washers Cand needle bearings a> from planetary gear spider Cia). Fig. 21 5. Removing internal gear hub ass’y 1, Remove sun gear GB). 1 2. Unscrew boltsGaD, and remove lock 2 plate GD. 16 3B. TRRIVEP ANF Ass'y ORD IL PIR VEN ASL HOD ERA WNT B27 BHU. RUECDEML. HE HVA BRL TI IAS IEP ANA Y Assly & AT. Fig. 20 4, TIRIVEVANLT Ass'yOOR WN CTDE TI AZ VELA YEDIAT A} tte. Bh CADE HL TH BAT. (Fig. 21) Az ey GDEWK 8 MUI FLX BRAL THUR. (Fig. 22 J2APIEURRA TCDD TIAR IE GD, A927 9 oe GD. =- KANT IY 7EDENT. 5. AI FLEPNT Ass'yOROSL Yo ¥e DEW EM. Be }GDEAUT Oy 9 PL DEMO te.R563—Z101 563-2101 _ DRIVING AXLE 3. Remove bearing nut GD, and remove the internal gear hub ass'y. yy Do not remove the tapered roller bear- ing unless its replacement is necesary. 1. Remove stop wireCi, and remove internal gear hub G&D 2. Remove the inner ring of tapered roller bearing CéDfrom internal gear hub GD. Fig. 25 ” 8 XT IY Thy KEDEMLTA ATE NT Ass'y BELOIT. p mu LSS Last —n2—le-s0 Bearing nut removing tool AT YLT $y MATA Fig. 24 6. 1 9-F WERT Ass'y OOH 2 WEAN SAT UY Ti, RMF SORM RUBS, MOHABOEE, 1 Aba TIA GD ENL TART LEN FED MAM. 2 ALP T WEENIE OS FAN FIL FED ORMENT. Fig. 26563-2101 563-2101 DRIVING AXLE 7. Removing wheel hub ass’y 7, RA INT ASS'y ORO IL 1, Taking care not to damage ofl seal L 44 VD EMHU BE SRBUT. GD, suspend the wheel hub ass'y AWAD Rasy BI UAT, HERS. from an overhead crane, and remove it. Fig. 27 8. Disassembling wheel hub ass’y 8, KA NANT Ass'y OR NOTE am ‘Do not remove the outer rings of HFN-O-9NT IY ORM, BUT 42 the tapered roller bearings and the DIL has SATS ICED disk plate unless their replacement Harnre, is necessary. 1, Remove oi1 seal GD. 1 thy. aDemos. 2, Remove retaining ring@, spacers@, 2 JF-aY YY YBRNUTAR-9@, BF @, and the inner ring of tapered ROB FAT I LY EDONMENT roller bearing GSD 3. Remove the outer rings of tapered 8 FB 347 1 CD, EDOM roller bearings is, G&D. ams. 4. Unscrew bolts Giand remove disk 4 RU TDENLT 4 A 7L— KD eM plate GD. @ @ Fig. 28 2663-2101 563-2101 DRIVING AXLE 9, Removing tie rod ass’y 9. NOTE L YsDrive off the tie rod end pin from bottom upward. 1. Remove lock plate ®, and drive off tie rod end pin @. 2. Remove the tie rod ass'y from 2 knuckle @ . 10. Removing knuckle ass’y 10. 1. Unscrew bolts and remove plates 1 2. Holding the knuckle ass"y with a crane, remove king pins @ and o by using extraction bolts. CAUTION 8 yrBALL JOINT ASS'Y G2D AND AXLE SHAFT @ ARE LIABLE TO DROP OFF. CAREFULLY REMOVE THE KNUCKLE ASS, AVOIDING THEIR DROP. 3. Remove the knuckle ass'y from axle housing & . 9 2 94 Dy KAss'y ORO IU BF TU-NBENLT, F1oy KEY REY Det bie<. ER W94 Oy REY REVI FRY EID STHTBRC TE, BADD RAS BI 27 MDMEAT. ty DIL Ass'y OBO IL AO ADEL TIL KOBE. PoP WM Assy BF LAU TREEL Hee A METH FEO, WENT. Vb PoP Waly BT IALNIZY TOD ENTS KER te RN a4 vb Assy QD RUT IANE 77 }@iRI RS SEREKESOTERL RMSMDCRERSCE, Fig. 30563-2101 11. Disassembling knuckle ass’y NOTE yDo not remove the knuckle spindle and thrust wash unless their replacement is necessary. 1, Extract axle shaft @ and ball joint ass'y GD. 2. Unscrew bolts ®, and remove knuckle spindle ®. 3. Renove thrust washer @@D, oil seal @and spacer ® from knuckle spindle ®. 663-2101 DRIVING AXLE 1 Fy DILAss'y OFF 2m Set yDUREY KL, RIAD oY Hl R AT SHEMMINEMOHSROTE, lL FRAY eT hORE: Detams. We at Y Assy 2 KURO EAL TH SD UAEY KUBEMT, 8. Hy DRAB MBE AIRNI GL y AAEM, AR PBEM S, TD. Fig. 31 12, Disassembling axle housing ass’y NOTE yxDo not remove the boot and king pin bush unless their replacement is necessary. 1, Cut band @ for holding boot @, and remove the boot ®- NOTE yeDrive off the king pin bushes from inside of the axle housing outward. 2. Extract king pin bushes @ and oil seal @ . 20 12. TOAMNISIT Ass'y OFM 2m We TI YRORYI EVI yd ald, BAT SD ESBIBSC, MOKERVTE, L FOI RABO SY KOSUMLTS—OENT. 2 ALT ELT yy ORAL Ve — EHR Be ER WELIED Ty dald, TIANNDI ITN MED, MYC > THT BRK CE,563-2101 R563—Z101 DRIVING AXLE 13. Removing differential ass’y aa 1. Unscrew bolts @ and@, and remove Fig. 32 FI pL ye eIb Assy DRO IL 1 HUD, @ENUTHI 7 Vy Assy 2 the differential ass'y. bar. (© CLEANING 0 1) Metal parts 1) SSB Wash in clean kerosine, and dry by blowing air. 2) Rubber parts CAUTION DO NOT USE MINERAL OIL. Clean with alcohol or clean cloth. © CHECK 1) Checking gears and splines Check them for wear, pitting, etc., and replace if faulty. 2) Checking planetary gears and planetary pins Check the bores of the planetary gears and the outside of the plane~ tary pins, and replace if faulty. 3) Checking oil seal contact areas Check the seal areas for wear, damage, etc. tangible by fingers, and replace the oil seal if defects are tangible. 4) Checking axle shaft Measure the straightness, and if the standard value is exceeded, replace. 0.5 mm (0.02 in.) a Standard value : BAD EDEN CREP L. = 7 TEARS ES 2) 7 AaB FI VLR CN EM Bo Bk Pe At AMISEM LIT Ee O RR 1) BEPRORTI A VORB BRO FY TB ERRL, BRD SOIR RIT S. 2) PPAR IER FIRB VERNER OS 722) CNBR A BL, RNB 5 LORRI 4. ABD ELON B) AA se — UHRA RU 2 VEBICHEFECABIT'T & SURAE, (BAAD ATT HS. 4) TIARY 4? OAR thas eM L, EMME TOS BORIS be AA 0.5 on563-2101 863-2101 DRIVING AXLE 5) Checking king pin bush Measure the clearance between the king pin OD and the king pin bush ID, and replace the bush if the clearance is more than the use limit. Standard value : 0.10 to 0.21 mm (0.004-0.008 in.) Use limit : 0.35 mm (0.014 in.) 6) Checking boot Check for cracks and other damage, and replace if faulty. 7) Checking bearings Wash them in kerosine to thoroughly remove oil and grease, and check them for the following respects. If faults are found, replace the inner and outer rings in sets, and if no fault is found, apply grease thinly. + Turn by hand, and check if they turn quietly. “Damage, pitting, partial wear on outer rings. + Damage, pitting, partial wear on the tracking surface of inner rings. + Deformation and partial wear in cage. 8) Center brake (parking brake) “Dise plate thickness Standard value : 30mm(1.18 in.) Use limit : 29mm(1.14 in.) -Brake pad thickness Unworn thickness : 10.5mm(0.41 in.) Use limit : 3.8mm(0.15 in.) 9) Service brake “Disk plate thickness Standard value : 12.7 mm(0.50 in.) Use limit : 10.5 mm(0.41 in.) ‘Brake pad thickness Unworn thickness : 20 mm(0.787 in.) Use limit : 3 mm(0.118 in.) 2 B) EYP ELT ORR BLY CURBL EY FELT av APL OFA SBE LU, GEMMA BBLA TOS 6 OLST 35 2 ie fff: 0.1 ~ 0.21 an EFRBRKE : 0.35.0 6) 7-7 OM BE, ABBE RRL, Rit anieZiT 5. 1D) ATL rORhe Ben CHORR 2 HEATH RRC FAIA 6 RL KAOWY OS LOUANME~ » bRITS. HMO DIL) AAC MAIL TH So + ECMMES ECMO A eR + ARON + RD BLEED Dim DIS. AAA, MERE HE DBI, NAMED SR + AN, HARM ORE CHEE ATA) OA 8) RL -FL- RCRA IHF) FAY FU-bOMe Se = 80 mo PUTO + 29 an FEF rsy KOMS WisARGNES + 10.5 a0 GOHIMRKE : 8.8 mw 9) PEATE SF ROT LH OMS HEM © 12.7 am (eROTIRME : 10.5 om HF Un Fy ROME ARGS + 20 ow (ERIE = 8 oe563-2101 663-2101 DRIVING AXLE (© REASSEMBLY 1 2 CAUTION Ys REPLACE THE O-RINGS, OIL SEALS AND OTHER RUBBER PARTS, AND ALL THE PACKINGS WITH NEW PARTS. tr WHEN INSTALLING OIL SEALS, DEGREASE THE MOUNTING SURFACE, ‘APPLY LIQUID GASKET, AND FORCE THE SEALS IN PLACE. USE THREEBOND NO. 1104 OR EQUIVALENT ‘AS LIQUID GASKET ON METAL CLAD OIL SEAL, AND THREEBOND NO. 1212 OR EQUIVALENT ON RUBBER- SURFACE OIL SEALS. Remounting differential ass’y 1. Install the differential ass'y to axle housing @, and secure with bolts % and @. Torque : 21 + 3 kg.m £21.7 sz ft-1b) Reassembling axle housing ass’y 1, Force fit bush @ to axle housing @ . 2. Apply liquid gasket to the outside periphery of oil seal, and install it in axle housing @ by forcing. Then, apply grease to the lip of oil seal and the bush. 3. Force fit upper and lower king pin bushes i to axle housing @ . Then, apply lithium soap grease containing MoS: on the bush bores. 23 2 TORN O BS2T KER WOUYT, AANY-NROTABR, BRON y FRAC RINT SS WFAN NEMO NE SMR, EE BER Ubi BRIA T y hERBLTEATS. (RAAT y bi EOSOMIAMED BORAU—KY Khe 104 VMWARE LA Ly TAROGOBRY—AY Ki 1212TiaH AREBHTS. 1 FI rye eb Ass'y ORO LF ULE WAsy BID AWAD Y FANE ROBT, KV KB, OCHO Bo BEEK: 21k Beem UO Ass'y OBHIT 1 Fy Va@eT 2 AWD DY FENCEAT Bo 2 PAWL — VODA NTTCHEIR Af 277 9b REL CT PAWAY DY FOICERT Be LEAR, 44 VOR o TOBE 9 Yat) 2 BBMLT Boe Bo FLY ELT VaMETY RWNDDY TOOL F 2ICEAT HEA, FY a PSIBICMoS2 ADDI FILE Y ABRTBL TRS ” "563-2101 663-2101 DRIVING AXLE NOTE YeAccurately align the bolt holes. 4, Install boot @ at the specified position, and with the bolt holes accurately aligned, bind it with band @ using a band tightener tool. 3. Reassembling knuckle ass’y 1, Install spacer @ to knuckle spindle . With liquid gasket applied to the outside periphery, force fit oil seal @ into knuckle spindle @. Then, apply grease to the ofl seal lip. Force fit thrust washer Gin knuckle spindle ® NOTE vs Apply THREEBOND No. 12! or equivalent to the bore of the oil seal race. 4. Force fit the oil seal race on knuckle spindle ®. NOTE YcApply THREEBOND No.1374 or equivalent to the threads of bolts @. 4 F-YOSMEOMMICR ONY. Kv KMS TERIC Orbe a, NY KALE LCN K@OCHDH SZ. aR eA FRM AEM B DTC ee Fig. 35 3. Fy DI Assy OMALT L Fy PURELY KVBICAS— FOLDS, 2 AA VE MOON AMICI A > b BUT CH oP MALY KVOIEATS, EAR, 44 WLW y PBT) % BBL THC BF a PWAELEMBIATAND yy GD *& EAP. A Fy PWREY RUBIA VY WEA BEA Te ee WA YL REAMIERY RY ENo, TNR BBL THC, O41 seal race Tae Fig. 36 By PWALY EMBER HBTS y 7 VEDIC DOS. HH v2: 5545.5 Kee m 24663-2101 DRIVING 5, Install knuckle spindle @ to knuckle @vith bolts © . Torque : 55 # 5.5 kg-m (398 + 39.8 £t-1b) 6. Force fit ball bearing Gon ball joint ass'y@2, and insert it in knuckle spindle @ . Pack 300 g (10.6 02.) of lithium soap grease containing MoS, in ball joint ass'yGa, and install collar Cand axle shaft @ . 4, Reassembling tie rod ass'y NOTE ‘YeInstall the oil seal in the correct orientation. 1. Force fit tie rod bush @ and of1 seals @ into tie rod end @. Then, apply lithium soap grease contain~ ing MoS to the bush bore and to the lips of the oil seals. 563-2101 AXLE ze Yea h@O tab BIC, AU — AY KN 1374 AA REBT S. 6. Roe a ty bAs'y DIK ar yy 7 CDEEAUTS 9 2 URED FUBICHAT Be R19 9 1 Yb Assy CDAAMo 8: ADD! FOLK) AB BOR HAL tri 09 CBD 77 AVY 97 MBM AALS Fig. 37 DA By KAss'y OBST L 24 by REV ROE 1 Ty KF yy 2B, 44 WY VOREAS Se EAR, Fy Y 2 RO AAW AW 7 FHICMOS2 ADDY FDR ) 2 Bette UT BK ae WAAL -LORAFACERS B, 2. Screw tie rod end @ over tie rod @ until approximately 15 mm(0.59 in.) of the tie rod thread remains exposed. 5 Fig. 38 2 FAgy KEY OES Oy KOODUBIES meh # CA LAt.R563~2101 563-2101 DRIVING AXLE Reassembling wheel hub ass’y 1. Force fit the outer rings of tapered roller bearings Cis and CSDin wheel hub GD. 2. Install the inner ring of tapered roller bearing Cis®)and spacers @, @in wheel hubGi#>, and install retaining ring ®. 3. Apply liquid gasket to the outside periphery of oil seal), and force it into wheel hub GW. Then, apply grease to the lip of the oil seal. NOTE YrWhen force-fitting hub bolts G&D , direct the recesses on the heads towards the center. 4. Force hub bolts CH into wheel hub Ga « NoTE ye Apply THREEBOND No. 1374 or equivalent to the threads of bolts aD. 5.°Clamp disk plate CID with bolts aD. Torque : 3 ( 6 Reassembling internal gear hub ass’y 1. Force fit the inner ring of tapered roller bearing GSM to internal gear hub CAD. 2. Insert stop wire G@® in the groove in internal gear Ga>, install inter- nal gear hub@ai>, and then, insert outside stop wire Ci). 7. Reassembling planetary gear spider ass'y NOTE YeBring the recesses in the planetary pins in the outward position when force-fitting them. 5. RAIN Ass'y OMSIT kA IT GD ICF = 1 DON EEATS. 1 -on7 Ly 2 ok WA IEDIF 9-3-8 7 VOD OPM, AX-FB, BEIT Fa TYE FOCIEDS. BAA Y— VOD OMAR ICMR IAT 9 bei HLTH —VNFDIEAT Bo FEAR, PAULA) FHT) 2 BATT 0 “PNT ED IONS CD EBAT. ae Ye ANTAL RGD OFA, HOMR MED ORIEMOTEC CE, 5. F422 AV—hGID BU KD MOH Se HERE hoe : 84 Abge m ee Ye AVL GED maw, 2U—Ay NTI BYRERHTS. 6 FY I-FIEV NT Ass'y OHSLT 42a FW ENIGD IF — D2 7CDOWWEEAT SE. 2 AYP WE PCD OMICA L774 CD BANT 9 —F HER NTCED EM ADAL th MID A by F4CGD BANS, 1. TIRIVEP ANY Assy OMSUT 1 PIAR VERA YDB IAG FY GD. 29219 ove GDRES— KATY YF CGD EMNTII AZ VEL CED BEAT B563-2101 563-2101 DRIVING AXLE 1, Install planetary gearsCZD, thrust ae washers Cia and needle bearings n planetary gear spider, tke TIRDUEVEAR, ORSMEIMICEO and force fit planetary pinsC2. Force fit shaft stopper Cli) into cover Cis). 3. Install O-ring GDin cover, align the match marks and mount the cover on planetary gear spiderCi®) with bolts GD. 3.5 Torque + (25.3 0.5 kg-m + 3.6 ft-1b) 8, Installing knuckle ass'y NOTE ve Apply lithium soap grease ‘containing MoS: to the sliding surfaces of the king pins and king thrust washers. 1, When the king pin and related parts are not replaced, set king pin thrust washer @ and shims @ on upper king pin@, and set king pin thrust washer CD and shims @ on lower king pin @ in the state before disassembly, prior to the reassembly. When parts are replaced, calculate the shim thickness as described below, and set them to the respec tive king pins. SHIM THICKNESS CALCULATION PROCEDURE 1) On the knuckles, axle housing and the king pins, the machining errors on the respective standard dimensions are stamped or marked at the loca— tions A, B... F as shown below. The actual error values are 1/100 of the stamped values. Bre, 2 Wh CDC 4 7 ha hy SCD PEAT SS DN-GBDICO I v FAD EMO. BF BAUTHU KC CII AT ERR ED IMO Bo eR have B5+05i¢-m 8. ty DIL Ass'y DORON 1 FY FEL BRO RRS etic obo BE EMDR TE LOICEY FEY AIANI Ye WH, LAGE, KiOFL Fev eOCTY FEY SREP ye AD, VADELNEDMED RICE y MLTR Ko BY FEL BNR OMUR BITE o RBI. Fi BMICTE PENENOY AREMIBL TRY TE Vite y KUTBCe ze Sh RY TEYRUFY TEV AIANI VY eD SVBISMOS; ADDVFOLRIVAEB BUTHC. L) Py Fy FP AWNG DL TRORY FELICE ANAND IARI TB PRAMS FAC UBER FIRM, RASNTOSOT, 401/100 Olli @% NENA, Bony FOMETS. nucle ste housing King pin (upper) King pt, (lover ay Peano Sara sern Spste. few 4 a Indentification ee ¢ eRe} Y v Fig. 39 J (Example) When "-2" is stamped, the error is -0.02nm. oh wIEMIaes [— 2.1 Ole, 14-002 eS seeesyncad 7 2 aa563-2101 2. 663-2101 DRIVING AXLE 2) Measure the thickness of the king pin thrust washers, and denote the errors from the standard values by G and H. G : Error of king pin thrust washer @thickness from the standard thickness of 3.0 mm. H+ Error of king pin thrust washer 2) FL TEL AIANTy Ye OME SAE, MOR INT AREOMEG. HETS. GLP EL AIAN yp BOM B.O mle, TARE Hi RLY EY RIRNT yy CD OMMIAOO mics 5 aR, thickness from the standard thickness of 10.0 mm. (Example) When the actual king pin thrust washer @ thickness is 3.05 mm, G is +0.05 mm. 3) How to calculate required shim I) YOY RI AND y Ye BOKMAL 8.05 am OBS, COMLIL+005 meF, 3) vamon cress EMD? HM= 1L0-A+CHETG Upper shim thickness = FRO? i= 10-B4D+F+H 1O-A+C+ E+E Lower shim thickness = 1.0-B+D+F +H [Example of calculation] Cat) Part |Code|Stamped value S22 [es] 8 a Knuckle A =10 Farm a ‘Axle housing |C +8 FIAURODTTL—C King pin E =35 HVyeD E Thrust washer] —¢ =2 AARIGDs |G Shim thickness 1-( = 0.10) + 0.08 + ( — 0.35) + (-0.02) = 0.81 = 0.8 mm Install knuckle ass'y in axle hous- ing@, and install king pins @ and as prepared in Process 1. + Clamp king pins @ and @ with bolts Torque : 55 # 5.5 kg.m (398 £40 ft-1b) Pull the end of knuckle spindle @ by a spring balance in the steering di- rection, and read the balance. If the value is outside the standard value range, equally increase or de- crease the thickness of the upper and the lower shims, 0.05 mm at a time. When the value is within the specified range, apply THREE BOND No. 1374 or equivalent to the threads of bolts @ and tighten to the specified torque. Standard value : 5 £1 kg (11.0 £2.2 1b.) 2 HE 1~€0.10) +0.08-+(~0.85)+(—0.02 ) =081=08mOYAZANS. QR TIAWNDYY BIH yD VAsely BHADAY PML y RENAL TELM, BEROAIS. 3B FLT ELO, BERUHOTHDHI SZ. BA hw? : 654 55Ke-m A Py Due y KLAIEMBICITORRY HHO. UI DHINCHI YC Ako Hi 2K 5 5 BAD HOSA DROP, LFOY 4 & 5/100 TOF ICH UCR 3, SEMIAPNICAMUE, #v KeBIC zy — RL Na 1874 FAME 2 RAG LTRS be 2 COD DB. BAI: Ok Lhe 2B563-2101 563-2101 DRIVING AXLE Spring balance Nae Fig. 40 5. Install boot @ to knuckle @ with 5. PHIM EL HD, TU HBCS y 7 EDICT bolts @ and plate @ . 6. Plug the threaded extraction hole 6 in upper king pin @ 9. Installing wheel hub ass'y 8. CAUTION L ye TAKE CARE NOT TO DAMAGE OIL SEAL GSD WHEN INSTALLING THE WHEEL HUB ASS'Y. 1. Install the wheel hub ass'y to knuckle spindle @ « 10. Installing internal gear hub ass'y <1, Install the internal gear hub ass'y to knuckle spindle @, and vhile turning wheel hubCi, tighten bearing nut GD. Tighten bearing nut C5 until slight resistance ie applied to the rote- tion of wheel hub@#, and then, back off the nut 1/2 to 1 turn. Then, with a soft wire wound around heel hubGHB>, pull the wire with a spring balance, and rear the balance while turning the hub (reading@, 29 “we DOB. EMOFY FEL OOKET 7 PRI EDBLS RA MILT Ass'y ORO Py DUAL KUBICA UN Ass'y 21D HUB. KER se FE GD EMRE SEB T, BONLS. Fig. 41 10, 4 I—FILERNT Ass’y ORDA Fo PW RED RUBIA PWR A TAsdy PROD, 4 — VN F CD FUME SHEESH RT ILFF 7 b GD SHON Bo ZLTRA = AF DO MREIC LH EBL BETTI TH RAD EMD YAR, 1/2 ~ 1 BRT. Ric 4 = WFC OLD CRI A + SHUT NAPED CHEM OBO (ELLA D—WOKEL) SHANE « HIEIIEBEC< 7) Fro KEDEBSAU TOR, AAD CH ROBO CST > Fit 4 ne — REE) & BAM, O-Oowswemnicnss5<7 9 LIF 7 DOD TT RE MET 3 0563-2101 563-2101 DRIVING AXLE mainly oil seal resistance). Again ast tighten bearing nut G8 in the same ATI YH: 5.0~8.0KE way, and read the spring balance in- AT TPA: 25~4.08 dication ® during turning (bearing resistance + oil seal resistance). Adjust the tightness of bearing nut Deo that O-G@ falls within the standard value range. New bearing : 5.0-8.0 kg (11.0-17.6 1b.) Reused bearing : 2,5-4.0 kg (5:51-8.82 1b.) ea A NOTE 2 AT ILI y KEDCO 7 TL KD BH Cy YARD BHD ET Be %c Apply THREEBOND No. 1374 or equivalent to the threads of bolts Sift be? 2 5 Lhe ae 2. Apply lock plate CHD to bearing nutG@, and tighten bolts GD. {ALA GDorwemc, 29—K» te 1378 48 HRELGTS. Torque : 5 41 kg.m (36.2 £7.2 ft-1b) 3. Insert sun gear C2) in knuckle 8 PLE GED ET yD NALY KVBIAT Be spindle ® . 11, Installing planetary gear spider ass'y MN, THAIUEP ANAT Assy ORO 1, Install greased O-ring Gi on plane- 1 FRR AIEH Assy CF) 2 BUTE tary gear spider ass'y, align the OILY GDEM OHI, G27 REET IW match marks, and mount it to wheel REDHAT CUBIC DHT Be hub GH with bolts Ga. Torque : 11 4 2 kg.m (79.6 £ 14.5 £t-1b) BIRD: kok m a ab563-2101 R563-Z101 DRIVING AXLE 19 tie rod ass'y NOTE YeInstall tie rod end @ with bolts ected outward. ‘To prevent damage to oil seals @, accurately align the tie rod holes in tie rod end @ and knuckle @, before driving tie rod end pin @. ‘Drive in tie rod end pin @ with the recess facing the lock plate mounting bolt holes. 1. Install tie rod ass'y to knuckle @, drive in tie rod end pin 6, in~ stall lock plate®, and tighten bolts @ Torque : 2 ( 13. Installing disk brake ass'y 1, Install the disk brake ass'y and secure it with bolts Gib. Torque : 95 + 9.5 kg.m (687 £ 69 £t-1b) 14. Lubrication NOTE veUse A.P.1. Class GL-5 or higher SAE No. 90 hypoid gear oil. Fig. 44 12, 94 Hy FAss'y OOH L 24a KAsy BH 47 VOIR, F4Bo KF EUR EV@SHEAA, Py FTL hOEMY HU THY RB SHO Bo ity hvy + 254 05Kem ae Ye 9A By REY RQ TAIL FM EIHM AUTRONBSTE. te AAI — N@ERBLBNES 94 By KT TQ ery INGO 34 ay KREMRICA eta, kxy ReY@ensauce. th 94 oy ky KEY@OORS EN YIU = RRA AI KRM THACT E. 18, F4ADTL—* Ass’y ORO 1 FARIA Awly BV ACD TH DAY Be fT hy : 9549.5 Kem 14. ike LRA - VATED EALTHN-GDD *O1L LEVEL’ X¥#AKEAAIL, F97AUDKDS Laake, FI7EDAMHYLA VE And. (HME E) 31563-2101 R563—Z101 DRIVING. AXLE 1. Turn wheel hub Gas until the ae letters OIL LEVEL on coverciss> becomes horizontal, and pour gear Se EAA IIL, NRT REALL. OL oil through the hole for plug(ii> GL-5LLt, SAEM90 RATS. Gael eliiacarta esis coe ok the hole for plug Gam). (approx. 4 1it.(1.06 gal.) per side] Fig. 45 NOTE 2 FIANAD SY TB ERBO KL S97 D EH Doki, 79 POORD DLA VBC S syUse A.P.I, Class GL-5 or higher HSETANA. (#268) SAE No.90 hypoid gear oil. i= 2, After tightening drata plug ® st the bottom of axle housing@, Wr ERAT II, NARA KEP ILA, PL pour gear oil into the axle housing GL-5LLE, SAEM S0EERS SCE. Acid oi aeaeee’ eo crac Git tite the hole for plug @. Lapras. 26 lit. (6.87 gal.)] eo * oe cee \ \ Fig. 46 NOTE 8 PYAR 9 TURE Ray SUAS FRO Broa7 soem vy Use lithium soap grease containii MoS: . 2B 3. Inject grease through all the We TUR MOS2 ADU FODRIU REET Bresee cipples ana thet ieaed 2 holes for grease nipples. 32563-2101 @ ° 1 R563-Z101 DRIVING AXLE DIFFERENTIAL CARRIER ASS'Y DISASSEMBLY Removing differential carrier ass’y 1. Unplug the drain plug at the bottom of the axle housing and discharge the gear oil. Capprox. 26 lit. (6.87 gal-)] 2. Remove right and left axle shafts @, by following the "Axle ass'y disassembly procedure". 3. Unscrew bolts ® and@, and take out 2 the differential carrier ass'y from axle housing @. Disassembling differential carrier ass'y 1. Mount the differential carrier ass'y 2 on a special stand. Before starting to disassemble, measure the backlash, back surface runout and tooth contact pattern of ring gear @ with a dial indicator. If they are within the required limits, reproduce these values after reassembly. Q) FI pL ye yt PIT Assy 0 am J. FP Vrs yey T Ass'y OROIL FIAWND SLY EBD KV Y TITER FRAC VEMEMS. (266) TD AWAssy DAMP £BRL. HOT YRUY 7 hAEHEM ES UND ORMLTHI 7 VY ee IT Ass'y B72 AVANT YY TOD HMLONT. 2 FI pL yy yey UT Assy OOM PD Ve WH eI T Assy BAF Y KIMED HUB. Fig. 48 FI Vey ewe IT Assy AMINE. 74 WA LCL TE RBOK 9 DI 9 Yay EP HORN, ROM DFM L. EACH 2m SED CMEAICANIL, TMH OMEBALT OIC HR SES. 33563-2101 DRIVING bolt @ . (Fig. 51) 4. Mark bearing caps ® and carrier case @ with alignment marks. (Fig. 52) Fig. 51 6. Unscrew bolts &, remove bearing caps @ and remove ring nuts @. (Fig. 53) NOTE veMark the right and the left outer rings of tapered roller bearings ®,@® and ring nuts @ to avoid reassembling them in the wrong positions, 7. With a bar or a pipe put through Loosen lock nut @ and remove thrust Extract lock pins@, and slightly loosen right and left side nuts @. 563-2101 AXLE 8 yD Hy KOM, AIANKVKOATS (Fig. 51) ANT ILI R yy TBE RS ITT ADLOA ICe—7 B10 5. (Fig, 52) Fig. 52 5. 2 PELOSM EMM Lik, BEDI Ty b DEDLOZDS, 6 RUBEN, AT IL TH ey FORM ONL Rik, IVF y KOBNT. (Fig. 58) 7 WT RIBS IIL FAL, TELL eZ Assy BRONT. COB F—N-O-SAT IL IO, BOE MARGINS, (Fig. 54) =m yy ery h@, F—N—N- 3877, Oosais, MI0 TOM, AHEMMA RLY the differential case, take out the differential case ass'y. The outer tings of tapered roller bearings © come off simultaneously. (Fig. 54) RICV—DeMOTH SCE,563-2101 563-2101 DRIVING AXLE 3. Disassembling differential case assy Cordinary differential ) 1, Mark differential cases @ and ® with alignment marks. (Fig. 55) 2. Unscrew bolts®, @ and separate differential cases @ and ®. (Fig. 56) 3, Take out differential pinions ®, side gears, spider @ and thrust washers @, @® from differential case ®. (Fig. 57) NOTE yrDo not remove the tapered roller bearings, unless their replacement necessary. 4. Remove the inner rings of tapered roller bearings ®, @® from dif- ferential cases ® and®, with a pulley puller. (Fig. 58) 3B. FI pL YY pL T—2Ass'y OO (HROFT pL oy wl) LF Dry Yee 2D, GAI- 7 BGS. (Fig. 55) b®, @LALTHT 7 bv ver 2@s BEART. (Fig. 56) Fig. 56 B FILLY Y-AODEFI rey EME SHLD, HA KERB, ANA YORIRIAL Fo vas DEM NT. (Fig. 67) 4 FAVE MUCH 2 7 LLY ee -2®, B DOF—N=O- IAT IV ID, BOMBARD Rr. (Fig. 68) 2B WFAN ASAT UTIL, RAT SOE PUBS, MOHABOCE.R563—Z101 R563-Z101 DRIVING AXLE NOTE 5. A ADD TIL TERME LY 7 -ADMEAT. YxDo not remove the ring gear unless must be replaced. zm 5. Unscrew bolts 0 and remove ring WYLIE PR, RMT SURO L, B gear @ from differential case ®. phamoce, 4. Disassembling ass’y A FD pL YY yT—ZAss'yOOR Cno-spin differential ) (J-REY EI LYE eh) NOTE YrAlthough the disassembly procedure St MOTD pL IY pe EMCO TSS the same as that for ordinary 1 KU h@O. QEMBELS —REVFI pL ifferential case YyMAssy OATIIT (Ck EFI pL ® will be shot out by the springs pi7-2@ BREWS OT, SSPCGE of the no-spin differential ass'y AIRE y hUR AMFSCE, as bolts @ and @ are unscrewed, To Prevent this, set the special tool shown below on the assembly before Spring Driven clutch starting to disassembl Rey, RI9Y2 597 kay Special tool ane Moxi0 \ % fds 9, L100 MoD. Side gear Spider ‘center cam ass'y tte Bay eps b sas Fig. 59 Fig. 60 Removing drive pinion ass’y SA FERAY Ass'y ORO 1, Force crimped nut @ loose, and with L Fo bhOOAY AER, 2UkaAY IIL OB companion flange (companion yoke (28247 3-7O) MOU E @) secured with a proper tool TRUMELT. ty hERB TEL, against turning, unscrew the nut. Nut removing tool Fy MLA 225 Fig. 61 Fig. 62 = a563-2101 R563-Z101 DRIVING AXLE NOTE YTo facilitate adjustment after reassembly, stor without folding them. 2. Unscrew bolts, and remove the drive pinion ass'y. 6 Disassembling drive pi n ass’y NOTE yr Do not remove the bearing unk it must be replaced. bearing cage ® with a press. Fig. 63 2. Remove snap ring®, and remove roller bearing with a puller. Fig. 65 3. Remove the inner rings of tapered roller bearings @ with a puller. 20 Force out drive pinion ® from 2 AV AGDEMLT, KIT TES AD Assy SHER ma. removed shims @ ze We RRUMORBESRCT SRY, RORY & Oawasrnnksceess. Assy OF ae WAT UT, RAF SOE AROMA, BW bmamnze, 1 FUABRUTAT YY 77 = IAT SAVOEREMS © Fig. 64 2 AbyAILIBEML, OH INT IY BET FAUT EIS 6 Fig. 66 3, RACY - 9 BMOTH OPM 2H 51 4. Nao FNT ILD 37R663-Z101 R563-Z101 DRIVING AXLE 4. Remove the outer rings of tapered roller bearings @, ® from bearing cage @. A STIL PF V a HF NAR INT IY SD. BON EM EIS. =] Fig. 67 (© CLEANING 1) Metal parts Wash in clean kerosine, and dry by blowing air. 2) Rubber parts CAUTION YeDO NOT USE MINERAL OIL. Clean with alcohol or clean cloth. © CHECKS 1) Checking clearance between differen- tial pinion ID and spider oD. Standard value : 0.1-0.15mm (0.004-0.006 in.) Use limit + 0.25mm(0.010 in.) 2) Play between side gears and axle shafts With the axle shaft fixed, apply a dial indicator on the circumference of the side gear, and measure the play in the spline in the turning direction. Standard value : 0.1-0.31mm (0.004-0.012 in.) Use limit + 0. 5mm(0.020 in.) 3) Play between yoke and drive pinion With the drive pinion fixed, apply a dial indicator to the outside end of the key way for connect- ing the propeller shaft to the yoke, and measure the spline play in the turning direction. 0-0.27mm (0-0.011 in.) + 0-4mm(0.016 in.) Standard value : Use limit Om 1) ents MEN cHRIN CHEAL. = 7 CHEE, 2) FAB Fv LHR AAB CHALE 5 KER eat O IA LOE ee O me 1) FF VY VERA AEL 204 SAORI ae e * if eo 0.1~ 0.15 an 0.25 mm 2) PL KERET ORY eT hOND TOA IERIE T. M4 RESET AYN DBT. ATF AY ODMED ADH 2 & wet. of: ON 081 on OR we os'm 8) S-PLEST TESA ONS R247 USA EMELT, I-2OFORIYy 7 REALE ODMR IC 4 PL eT, RIDA YOEHION 2 BBET 3. Hom HS O~02T am on Re 04 oo 20R563-Z101 R663—2 101 4) 5) 6) 7) DRIVING AXLE Checking drive pinion and ring gear 4) K947¥=42, YUP POH Check each tooth for contact pat- HICH DORE ROR, EF 70K tern, wear extent, and pitting. REAR, SLORMMIEMIET LB DY X Slight stepped wear may be repaired YCET 5. BMMICHAM OS SBS ty PC by oilstone or fine files, but if RFS. the tooth face and flank are damaged, replace the drive pinion and the ring gear in a matched set. Checking side gears and differential 5) 4 F¥". 77 rbyyrees Cae MRHiOHMMIE, KILL TOS 6 ORT 5. If the tooth face and flank are ab- Bly FI 2 Lv a yt -ABM AIAKI 7 normally worn or damaged, replace be RSA EB RURL, IOARIRFE, KIBLTINS & them, Check also the differential DaRBT 2. case interior, thrust washers, YA REE ETI UL Y ESA YOMARER spider, and if they are abnormally BAIAKD 9 Ye OWIABRORM NL, ANTM worn of damaged, replace them. BUBVOTE» FTRETS. Replace the side gears and the dif- ferential pinions, together with the thrust washers in a matched set, because using used and new parts together tends to cause premature failure. Checking bearings 6) AT ILI OR Wash the bearings thoroughly in en CAMHER2 FEATL Y BRUT FRG AUR LE kerosine to remove grease, and check HOW GN EOLA NBEX o bAMT Zo them for the following respects. FURDSEU BDI, 7) AMC BALTIC » Replace faulty ones in sets of inner come aucanmse cman eset and outer rings, and apply grease thinly to those free from fault. = AROS. AEB, LABEL D AED -Turn by hand, and check for smooth SPAR © — FHI, ARS HERE A eee nee 2 OE AMPED Seca ae eee rene 1S, Pils SHRM CHEE ESTA) sR pitting, partial wear, etc. “Check the raceway surface of the inner ring for damage, pitting, and partial wear. Check the cage for deformation and partial wear. “Check the rollers, inner ring and outer ring surfaces for decoloring (just before seizure). Other parts 1) 20te Replace parts in which faults RROWYS NAME TRATS» are found. 39R563-Z101 R563~Z101 DRIVING AXLE © REASSEMBLY CAUTION ye REPLACE THE O-RINGS, OIL SEALS AND OTHER RUBBER PARTS, AS WELL AS ALL THE PACKINGS. ‘Yr WHEN INSTALLING OIL SEALS, DEGREASE AND APPLY LIQUID GASKET ON THE MOUNTING SURFACE, AND FORCE FIT. AS THE LIQUID GASKET, USE THREEBOND NO. 1104 OR EQUIVA~ LENT ON METAL CLAD OIL SEALS, AND USE THREEBOND NO, 1212 OR EQUIVA- LENT ON RUBBER SURFACE OIL SEALS, 1. Reassembling drive pinion ass’y NOTE yx When reusing the disassembled bearings, take care not to assemble them in the wrong locations. 1. Force fit the outer rings of tapered roller bearings @, @ into bearing cage @vith a press. 2. Force fit the inner ring of one tapered roller bearing @ on drive Pinion @ using a press. 3. Mount bearing cage @ and spacer ® on drive pinion ®, and force fit the inner ring of tapered roller bearing ® using a press. (Fig. 68) 4. Force fit roller bearing ® on drive pinion ® using a press. (Fig. 69) ikea Pr ] Fig. 68 5. Install snap ring @ on drive pinion ®. Force-fitting tool O Mant KER OUIT, A4 LY —NHOT ABR BUN 2 FLA RRACRATS, ye AA YER NY SMa, ERAS UR, MERIATy hERRLTEATS, MRAZ ha, OSM HSMRD OORAV—KY KO 1104 RidAR EAL, FAMO OR AY—AY ENIZI2 KIA SRT. KOA 7TERFY Assy OMSIT LNT er BAT yy DICTA RM TF NO + BOMB EEAT 2 ae WARRERAT SBS, MEHARRY KSCERTSC. 2 RIA TESA BTL ARTF Ato IAT VFODPUMEEAT Bo 3 KFA FESAL@IC, ATI ye, AX -PBSUDBA, TLABMOCr—N— 9-5 ATV YF@OMMEEAT 5, (Fig, 68) 4 FIAT SAYOIO INT IL IBEILAE BMOTEATS. (Fig, 69) Fig. 69 BRIA FESALOAD TIL IOEMO NY BeR563—Z101 DRIVING NOTE yeTo adjust the preload accurately, leave cover @ uninstalled. 6. Install companion flange ® (com- panion yoke ®) on drive pinion (®, and tighten nut @. Torque : 50 + 5 kg.m (362 # 36.2 £t-1b) NOTE Ye Read the preload value during rotation, not the starting value. %Do not grind spacer @ too much, as too thin spacer @ will damage the bearings when nut @ is tightened. 7. With a small amount of gear oil applied to the bearings, wind a wire around the bearing cage, and measure the preload with a spring balance. If the reading is smaller than the standard value, grind spacer ® little by little to increase pre~ loading. If the reading is larger than the standard value, replace spacer @ with a new part, and adjust. Standard value New bearing :1,4-2.0 kg (3.09-4.41 1b.) Reused bearing: 0.7-1.0 kg (1.54-2.21 1b.) 8. After adjusting the preload to within the standard value range, nark drive pinion @ and nut @ with match marks. a" 6. F247) 8 FLO K eaRMRAEPTICARE LIB 563-2101 AXLE AVBIUIYN=4YIFYB(3 YNEALI~ 9B) EMO, Fy KOE HUB. whe: 50 5 Ae ze Ye TUN KRBE ERICA Sa, 1—-Ois ROHUROZE. TAT DLN AAV EDEL Ky <7) C74 BMS DAD TILE-K BET So BEAM rf BSARMBIAL LE DVS MBAR, ANF DER CAMEL RMT 5. Eh, RUM A DASE, 2A YOR ERR TMBT So a AT IVY HGS 1A~ 20K AT YY FRE | 0.7 ~ LOK am or TU RRR TRK, DROME ME sere, Ye AA-AQEBBLECHRTSE, ty @ EBHORBIENT Vy TERMS SRN BH SOTEBT SCE. gages ALBEF o KBICAT—F BHU SSR563-Z101 563-2101 DRIVING AXLE 9. Unscrew nut ®, and remove companion flange ® (companion yoke ® ). NOTE Ye Apply liquid gasket on the periphery of oil seal @. 10. Force fit oil seal @ in cover ®, and apply grease to the lip of oil seal ®. NOTE ‘Be sure to use a new packing @. 11. Install packing ®, cover @, flange slinger@, and companion flange (companion yoke @), tighten nut @until the match marks align and then crimp nut @& . 2. Reassembling differential case ass’y (ordinary differential) 1, Force fit the inner ring of tapered roller bearing (9 on differential case®, and the inner ring of tapered roller bearing @ on differ- ential case ®. NOTE ve Apply THREE BOND No. 1374 or equivalent to the threads of bolts @. 2, Install ring gear (9 on differential case®, and clamp it with bolts ®. 27 £4 kgm (195 # 29 £t-1b.) Torque : 9 Fy OER, BEA IIB (IY AL A-7B) ENT. 10 WN @lCAA WY -WOREATS, EAB, + AVY = VB y TEC) ABET Bo ae Ye AAS @ SMEAR 7 y hE BS5zE, LL Ky FL @, WN-@, PIV VAIVAW, IV 2B (Iva 4v3-@) eR DU, Fy hOEEL— 7B S £ CRE sty hBEDLBS. ae Se Nye Oid, OTRRICRAT ECE. Fig. 71 2 FP pL yy yT—2 Aos'y DHSLT (OFT pL Yd yb) L FI bye we -AOKF-8- BHT) LIBORBE, FI 7 VI Ey wr ABIer NO FRT YY TWODARBERT 3. 2 FIV YY he A@MCV FH PVM OH Wy Hv ROD CHIT BA hey : 2TtAigem eB AL KDOBUBICAY—AY F te 1374S, eRBT SCE.563-2101 RS63-Z101 DRIVING AXLE 3. Install spider @, side gears, dif- ferential pinions@, and thrust wash~ ers@, @in the differential cases, and measure the backlashes between side gears @ and differential pin~ ions @. If the measured backlashes are out of the specified standard, replace all the thrust washers. 0.25-0.36mm (0.010-0.014 in.) + 0.5mm (0.020 in.) Standard value Use limit NOTE yx Apply THREE BOND No. 1374 ‘or equivalent to the threads of bolts Mand @. . If the backlashes are within the specified range, align the match marks on the differential cases, and clamp them together with bolts @ and @. 10.5 # 2 kg.m(75.9 #15 £t-1b aa a Torque : 3. Reassembling differential caso ass’y Cno-spin differential ) NOTE se Install no-spin differential ass’y @, as set with the special tool (Fig. 59), into the differential cases, and then, remove the special tool. If the special tool comes off before stalling ass’y ® into the dif- ferential cases, be sure to align the recess in the holdout rings and the spider key before installing 1. Reassemble in the same way as the ordinary differential. a FD VL WEARER FO. 94 RE PO FI 7 VY WESAYD, AAAI Dy DRMAAA, M4 KEMDET Ie VY eh LEAWOOD FY 2 BEETS. N97 I 9 Y A BHABLDIG, AD ANT 7 Ly BLTRIT Bo SGML: 0.25~0.56.m SGFIBRISE : 0.5 om NP Gov PRA THNIE FI 7 vy PUTA ADETA=2 BERTH HO, OCH HUB. BiH hey : 105-4 2Kgem ae Ye A h@, Qorav WEA Y— A F374 RERHT SCE. ) FV pV YY eZ Ass'yOMSLT (J-REYFI pL YY ehh) 1 MLLER LOFT 7 ee yr ERECT de Yes REV FD ple yb hesy @ ERAT BC Fig.69 BRITE y MLERBOL ETI PUYE pT —ACBBRS, TORBAL RES. BUR, MADIMCHATAD BFNAMAE, RETO YY FOOR BME ANA TOL- EDS BDETHABA Tab.R563-Z101 563-2101 DRIVING AXLE 4. Reassembling differential carrier ass’y NOTE yyWhen reusing the removed bearings and bearing caps, take care not to install the right and left bearing outer rings and bearing caps in the wrong location: 1. With the outer rings put on tapered roller bearings @ and #9 on both sides of the differential case ass'y, place the assy on carrier case @, install ring nuts @ and bearing caps ®, and tighten bolts ®. Torque : 47.5 2. Adjusting preload NOTE ‘YeMeasure the preload while the differential case and do not measure the starting torque. wx When adjusting, align the grooves in ring nuts @ and the pin holes in bearing caps @. Because drive pinion @® will be installed and adjusted afterward, adjust the differential case ass'y with ring gear @ shifted slightly backward, Gradually and equally tighten right and left ring nuts @ until the spe- cified preload is applied, while mea- suring the preload with a spring balance pulling a wire wound on the circumference of the differential case (spider area). - 6.5 kg.m(344 # 47 ft-1b) AFD PLY yey UT Ass'y OMSLT L FD 7 vy yd AAssly HDF — 0 — BAT IL 7B, BINAWERBTH « VTE % ODES, IAF OAT IL Tey FORMING TRY BEMIS, BAEK 5 475 46.5 haem 2 TAMRERAT SMA, NTU TARO AT YY 7% yy TORBEMDBAROES cyace. Fig. 75 2 Fv om KaaRE HBOI ITI y KORBL CRA ICMEDHU I EOF VO- KEBAB, MEG, FI 7 LY Lg WE = ROWER (2064 AATEC 4 BS, Wa) TP LO KeRARS, ee STV YH + 27~ 8.8K AT Vy PBI: 1~ 19g ae 7 LA KiRseMNG TIE eoace. RRIF y K@QOMENT ITE ey T@OevREBECE. ek94 74 @ MAHL FI pL I Ey a AbsyiaVy THY QRBMICSET magece. er Ome IR563—Z101 DRIVING Standard value New bearing : 2.7-3.8kg (5.95-8.38 1b.) Reused bearing : 1.4-1.9kg (3.09-4.19 1b.) Fig. 76 3. Measuring runout of ring gear back face NOTE YeIf the runout is larger than the incorrect tightening of ring nuts @ and bolts @ and pinching of foreign pieces are suspected. Repeat disassembl- ing and reassembling, and if the runout is still larger than the use limit, replace the ring gear and the related parts. With a dial indicator stylus normal- ly applied to the back face of ring gear@, turn it one turn, and read the deflection. Standard value : 0.1mm (0.004 in.) max. Use limit + 0.2mm(0.008 in.) 6 563-2101 AXLE Fig. 8. De MOE Ye Pe OMMMICY 4 ey — 2 BENCH ODL F ELS LEELEMO ME RARS, sei + 0.1 am ‘EIA = 0.2 om 2m AMOR DME KOKEUMA, YI TT yr ORE QOMOHUFR, LIAM OMA DG ASNSO THB T ETE 3. BMA ETE TOMAR LOR NS SBARMTBRETIAT 3,563-2101 DRIVING 4. Put match marks on the right and left, where the grooves in ring nuts @ and the pin holes in bearing caps @ are in alignment. 5. Remove the differential case ass'y from carrier case @ 6. Installing drive pinion ass'y NOTE yrAlign the bolt holes and the oil hole in carrier case shims @, bearing cage icking @, and cover @, when stalling them. 1) When parts are not replaced Install shims @ removed and stored during disassembly, on bearing cage & with THREEBOND No. 1104 or equivalent applied only to the surface coming into contact with carrier case @). Then, insert the drive pinion ass'y into the carrier case, and clamp with bolts o. ‘Torque : 942kg.m(65.1414,5£t-1b) 2) When parts (drive pinion, ring gear, bearing, etc.) are replaced Position the drive pinion ass'y on carrier case ) without shims(?, and with feeler gauges of the same thickness (0.65-1.45mm) inserted at 2 to 3 positions instead of the shims, tentatively tighten equally spaced three bolts «. (Shims (are in four thickness; 0.1 mm, 0.15mm, 0.20mm, and 0. 50mm). Determine the shim thickness by adjusting the tooth contact pattern as will be described later in this manual, and then, finally install the drive pinion ass'y in the same way as "When parts are not replaced” as explained above. 46 RB63—Z101 AXLE AVL T hy ROBERT IL IS yy TOOULR Bo COATICERE BATH 2 EHO S. BRITT -ADmS BAT. Dr Vv a Ve—ZAshy 6 RIAF Ea AY Asey ONO 2S tet y97 7-2, 24Q, xP yv7F—9 OD. 9@ ax-@O on ez, Bo RESHETMONGSECE, 1) BAN EONS MEYER Ic ADO S By DEF A MOAICA YAY BIMELTST V7 75 SOUL O TS, E LU D4 FESAYAsty BH VTA AIC MAL, fe ROUTED AOS. HEE ho 942K m MCR IA Feat, 1%) RL ae PLOBANETR IAS Eat PITT ADEMATS) UT 2~ 8/7 HHICTEMS ( 0.65~ 145 0m) D247 EAR OBIES AL EL ROC BA) BRINE ANTHMDT 3 CL ADEM EAS OL any 0.15 mn, 0.25 0m, 0.50 and A RIAA DEF. ) HLT A Mn @aitE” Bia, Ate: Utes HG ERAN EI LAE UMN Hea TKIA FERAL Assy BIOL Be Yueee AT YY563-2101 R563-Z101 DRIVING AXLE NOTE 1 FI ULL WT Assy BH ITA“ AD MOH Ae ‘When installing the differential case ass’y in carrier case ©, 2B in the match marks made on Process 4 Se FD Lv vy r—anssy #44977-2], with the pin holes in bearing caps (RONG SM, TUR KAMILL ROS @., so as not to change the FMA TI Tt yb @ CHGAr—-7ES adjusted preload. T YL Te eyIQOEY REBT EE. Recheck the runout of the back te BUY 7¥7@ OWMORN ERB THC surface of ring gear @. cee 7. Install the differential case ass'y to carrier case @~ 8. Adjusting backlash By 2 Foy ile Apply the stylus of the dial indica~ Ye FER OMMTICY 4 7 BEIT tor prependicular to a gear tooth So P95 a CNET Bo face of ring gear @i and measure the S727 aD TEWADB EI IEF backlash. @ewih ae CMM ITE DH TTT O- F If the backlash in outside the stan- BBD HNTB ED, HOV Fy b ED. dard value range, readjust it by HIF CEH OE RAT C Eo displacing ring nuts @ . JMR: 0.25~0.98 aa However, since the preload has been correctly set, and can not be changed, loosen one ring nut, and tighten the other by the same amount. Standard value : 0.25-0.33mm (0.010-0.014 in.) 9. Adjusting tooth contact 9. HRD ORME YL FEPOO 7 ~ SOW TIC MA AC HY, Yr 7% SHURE S th HD eh fe. C2 ~ 8 SESH) NOTE sx To prevent changing the preload, tighten and loosen the right and an the left ring nuts @ by the same amount. AMER, TU KOBE RRS UF Inspect the tooth contact pattern of yh @is, EAMMBRSES COS. ring gear @ by applying a thin coat of red lead oxide on 7 to 8 teeth in each of 2-3 equally spaced locations, and by turning it forward and back- ward several turns. 47R563-Z101 563-2101 DRIVING AXLE ADJUSTING METHOD hoe oe Good No adjustment 1 pattern | is required Roweso | BRU Reduce shims@to shift drive pinion @towards ring gear@, and adjust High backlash with ring nuts @. bearing | “AO@MSLTK 91 Fea 408 IL 7er@ 2 mia) | ESM Io 7 ro Bes 75 y a eT ovary 3 1 Eo Increase shims@to shift drive pinion \@away from ring gear @, and adjust backlash with ring nuts @. Low VAOEMPLTKI4 FUERA LBEI LIFT ®) 3 bearing | m5BR0. 97 Fs OC II yy a SME momo | ra. Conner yen) tot NOTE ye Apply THREE BOND No. 1374 or equi- valont 10 the threads of bolts @ patterns are bolts ® to the 10. When good contact obtained, tighten specified torque. Torque : 47.5 (344 6.5 kgem + £47 ft-1b) 10. RUBS £0 HBF BHU. Bt hae OBER by CHE ATS + 6.5%e+m ee Fe RRB Ot VBI AY —KY 1974 A RBRTSECE, 8563-2101 R563—Z101 11. Check the back face runout and the backlash of ring gear @) for the last time. NOTE YyBe sure to use new lock pins @. 1) If the reading is within the stan- dard range, insert lock pins @ through the pin holes in bearing caps ®. 2) If the reading is outside the stan dard value range, disassemble and reassemble once more, or replace the parts. Fig. 84 NOTE yr Apply THREE BOND No. 1211 or equivalent to the threads thrust bolt ©. 12. Force fit thrust plug @ on thrust bolt @, screw it into carrier case @until it makes light contact with the back face of ring gear @, back off 1/6 turn, and lock with lock nut @~ 15 + 3 kgm (108 # 21.7 £t-1b) ‘Torque = iL 12, Fig. 83 YL FEPOAMOMRNRON 2 29 ov Okt Foyt 1) BIE CHIE, AT IY TH 9 TOOL Key 2 EYOSANSS eB We AyPEYORLIRACRMTS, 2) ABET HAUL, BELA C LIMBA 2 o Fig. 85 RIAA OIA IASI YOREAL, ¥ RIT T A ADICALIAA, I 7 PO TFTICRE Mite SRILA IIR, 1/6 ONL TY DP yhOTCI 72 TB. wR have 1548 ze $e 252 ba H@OBUBEAY— KY KAI WARERHT SCE,563-2101 563-2101 DRIVING AXLE 5. Remounting differential carrier ass’y 1, With packing @ inserted, install the differential carrier ass'y to axle housing @, and clamp with bolts @ and @. Torque ? 21 + 3 kg.m (152 & 22 fe-1b) 2. Install the right and left axle shafts by referring to "AXLE ASS'Y reassenbly procedure", and reassem- ble the housing. 6, Lubrication NOTE weUse A.P.1. Class GL-5 or higher SEA No. 90 hypoid gear oil. Screw drain plug @ at the bottom of axle housing @ and pour gear oil into the housing until oil starts to wooze out from the hole for plug & . [approx. 26 lit. (6.87 gal.)] Fig. 86 5. FI pL pit IT Ass'yORONG L F772 NTT PANNG SY FOICM OAT, DTH Bo ttt hve PEE IT Assly 8g ELBA WhB 218 keem 2 PPARs O MACE BML CEE DOT IAWS eI BHALA, NISL PBEM AMDT Be 6. iA LTP AWAD Y YORBO RLV 9 PDC WATT, 79 7BORD HEYA UESICLA WBRTANS. (#9260) ze Ye PAA IRN RA REY AAA PEE GL-5LLt, SAE MODEHRT SCL, i= Fig. 87 2bR563—Z101. 563-2101. DRIVING AXLE © ADJUSTMENT ome 1. Steering angle adjustment 1, RFT UY TAOS 1. Set the outriggers to lift the tires 9 L 2 U-Y8Y ry AT > SUTMMAFT IY IT off the ground. Expell the air from 2X BMAF IU TL VULPES, VIF the steering cylinders by cycling AOET— 2K. the cylinders in the 4-wheel steer mode 2-3 times. 2. Set the outriggers on a level sur- ELD? 4 ERE OMI LICE £55 7K face bringing the clearance between VRMLTD VV BY 4 AT TTS. the tires and the surface equal on both sides. 3. Using a steering angle measuring 8. PAPO BUTERE RIOT AG MORAZ FT 9 jig, adjust the maximum steering LPM EA by ALU RANT, BERIDRAA angles in both the A and B direc FTL TEA by SAU A BICTHBT Bo Se eee ere nee BBA: V—MRRTS 4 HA XICLD a eee FULBB, MEROF- UATE Tv Adjustment angle: SERLTR EI This varies with the crane model and the tire size. See the service manual covering your model. Stopper bolt A Bea ER Fig. 88 (Reference (85) King pin angle YET AMES 0 Camber 210% ceeve Caster o° Bene Toe-in 0-2 mm (0-0.08 in.) 9 * ht 0 ON 2amPRINTED IN JAPAN ©2006 TADANO LTD.