SERVICE MANUAL

G6-42P
9140-4002
November 2008
Starting Serial No.
0189001 thru 0189345
& 0160000230 thru Current

CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG DRIVE
McConnellsburg, PA
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417

Operation & Safety

Manual
Keep this manual with machine at all times.

Model
G6-42P
S/N 0160004018 & After
31200148
Original
November 25, 2008

An Oshkosh Corporation Company

CALIFORNIA PROPOSITION 65

BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of California
to cause cancer and
reproductive harm.

WASH HANDS
AFTER HANDLING!
CALIFORNIA PROPOSITION 65

EXHAUST WARNING
Diesel Engine exhaust and
some of its constituents
are known to the State of
California to cause cancer,
birth defects and other
reproductive harm.

Revision Log
Revision Log

REVISION LOG

November 25, 2008 - A - Original Issue of Manual

31200148

Read This First

Read This First

This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and
lessees with the precautions and operating procedures essential for the safe and
proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to
make specification changes without prior notification. Contact JLG Industries, Inc.
for updated information.

Operator Qualifications
The operator of the machine must not operate the machine until this manual has
been read, training is accomplished and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
Operation within the U.S.A. requires training per OSHA 1910.178.
Operators of this equipment must possess a valid, applicable drivers license, be in
good physical and mental condition, have normal reflexes and reaction time, good
vision and depth perception and normal hearing. Operator must not be using
medication which could impair abilities nor be under the influence of alcohol or any
other intoxicant during the work shift.
In addition, the operator must read, understand and comply with instructions
contained in the following material furnished with the material handler:
This Operation & Safety Manual
Telehandler Safety Manual (as required)
All instructional decals and plates
Any optional equipment instructions furnished
The operator must also read, understand and comply with all applicable Employer,
Industry and Governmental rules, standards and regulations.

Modifications
Any modification to this machine must be approved by JLG.

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Read This First

This product must comply with all safety related bulletins. Contact JLG Industries,
Inc. or the local authorized JLG representative for information regarding safetyrelated bulletins which may have been issued for this product.
JLG Industries, Inc. sends safety related bulletins to the owner of record of this
machine. Contact JLG Industries, Inc. to ensure that the current owner records are
updated and accurate.
JLG Industries, Inc. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death of
personnel or when damage has occurred to personal property or the JLG product.

FOR:
Accident Reporting and Product Safety Publications
Current Owner Updates
Questions Regarding Product Applications and Safety
Standards and Regulations Compliance Information
Questions Regarding Product Modifications

CONTACT:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(Addresses on back cover)

In USA:
Toll Free: 1-877-JLG-SAFE (877-554-7233)
Outside USA:
Phone:
+1-717-485-5161
E-mail:
[email protected]

Other Publications Available

Service Manual .............................................................91404002
Illustrated Parts Manual.................................................91404001

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This Page Intentionally Left Blank

31200148

Table of Contents

Table of Contents

TABLE OF CONTENTS
Revision Log
Read This First
Operator Qualifications ...................................................... b
Modifications ...................................................................... b
Other Publications Available .............................................. c

Table of Contents
Section 1 - General Safety Practices
1.1 Hazard Classification system...............................................1-1
Safety Alert System and Safety Signal Words ................1-1
1.2 General Precautions ............................................................1-1
1.3 Operation Safety ..................................................................1-2
Electrical Hazards ...........................................................1-2
Tip Over Hazard..............................................................1-3
Travel Hazard .................................................................1-6
Load Falling Hazard........................................................1-7
Lifting Personnel .............................................................1-8
Driving Hazards on Slopes .............................................1-9
Pinch Points and Crush Hazards ..................................1-10
Fall Hazard....................................................................1-12
Chemical Hazards.........................................................1-13

Section 2 - Pre-Operation and Inspection

2.1
2.2
2.3
2.4

Pre-Operation Check and Inspection...................................2-1

Safety Decals.......................................................................2-3
Walk-Around Inspection.......................................................2-6
Warm-Up and Operational Checks ......................................2-8
Warm-Up Check .............................................................2-8
Operational Check ..........................................................2-8
2.5 Operator Cab .......................................................................2-9
2.6 Windows ............................................................................2-10
Cab Door Window (if equipped) ....................................2-10

Section 3 - Controls and Indicators

3.1 General ................................................................................3-1
3.2 Controls ...............................................................................3-2
Transmission Control Lever ............................................3-3
Ignition Switch.................................................................3-4
Boom Joystick .................................................................3-5
Attachment Tilt and Frame Sway Lever ..........................3-6
Auxiliary Control Joystick (if equipped) ...........................3-7
Dash Controls and Indicators..........................................3-8
Park Brake Switch...........................................................3-9
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Table of Contents
Parking Procedure.......................................................... 3-9
Heater........................................................................... 3-10
3.3 Operator Seat.................................................................... 3-11
Seat Adjustments ......................................................... 3-11
Seat Belt ....................................................................... 3-13
3.4 Boom Angle and Extension Indicators .............................. 3-14
3.5 Mirror ................................................................................. 3-14

Section 4 - Operation
4.1 Engine ................................................................................. 4-1
Starting the Engine ......................................................... 4-1
Cold Weather Starting Aids ............................................ 4-2
Battery Boosted Starting................................................. 4-3
Normal Engine Operation ............................................... 4-4
Shut-Down Procedure .................................................... 4-4
4.2 Operating with a Load ......................................................... 4-5
Lift Load Safely............................................................... 4-5
Picking Up a Load .......................................................... 4-5
Transporting the Load .................................................... 4-6
Leveling Procedure......................................................... 4-6
Placing the Load............................................................. 4-7
Disengaging the Load..................................................... 4-7
4.3 Operating with a Suspended Load ...................................... 4-8
Lift Load Safely............................................................... 4-8
Picking Up a Suspended Load ....................................... 4-8
Transporting a Suspended Load .................................... 4-9
Leveling Procedure......................................................... 4-9
Placing a Suspended Load........................................... 4-10
Disengaging a Suspended Load .................................. 4-10
4.4 Loading and Securing for Transport.................................. 4-11
Tiedown ........................................................................ 4-11
Lifting ............................................................................ 4-12

Section 5 - Attachments
5.1
5.2
5.3
5.4

Approved Attachments ........................................................ 5-1

Unapproved Attachments.................................................... 5-2
Telehandler/Attachment/Fork Capacity ............................... 5-3
Use of the Capacity Chart ................................................... 5-4
Capacity Indicator Locations .......................................... 5-4
Sample Capacity Chart................................................... 5-5
Example.......................................................................... 5-6
5.5 Attachment Installation ........................................................ 5-7
5.6 Adjusting/Moving Forks ....................................................... 5-9
5.7 Attachment Operation ....................................................... 5-10
Carriage w/Forks .......................................................... 5-11
ii

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Table of Contents
Crane Hook...................................................................5-12
Bucket ...........................................................................5-14
Truss Boom...................................................................5-16
Boom Head-Mounted Winch.........................................5-18
6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m)
Carriage ........................................................................5-19
6 ft (1,8 m) - 100 Swing Mast W/Side Shift..................5-21
Swing Carriage .............................................................5-23
Side Tilt Carriage ..........................................................5-25
Personnel Work Platform ..............................................5-27

Section 6 - Emergency Procedures

6.1 Towing a Disabled Product..................................................6-1
Moving Short Distances ..................................................6-1
Moving Longer Distances ...............................................6-1
6.2 Emergency Lower of Boom..................................................6-2
6.3 Emergency Exit from Enclosed Cab ....................................6-2

Section 7 - Lubrication and Maintenance

7.1 Introduction ..........................................................................7-1
Clothing and Safety Gear................................................7-1
7.2 General Maintenance Instructions .......................................7-2
7.3 Service and Maintenance Schedules...................................7-3
10 & 1st 50 Hour Maintenance Schedule .......................7-3
50, 250 & 500 Hour Maintenance Schedule ...................7-4
1000 & 1500 Hour Maintenance Schedule .....................7-5
7.4 Lubrication Schedules .........................................................7-6
50 Hour Lubrication Schedule.........................................7-6
250 Hour Lubrication Schedule.......................................7-7
7.5 Operator Maintenance Instructions......................................7-8
Fuel System ....................................................................7-8
Air Intake System ..........................................................7-10
Engine Oil .....................................................................7-12
Hydraulic Oil..................................................................7-13
Tires ..............................................................................7-14
Hydraulic Return Filter ..................................................7-17
Engine Cooling System.................................................7-18
Battery...........................................................................7-19

Section 8 - Additional Checks

Section 9 - Specifications
9.1 Product Specifications .........................................................9-1
Fluid and Lubrication Capacities .....................................9-1
Tires ................................................................................9-2
Performance ...................................................................9-2
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Table of Contents
Dimensions..................................................................... 9-3

Index
Inspection, Maintenance and Repair Log

iv

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Section 1 - General Safety Practices

SECTION 1 - GENERAL SAFETY PRACTICES

1.1

HAZARD CLASSIFICATION SYSTEM

Safety Alert System and Safety Signal Words

DANGER

OW0010

DANGER indicates an imminently hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING

OW0021

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION

OW0031

CAUTION indicates a potentiality hazardous situation which, if not avoided, may

result in minor or moderate injury.

1.2

GENERAL PRECAUTIONS

WARNING
Before operation, read and understand this manual. Failure to comply with the
safety precautions listed in this manual could result in machine damage, property
damage, personal injury or death.

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1-1

Section 1 - General Safety Practices

1.3

OPERATION SAFETY

Electrical Hazards

10 FT
(3 M)

OW0040

This machine is not insulated and does not provide protection from contact or
being near electrical current.
NEVER operate the telehandler in an area where overhead power lines,
overhead or underground cables, or other power sources may exist without
ensuring the appropriate power or utility company de-energizes the lines.
Always check for power lines before raising the boom.
Follow employer, local and governmental regulations for clearance from
powerlines.

1-2

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Section 1 - General Safety Practices

Tip Over Hazard
General
For additional load requirements, refer to the appropriate capacity chart.

OW0050

Never use an attachment without the appropriate JLG approved capacity chart
installed on the telehandler.
Understand how to properly use the capacity charts located in cab.
DO NOT exceed rated lift capacity.
Be sure that the ground conditions are able to support the machine.

OW0080

DO NOT raise boom unless frame is level (0 degrees), unless otherwised noted
on capacity chart.

4 FT
(1,2 M)

OW0100

DO NOT level machine with boom/attachment above 4 ft (1,2 m).

(AUS - DO NOT level machine with load more than 11.8 in. (300 mm) above
ground surface).

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1-3

Section 1 - General Safety Practices

OH2291

MAINTAIN proper tire pressure at all times. If proper tire pressures are not
maintained, this machine could tip over.
Refer to manufacturers specifications for proper fill ratio and pressure
requirements for tires equipped with ballast.

OH20911

Always wear the seat belt.

Keep head, arms, hands, legs and all other body parts inside operators cab at all
times.

OH2221

If the telehandler starts to tip over:

DO NOT JUMP
BRACE YOURSELF and STAY WITH THE MACHINE
KEEP YOUR SEAT BELT FASTENED
HOLD ON FIRMLY
LEAN AWAY FROM THE POINT OF IMPACT

1-4

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Section 1 - General Safety Practices

Non-Suspended Load

OW0060

DO NOT drive with boom raised.

Suspended Load

OW0150

Tether suspended loads to restrict movement.

DO NOT raise the load more than 11.8 in (300 mm) above ground surface or the
boom more than 45.
Weight of all rigging (slings, etc.) must be included as part of load.
Start, travel, turn and stop slowly to prevent load from swinging.
When driving with the boom raised, DO NOT exceed walking speed.
Beware of wind. Wind can cause a suspended load to swing and cause
dangerous side loads - even with tag lines.
DO NOT attempt to use telehandler frame-leveling to compensate for load swing.
Keep heavy part of load closest to attachment.
Never drag the load; lift vertically.

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1-5

Section 1 - General Safety Practices

Travel Hazard

4-Wheel Steer

Pivot Steer

OW0120

Steering characteristics differ between 4-Wheel Steer & Pivot Steer telehandlers
as shown above. Identify the telehandler you are operating & others on the
jobsite.
Ensure that adequate clearance is provided between both rear tail swing and
front fork swing.
Unlike a conventional 4-wheel steer telehandler the rear wheels of a pivot steer
telehandler turn a wider circle than the front wheels.
Look out for and avoid other personnel, machinery and vehicles in the area. Use
a spotter if you DO NOT have a clear view.
Before moving be sure of a clear path and sound horn.
When driving, retract boom and keep boom/attachment as low as possible while
maintaining visibility of mirrors and maximum visibility of path of travel.
Always look in the direction of travel.
Always check boom clearances carefully before driving underneath overhead
obstructions. Position attachment/load to clear obstacles.

1-6

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Section 1 - General Safety Practices

Load Falling Hazard

OW0130

Never suspend load from forks or other parts of carriage.

DO NOT burn or drill holes in fork(s).
Forks must be centered under load and spaced apart as far as possible.

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1-7

Section 1 - General Safety Practices

Lifting Personnel

OW0170

When lifting personnel, USE ONLY a JLG approved personnel work platform,
with proper capacity chart displayed in the cab.

OW0190

DO NOT drive machine from cab when personnel are in platform.

1-8

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Section 1 - General Safety Practices

Driving Hazards on Slopes

OW0200

To maintain sufficient traction and braking capabilities, travel on slopes as follows:

When unloaded, the rear of the machine is the heavy end. Drive with forks
pointed downhill.
When loaded, the front of the machine is the heavy end. Drive with the forks
pointed uphill.
For additional travel requirements, refer to the appropriate capacity chart.
To avoid overspeeding the engine and drivetrain when driving down slopes,
downshift to a lower gear and use the service brake as necessary to maintain a
slow speed. DO NOT shift into neutral and coast downhill.
Avoid excessively steep slopes or unstable surfaces. To avoid tip over DO NOT
drive across excessively steep slopes under any circumstances.
Avoid turning on a slope. Never engage inching or shift to Neutral when going
downhill.
DO NOT park on a slope.

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1-9

Section 1 - General Safety Practices

Pinch Points and Crush Hazards
Stay clear of pinch points and rotating parts on the telehandler.

OW0210

Stay clear of moving parts while engine is running.

OW0220

Keep clear of steering tires and frame or other objects.

OW0230

Keep clear from under boom.

1-10

31200148

Section 1 - General Safety Practices

OW0240

Keep clear of boom holes.

OW0250

Keep arms and hands clear of attachment tilt cylinder.

OW0260

Keep hands and fingers clear of carriage and forks.

OW0960

Keep others away while operating.

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1-11

Section 1 - General Safety Practices

Fall Hazard

OW0280

Enter using the proper hand holds and steps provided. Always maintain 3-point
contact when mounting or dismounting. Never grab control levers or steering
wheel when mounting or dismounting the machine.
DO NOT get off the machine until the shutdown procedure on page 4-4 has been
performed.

OW0290

DO NOT carry riders. Riders could fall off machine causing death or serious
injury.

1-12

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Section 1 - General Safety Practices

Chemical Hazards
Exhaust Fumes
DO NOT operate machine in an enclosed area without proper ventilation.
DO NOT operate the machine in hazardous environments unless approved for
that purpose by JLG and site owner. Sparks from the electrical system and the
engine exhaust can cause an explosion.
If spark arrestors are required, ensure they are in place and in good working
order.

Flammable Fuel

OW0300

DO NOT fill the fuel tank or service the fuel system near an open flame, sparks
or smoking materials. Engine fuel is flammable and can cause a fire and/or
explosion.

Hydraulic Fluid

OW0950

DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the
engine is running or when the hydraulic system is under pressure.
Stop engine and relieve trapped pressure. Fluid in the hydraulic system is under
enough pressure that it can penetrate the skin.
DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to
search for leaks. Wear gloves to protect hands from spraying fluid.

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1-13

Section 1 - General Safety Practices

This Page Intentionally Left Blank

1-14

31200148

Section 2 - Pre-Operation and Inspection

SECTION 2 - PRE-OPERATION AND INSPECTION

2.1

PRE-OPERATION CHECK AND INSPECTION

Note: Complete all required maintenance before operating unit.

WARNING
FALL HAZARD. Use extreme caution when checking items beyond your normal
reach. Use an approved ladder.
The pre-operation check & inspection, performed at beginning of each work shift or
at each change of operator, should include the following:
1. Cleanliness - Check all surfaces for leakage (oil, fuel or battery fluid) or foreign
objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent
metal cracks or other discrepancies.

OAH1000

PARENT METAL CRACK

WELD CRACK

3. Safety Decals - Ensure all safety decals are legible and in place. Clean or
replace as required. See page 2-3 for details.
4. Operation and Safety Manuals - Operation and Safety Manual and AEM
Safety Manual (as required) are located in cab manual holder.
5. Walk-Around Inspection - See page 2-6 for details.
6. Fluid Levels - Check fluids, including fuel, hydraulic oil, engine oil and coolant.
When adding fluids, refer to Section 7 - Lubrication and Maintenance and
Section 9 - Specifications to determine proper type and intervals. Before
removing filler caps or fill plugs, wipe all dirt and grease away from the ports. If
dirt enters these ports, it can severely reduce component life.
7. Attachments/Accessories - Ensure correct load charts are installed on the
telehandler. If provided, reference the Operation and Safety Manual of each
attachment or accessory installed for specific inspection, operation and
maintenance instructions.

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2-1

Section 2 - Pre-Operation and Inspection

8. Operational Check - Once the walk-around inspection is complete, perform a
warm-up and operational check (see page 2-8) of all systems in an area free of
overhead and ground level obstructions. See Section 3 - Controls and
Indicators for more specific operating instructions.

WARNING
If telehandler does not operate properly, immediately bring machine to a stop,
lower boom and attachment to ground and stop the engine. Determine cause and
correct before continued use.

2-2

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Section 2 - Pre-Operation and Inspection

2.2

SAFETY DECALS

Ensure all DANGER, WARNING, CAUTION and instructional decals and proper
capacity charts are legible and in place. Clean and replace as required.

Model

Year of Manufacture

Serial Number

Maximum Weight Without Attachments (lbs/kg)

Maximim Capacity (lbs/kg)*

As released from factory this truck meets design specifications in ASME B56.6-2002 Part III
One or more of the following patents may apply to this truck: U.S. Nos. 4,954,041
5,639,119 5,813,697 5,230,399 5,052,532. Other patents pending.

6,349,969

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.

9114-3283

1705882
Manufactured by
JLG Industries Inc.
McConnellsburg, PA
17233-9533 USA

1705881
(After S/N
0160022389)

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND
SMOKING MATERIALS WHEN REFUELING
INJURY OR DEATH COULD RESULT
FROM FIRE.
9114-3286

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE
WHILE RUNNING.
RIDERS COULD FALL OFF MACHINE
CAUSING SERIOUS INJURY OR DEATH.

Refer to load capacity chart for truck with attachment, and individual load ratings stamped
on forks, if equipped. Use lowest capacity of all rattings.

91143283

1705882
(Before S/N
0160022389)

9114-3282

91143286

91143282

91323030
TURBOCHARGER DAMAGE CAN RESULT
FROM QUICK START-UP & SHUTDOWN.
FOR LONGER TURBOCHARGER LIFE
AND TO MINIMIZE TURBOCHARGER
DAMAGE, IDLE ENGINE AT LEAST
3-5 MINUTES AFTER START-UP
AND BEFORE SHUTDOWN.

NEVER OPERATE MACHINE WITHOUT

CONSULTING PROPER CAPACITY CHART FOR THE
CARRIAGE/FORK COMBINATION BEING USED.
9132-3030

9134-3016

90553028

91343016

FOR SAFE OPERATION OF MACHINE AND TO MINIMIZE RISK OF

SERIOUS INJURY, READ AND OBSERVE THE FOLLOWING:
1. ONLY TRAINED AND AUTHORIZED PERSONNEL MAY
OPERATE THIS MACHINE.
2. BEFORE OPERATING, READ AND UNDERSTAND ALL CAPACITY
CHARTS, OPERATOR MANUALS AND SAFETY MANUALS. IF
MANUALS ARE NOT AVAILABLE, CONSULT AN AUTHORIZED
GRADALL DEALER. UNDERSTAND ALL CONTROLS IN CAB AND
CHECK FOR PROPER OPERATION. CLEAR LOOSE OBJECTS
OFF MACHINE AND SOUND HORN BEFORE STARTING ENGINE.

7. WHEN TRAVELING WITH LOAD, FULLY RETRACT BOOM AND

PLACE FORKS IN CARRY POSITION (APPROX.12" ABOVE
GROUND). TILT CARRIAGE BACK SLIGHTLY TO CRADLE
LOAD. USE EXTREME CAUTION WHEN TURNING.

15. BEFORE ADJUSTING OR SERVICING, PLACE

FORWARD/REVERSE LEVER IN NEUTRAL, REST BOOM ON
GROUND OR SUPPORT, SET PARKING BRAKE, SHUT OFF
ENGINE AND CHOCK WHEELS.

8. ON INCLINES, TRAVEL WITH LOAD UP-GRADE.

16. BEFORE LEAVING MACHINE UNATTENDED, PLACE

FORWARD/REVERSE LEVER IN NEUTRAL, LOWER BOOM,
SET PARKING BRAKE,AND SHUT-OFF ENGINE. CHOCK
WHEELS IF MACHINE MUST PARK ON AN INCLINE.

9. DO NOT USE BOOM AS WALKWAY.

10. USE TWO HANDS WHEN CLIMBING ON MACHINE.

3. OPERATOR MUST BE SEATED WITH SEAT BELT FASTENED.

ASSURE FORWARD/REVERSE LEVER IS IN NEUTRAL,PARK
BRAKE APPLIED AND ALL HYDRAULIC CONTROLS ARE IN
NEUTRAL BEFORE IGNITION SWITCH IS TURNED ON.

11. USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK

PLATFORM FOR LIFTING PERSONNEL. NO RIDERS ON MACHINE,
FORKS, LOAD, OR OTHER LIFTING ATTACHMENTS AT ANY
TIME. DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE
PROPER GRADALL MATERIAL HANDLER/PERSONNEL WORK
PLATFORM CAPACITY CHART DISPLAYED IN THE CAB. DO NOT
DRIVE MACHINE WITH PERSONNEL IN PLATFORM.

4. DO NOT OPERATE MACHINE WITHOUT PROPER CAPACITY

CHART IN PLACE.
5. BEFORE MOVING, BE SURE OF A CLEAR PATH AND SOUND
HORN. WATCH FOR PEDESTRIANS AND OBSTRUCTIONS.
CHECK OVERHEAD AND SIDE CLEARANCES. ALWAYS LOOK
IN DIRECTION OF TRAVEL.

12. KEEP OTHERS AWAY FROM MACHINE WHILE OPERATING.

DO NOT STAND UNDER BOOM OR LOAD.
13. USE EXTREME CARE WHEN HANDLING LONG, HIGH, OR
WIDE LOADS. DO NOT HANDLE UNSTABLE OR LOOSELY
STACKED LOADS.

6. START, TURN, AND BRAKE SMOOTHLY. REDUCE TRAVEL

SPEEDS FOR TURNS, SLIPPERY, OR UNEVEN SURFACES.
AVOID RUNNING OVER LOOSE OBJECTS OR HOLES IN THE
ROADWAY SURFACE.

14. FORKS TO BE CENTERED UNDER LOAD AND SPACED APART

AS FAR AS POSSIBLE.

17. LEVEL MACHINE BEFORE LIFTING ANY LOAD ABOVE 4

FEET. (IF EQUIPPED WITH FRAME LEVELING).
18. OPERATOR PROTECTION (SUCH AS HARD HATS, SAFETY
GLASSES, AND/OR HEARING PROTECTION) SHOULD BE
WORN WHEN JOB CONDITIONS WARRANT. ALWAYS USE
SEAT BELT.
19. IMPROPER USE OF MACHINE COULD RESULT IN MACHINE
TIPPING OVER. IF MACHINE STARTS TO TIP OVER, DO
NOT LEAVE OPERATORS SEAT. LEAN AWAY FROM TIP &
BRACE YOURSELF.
20. KEEP MIRROR(S) CLEAN AND PROPERLY ADJUSTED.
OBJECTS IN MIRROR ARE CLOSER THAN THEY APPEAR.
9055-3028 REV. A

A
91413012
GRADALL HANDLER
SERVICE INSTRUCTIONS
FOR: G6-42P

SERVICE INTERVALS
DAILY
OR
10 HRS

WEEKLY
OR
50 HRS

EVERY
5WKS OR
250 HRS

3 MO.
OR
500 HRS

6 MO.
ANNUALLY
OR
OR
1000 HRS 1500 HRS

TYPE OR
EQUIVALENT

DIESEL ENGINE
AIR CLEANER ELEMENT--------------**--------------------------------------------F U E L F I L T E R S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - - O I L F I L T E R - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE - - - - - - - - - - - - - - - - - - O I L ( 1 4 . 5 Q T . ) ( 1 3 . 6 L T R . ) - - - - - CHECK - - - - - CHANGE - - - - - - - - - - - - - - - - - - - SAE 15W-40-CD ***
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - DIESEL FUEL #2
D I E S E L F U E L ( 3 8 G A L . ) ( 1 4 3 . 8 LT R . )
FILL
HYDRAULIC SYSTEM
MOBIL 424
O I L ( 4 3 G A L . ) - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - INSPECT - - - - - - CHANGE
F I L T E R S - - - - - - - - - - - - - - - - - - - - - - - - - - * - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHANGE
H Y D . TA N K B R E AT H E R / F I LT E R C A P - - - - - - - - - - - - - CHECK - - - - - - CHANGE - - - - - FRONT AXLE LUBE
MOBIL 424
- - - - - - - - - - - - - CHECK - - - - - - CHANGE - - - - - CENTER SECTION (15.75 QT.)(14.9 LTR.)
- - - - - - - - - - ------------EACH WHEEL HUB (1.4 QT.)(1.3 LTR.)
REAR AXLE WHEEL END LUBE (4 PT.) (1.9 LTR.)
WHEEL NUT TORQUE-300/350 FT-LBS
RADIATOR
(1.9 GAL.) (7.2 LTR.) WATER
(1.9 GAL.) (7.2 LTR.) ANTI-FREEZE
(.5 QT.)(.47 LTR.) OF SUPPLIMENTAL
COOLANT ADDITIVE (SCA)

CHECK - - - - - - CHANGE - - - - - - - - - - - - - - - - - - - - - - - - TORQUE - - - - - - - - - - - - ------

*****

MOBIL 424

ETHYLENE GLYCOL
- - - - - - - - - - - - - - - - - - - - - - - - - - ANTI-FREEZE

TIRES: (12 PLY)

6 5 P S I - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - TIRES: RADIAL 70 PSI - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - - - - - - - - CYLINDER FITTINGS EACH END - - - - - * * * * - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - R E A R A X L E ( 1 2 ) F I T T I N G S - - - - - - - - * * * * - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - FRONT AXLE PIVOT (2) FITTINGS - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - A L L B E A R I N G S P A D S - - - - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - FRONT BOTTOM BEARING PADS - - - - - - - - - - - GREASE CHECK - - - - - - - - - - - - - - - - - - B O O M P I V O T ( 2 ) F I T T I N G S - - - - - - - - - * * * * - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - H E A D P I N ( 2 ) F I T T I N G S - - - - - - - - - - - * * * * - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - Q U I C K S W I T C H ( 1 ) F I T T I N G - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - R E T R A C T & E X T E N D C H A I N - - - - - - - - - - - - - - - - - - - - - CHECK - - - - - - - - - - - - - - - - - - SEE OPERATOR & MAINTENANCE MANUAL
R E T R A C T & E X T E N D C H A I N S H E A V E S - - - - - - - - - - - - - - - - GREASE - - - - - - - - - - - - - - - - - - - - - - - - - -

MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY
MYSTIK TETRIMOLY

MYSTIK TETRIMOLY

THIS CHART MUST BE USED IN CONJUNCTION WITH SERVICE MANUAL AND RECOMMENDED PROCEDURE.
* CHECK INDICATOR ON HYDRAULIC FILTER. CHANGE FILTER IF NEEDLE IS IN RED
AT FULL THROTTLE AND AT OPERATING TEMPERATURE.
** CHECK AIR CLEANER RESTRICTION INDICATOR. CLEAN OR CHANGE PRIMARY FILTER IF NECESSARY.
SAFETY ELEMENT TO BE CHANGED EVERY 3RD CHANGE OF PRIMARY FILTER ELEMENT.
*** CONSULT DEALER FOR RECOMMENDATIONS AT EXTREME TEMPERATURES.
**** DAILY SERVICE MAY BE REQUIRED FOR OPTIMUM LIFE DEPENDING UPON APPLICATION SEVERITY.
*****IF COOLANT IS ADDED TO RADIATOR ADD 3% SCA BY VOLUME.
IT IS RECOMMENDED THAT FILTER ELEMENTS, FRONT AXLE LUBRICANT, AND ENGINE OIL BE
CHANGED AFTER FIRST 100 HRS ON NEW OR REBUILT UNITS.

9150-3102 REV. -

9141-3012

91503102

91323030
NEVER OPERATE MACHINE WITHOUT
CONSULTING PROPER CAPACITY CHART FOR THE
CARRIAGE/FORK COMBINATION BEING USED.
9132-3030

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED PERSONNEL WORK PLATFORM.
DO NOT DRIVE MACHINE WITH PERSONNEL IN PLATFORM.
WHEN PERSONNEL ARE IN PLATFORM REMAIN SEATED IN CAB WITH PERSONNEL
IN DIRECT LINE OF SIGHT.
OPERATE CONTROLS LIGHTLY AND CAUTIOUSLY WHEN LIFTING PERSONNEL.
READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL BEFORE LIFTING PERSONNEL.
DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL
HANDLER/PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

80603022

9055-3027 REV. A

90553027

AVOID HIGH VOLTAGE LINES.

IT IS UNLAWFUL TO PLACE
ANY PART OF THIS MACHINE
OR LOAD WITHIN 10 FEET
OF HIGH VOLTAGE LINES
UP TO 50,000 VOLTS.
DEATH OR INJURY MAY
RESULT FROM CONTACTING
ELECTRIC LINES.

8060-3022

OY1061

VIEW A-A

31200148

2-3

Section 2 - Pre-Operation and Inspection

EXHAUST SYSTEMS CAN BE HOT.

KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.
HOT EXHAUST COMPONENTS CAN CAUSE
SEVERE BURNS.
9114-3280

91143285

91143281

JUMP STARTING INSTRUCTIONS

91403573
- 35
7

WHEN JUMP STARTING MATERIAL HANDLER

* NEVER ALLOW VEHICLES TO TOUCH
* CONNECT THE POSITIVE (+) JUMPER CABLE TO
POSITIVE (+) POST OF DISCHARGED BATTERY
* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER
CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY
* CONNECT THE NEGATIVE (-) JUMPER CABLE TO
NEGATIVE (-) POST ON BOOSTER BATTERY
* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER
CABLE TO GROUND POINT ON MACHINE AWAY FROM
DISCHARGED BATTERY
* FOLLOW STANDARD STARTING PROCEDURES
* REMOVE CABLES IN REVERSE ORDER AFTER MACHINE
HAS STARTED

STAY CLEAR OF MOVING PARTS

WHILE ENGINE IS RUNNING.
MOVING PARTS CAN CAUSE
SERIOUS INJURY.
9114-3281

9114-3285

91
40

91143280
BEFORE
S/N 0160026801

91403569

91143282

FULL

ADD

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.

HYDRAULIC
OIL LEVEL

CHECK OIL LEVEL WITH

HANDLER LEVEL AND ALL
CYLINDERS RETRACTED.
2.5 GALLON BETWEEN
ADD AND FULL MARKS
9140-3569

9114-3282

Genuine Parts

HYDRAULIC SYSTEM

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.

FILL WITH TRACTOR HYDRAULIC FLUID

R
or equivalent.

91083492

9114-3282

91143282

For Mobil Product Information, Call 1-800-662-4525.

9114-3288

91143288

LEAD ACID BATTERIES PRODUCE FLAMABLE AND

EXPLOSIVE GASSES
WHEN CHECKING, TESTING, USING
BOOSTER BATTERY OR CHARGING BATTERIES:
* DO NOT USE SMOKING MATERIALS NEAR BATTERIES
* KEEP FLAMES AND SPARKS AWAY FROM BATTERIES
* WEAR SAFETY GLASSES
* ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE
IS AT PROPER LEVEL IN EACH CELL
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR DAMAGE TO THE
ELECTRICAL SYSTEM

9114-3284

91143284

91163028

91413061
9151-3207 REV.-

VIEW B-B

91403529
TRACTION LOCK
LOCKS FRONT & REAR AXLES
HYDRAULICALLY FOR INCREASED
TRACTION. DO NOT USE ON
IMPROVED SURFACES.
MACHINE MUST BE IN 4X4
MODE.

80603026

9140-3529

COOLING SYSTEM
IS PRESSURIZED.
REMOVE CAP SLOWLY.
HOT FLUID CAN
CAUSE BURNS.

8060-3026

VIEW C-C

VIEW D-D

91413024
FORWARD DRIVE
PRESSURE
TEST PORT
REVERSE DRIVE
PRESSURE
TEST PORT

CHARGE
PRESSURE
TEST PORT
IMPLEMENT
PRESSURE
TEST PORT
9141-3024 (-)

OY1071

VIEW OF HYDRAULIC TANK

2-4

31200148

Section 2 - Pre-Operation and Inspection

Safety Decals 3

80603037

4105262
50 60
70 80

91143282
STAY CLEAR OF PINCH POINT AREA
ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.

PINCH POINT
KEEP OUT

40
20
-10 0 10 30

9114-3282

REACHING INTO BOOM

HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A

50

60

70

80

40
30
-10

10

20

ATTACHMENT MUST BE SECURED TO MACHINE.

CHECK TO ASSURE QUICK SWITCH PLUNGER
PIN IS FULLY ENGAGED AND LOCKED AFTER
ATTACHMENT CHANGE.
IF PLUNGER PIN IS NOT FULLY ENGAGED
AND LOCKED ATTACHMENT MAY FALL OFF
CAUSING SERIOUS INJURY OR DEATH.

9114-3290

91143290

91513210

A
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A

91513210

91143282

PINCH POINT
KEEP OUT

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.

REACHING INTO BOOM

HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.

9114-3282

8060-3037-A

91513210
PINCH POINT
KEEP OUT

91513210

REACHING INTO BOOM

HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3037-A

READ AND UNDERSTAND THE FOLLOWING PRIOR TO LIFTING PERSONNEL.

WHEN LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED
PERSONNEL WORK PLATFORM.
ALL PERSONNEL IN PLATFORM MUST WEAR A FULL BODY HARNESS WITH
LANYARD ATTACHED TO A DESIGNATED ANCHORAGE POINT.
READ AND UNDERSTAND PERSONNEL WORK PLATFORM USER'S MANUAL
BEFORE OCCUPYING PERSONNEL WORK PLATFORM.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH.

9055-3026 REV. A

OY1250

VIEW A-A

31200148

VIEW B-B

2-5

Section 2 - Pre-Operation and Inspection

2.3

WALK-AROUND INSPECTION

16
1
15

2
3

14

13

12
5
6
7

11
8

10

OY0181

Begin your walk-around inspection at item 1, as noted below. Continue to your right
(counterclockwise when viewed from top) checking each item in sequence.
INSPECTION NOTE: On all components, make sure there are no loose or missing
parts, that they are securely fastened and no visible leaks or excessive wear exists
in addition to any other criteria mentioned. Inspect all structural members including
attachment for cracks, excessive corrosion and other damage.
1. Boom Sections & Lift, Tilt, Extend/Retract, Compensating (Slave) Cylinders Check front, top, side & rear slider pads for adequate grease.
Pivot pins secure; hydraulic hoses undamaged, not leaking.
Check extend/retract cables and adjustment blocks for adequate tension.
2. Front Axle - Pivot pins secure; hydraulic hoses undamaged, not leaking.
3. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.

2-6

31200148

Section 2 - Pre-Operation and Inspection

4. Cab & Electrical Check window glass is in place and clean; gauges, switches, joysticks, foot
controls & horn operational.
General appearance; no visible damage; proper load charts and applicable
Operator & Safety manual located in manual holder.
Make sure emergency escape hammer is in place (enclosed cabs only).
Check seat belt for damage, replace belt if frayed or cut webbing, damaged
buckles or loose mounting hardware.
5. Fuel Tank - Check fluid level, refill as required; filler cap is securely fastened.
6. Air Cleaner - Air cleaner element condition indicator, check for clogged
condition. Replace element as required.
7. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
8. Main Control Valve - See Inspection Note.
9. Back-up Alarm - See Inspection Note.
10. Rear Axle - Steer cylinders undamaged, not leaking; pivot pins secure;
hydraulic hoses undamaged, not leaking.
11. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
12. Engine Compartment Engine Crankcase and Radiator, check level & refill as required.
Drive belts, check condition & replace as required.
Hydraulic pump & reservoir, recommended fluid level on sight gauge
(lubricant must be cool), breather cap secure and working.
Engine cover properly secured.
13. Mirrors - Clean and undamaged.
14. Wheel/Tire Assembly - Properly inflated and secured; no loose or missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepancies.
15. Sway Cylinder - Pins secure; hydraulic hoses undamaged, not leaking.
16. Attachment - Properly installed, see Attachment Installation on page 5-7.

31200148

2-7

Section 2 - Pre-Operation and Inspection

2.4

WARM-UP AND OPERATIONAL CHECKS

Warm-Up Check
During warm-up period, check:
1. Heater, defroster and windshield wiper (if equipped).
2. Check all lighting systems (if equipped) for proper operation.
3. Voltmeter should show 13.5 to 14 volts.
4. Adjust mirror(s) for maximum visibility.

WARNING
CUT/CRUSH/BURN HAZARD. Keep engine cover closed while engine is running
except when checking hydraulic filter condition indicator.

Operational Check
When engine warms, perform an operational check:
1. Service brake and parking brake operation.
2. Forward and reverse travel.
3. Steering in both directions with engine at low idle.
4. Horn and back-up alarm. Must be audible from inside operators cab with engine
running.
5. All boom and attachment functions - operate smoothly and correctly.
6. Perform any additional checks described in Section 8.
7. Hydraulic Filter Condition Indicator.

2-8

31200148

Section 2 - Pre-Operation and Inspection

2.5

OPERATOR CAB

The telehandler is equipped with a standard open ROPS/FOPS cab. An optional

enclosed ROPS/FOPS cab is available.

WARNING
Never operate telehandler unless the overhead guard and cab structure are in
good condition. Any modification to this machine must be approved by JLG to
assure compliance with ROPS/FOPS certification for this cab/machine
configuration. If damaged, the CAB CANNOT BE REPAIRED. It must be
REPLACED.

31200148

2-9

Section 2 - Pre-Operation and Inspection

2.6

WINDOWS

Keep all windows and mirrors clean and unobstructed.

Cab Door Window (if equipped)

2
3

OAL0010

During operation the window must either be latched open or closed.

Open the cab door window (1) and secure it in the latch.
Press the release button (2) inside the cab or pull on the lever (3) outside the cab
to unlatch the window.
During operation the lower door (4) must be closed.

2-10

31200148

Section 3 - Controls and Indicators

SECTION 3 - CONTROLS AND INDICATORS

3.1

GENERAL

This section provides the necessary information needed to understand control

functions.
Note: The manufacturer has no direct control over machine application and
operation. The user and operator are responsible for conforming with good safety
practices.

NOTICE
EQUIPMENT DAMAGE. When a red light illuminates, immediately bring machine
to a stop, lower boom and attachment to ground and stop the engine. Determine
cause and correct before continued use.

31200148

3-1

Section 3 - Controls and Indicators

3.2

CONTROLS
4
2

11
10
9

7
OY0023

1. Transmission Control Lever: See page 3-3.

2. Instrument Panel: See Dash Controls and Indicators on page 3-8.
3. Steering Wheel: Turning the steering wheel to the left or right steers the
machine in the corresponding direction.
4. Frame Level Indicator: Enables the operator to determine the left to right level
condition of the telehandler.
5. Boom Joystick: See page 3-5.
6. Heater Control (if equipped): See page 3-10.
7. Accelerator Pedal: Pressing down the pedal increases engine and hydraulic
speed.
8. Traction Lock Pedal: Operates traction-lock valve which functions to restore
traction when a wheel spins.
9. Service Brake Pedal/Inching Travel Pedal: Operates the service brakes on the
front axle. Permits slow travel speed while engine speed is kept high for other
handler functions. The further the pedal is depressed, the slower the travel
speed.
10. Ignition Switch: Key activated. See page 3-4.
11. Attachment Tilt and Frame Sway Lever: See page 3-6
Auxiliary Control Joystick (if equipped): See page 3-7

3-2

31200148

Section 3 - Controls and Indicators

Transmission Control Lever

15
F

OX0081

Transmission control lever (15) engages forward or reverse travel.

Lift and push lever forward for forward travel; lift and pull lever rearward for
reverse travel. Move lever to centered position for Neutral.
When traveling in REVERSE, the back-up alarm will automatically sound.
Drive in reverse and turn only at slow rates of speed.
Do not increase engine speed with the transmission in forward or reverse and the
service brake depressed in an attempt to get quicker hydraulic performances.
This could cause unexpected machine movement.

WARNING
TIP OVER/CRUSH HAZARD. Bring telehandler to a complete stop before
shifting transmission control lever. A sudden change in direction of travel could
reduce stability and/or cause load to shift or fall.

31200148

3-3

Section 3 - Controls and Indicators

Ignition Switch

F
N
R

ACC

OFF

RUN
START

OY0051

In "ACC" or "RUN" position, voltage is available for all electrical functions.

Full clockwise rotation to "START" engages starter motor.
Counter-clockwise rotation to "OFF" stops engine and removes voltage from all
electrical functions.

3-4

31200148

Section 3 - Controls and Indicators

Boom Joystick

IF EQUIPPED

OX0060

The boom joystick (1) controls the boom and attachment tilt (if equipped) functions.
Boom Functions
Move the joystick back to lift boom; move joystick forward to lower boom; move
joystick right to extend boom; move joystick left to retract boom.
The speed of boom functions depends upon the amount of joystick travel in
corresponding direction. Increasing engine speed will also increase function
speed.
For two simultaneous boom functions, move the joystick between quadrants. For
example; moving the joystick forward and to the left will lower and retract boom
simultaneously.
Attachment Functions (if equipped)
Tilt control is actuated by the switch (2).
Depress the rear of the switch to tilt up; depress the front of switch to tilt down.

WARNING
TIP OVER/CRUSH HAZARD. Rapid, jerky operation of controls will cause rapid,
jerky movement of the load. Such movements could cause the load to shift or fall
or could cause the machine to tip over.

31200148

3-5

Section 3 - Controls and Indicators

Attachment Tilt and Frame Sway Lever

FUEL

QUARTZ

TEMP

0 0 0 0 0 0

80

OIL

E
0
240 16
VOLTS
-

100

10

OFF
ACC

START

RUN

WORK

TRAVEL

IGNITION

MACHINE MUST BE
IN NEUTRAL AND
PARK BRAKE ON
TO START

OY0143

This lever (4) controls the attachment tilt and the left to right frame sway.
Attachment Tilt Function
Move lever forward to tilt attachment down; move lever back to tilt attachment up.
Sway Function
Move the lever left to sway frame left, move the lever right to sway frame right.
A level indicator is located in the upper front window frame to permit operator to
determine whether the telehandler frame is level.

WARNING
TIP OVER HAZARD. Always move boom as low as possible while allowing for
best visibility of right hand mirror before leveling frame. Attempting to level
machine with boom raised could cause it to tip over.

3-6

31200148

Section 3 - Controls and Indicators

Auxiliary Control Joystick (if equipped)

Auxiliary
Hydraulics

FUEL

QUARTZ

TEMP

0 0 0 0 0 0

80

OIL

E
0
240 16
VOLTS
-

100

10

OFF
ACC

START

RUN

WORK

TRAVEL

IGNITION

MACHINE MUST BE
IN NEUTRAL AND
PARK BRAKE ON
TO START

Sway
(optional)

1
Attachment
Tilt
(optional)

OX0224

The auxiliary control joystick (1) controls the auxiliary hydraulic functions, left to right
frame sway (if equipped), and attachment tilt (if equipped).
Auxiliary Hydraulics Function
Controls function of attachments that require hydraulic supply for operation. See
Section 5 - Attachments for approved attachments and control instructions.
Frame Sway (if equipped)
Move the joystick left to sway frame left, move the joystick right to sway frame
right.
A level indicator is located in the upper front window frame to permit operator to
determine whether the telehandler frame is level.
Attachment Tilt (if equipped)
Move joystick up to tilt down; move joystick down to tilt up.

31200148

3-7

Section 3 - Controls and Indicators

Dash Controls and Indicators
.

1
FUEL

QUARTZ

TEMP

80

OIL

E
0
240 16
VOLTS
-

100

10

WORK

OFF

OFF

START

ACC

START

ACC

RUN

WORK

RUN

0 0 0 0 0 0

TRAVEL

IGNITION

MACHINE MUST BE
IN NEUTRAL AND
PARK BRAKE ON
TO START

TRAVEL

IGNITION

6 5 4
OY0084

1. Hourmeter: Indicates total time of engine operation in hours and tenths of

hours.
2. Park Brake Switch: See page 3-9.
3. 4-in-1 Gauge:
a. Engine Coolant Temperature Gauge
b. Engine Oil Pressure Gauge
c. Fuel Gauge
d. Voltmeter indicates alternator output and battery condition.
4. Horn Button: Depress button to sound horn.
5. Ignition Switch: See page 3-?.
6. 4X2/4X4 Switch: Engages and disengages rear-wheel drive motors. Rear drive
motors are engaged for four-wheel drive. Indicator light on switch glows (amber)
to indicate four-wheel drive is engaged. When park brake is applied, light will
not glow.

3-8

31200148

Section 3 - Controls and Indicators

Park Brake Switch

F
N
R

OY0122

Park brake switch controls the application and release of the park brake. Indicator
light illuminates to indicate brake is applied.
With the engine running and the park brake switch in "OFF" position (1), park
brakes are disengaged.
With switch in "ON" position (2), park brake is engaged and transmission will not
engage forward or reverse.

WARNING
MACHINE ROLL-AWAY HAZARD. Always move park brake switch to "ON"
position, lower boom to ground and stop engine before leaving cab.

WARNING
CRUSH HAZARD. Turning engine off applies the park brake. Applying park brake
or turning engine off while traveling will cause unit to stop abruptly and could
cause load loss. Either may be used in an emergency situation.

Parking Procedure
1. Using service brake, stop telehandler in an appropriate parking area.
2. Follow Shut-Down Procedure on page 4-4.

31200148

3-9

Section 3 - Controls and Indicators

Heater

3
4
3

1
OY0060

1. Heater
2. Access Cover/Heat Vent
3. Air Vents
4. Defroster Fan: Two speed fan. Press fan switch down for slow speed; press
switch up for fast speed. Return switch to middle position to turn off.
5. Temperature Control Switch
6. Heater Fan Switch: On/Off switch.

3-10

31200148

Section 3 - Controls and Indicators

3.3

OPERATOR SEAT

Seat Adjustments
Before S/N 0160016100

1
OX0012

Prior to starting engine adjust seat for position and comfort as follows:
1. Use handle to move seat fore and aft
2. A two inch seat belt is standard equipment. If required, an optional three inch
belt is available.

31200148

3-11

Section 3 - Controls and Indicators

S/N 0160016100 & After

3
4
1
2
OX0520

Prior to starting engine adjust seat for position and comfort as follows:
1. Turn the knob on the front of seat to adjust the suspension. Turn the knob
clockwise to increase stiffness. Turn the knob counterclockwise to reduce
stiffness.
2. Pull up on handle to move seat fore and aft.
3. Arm rest can be moved up or down for comfort.
4. A two inch seat belt is standard equipment. If required, an optional three inch
belt is available.

3-12

31200148

Section 3 - Controls and Indicators

Seat Belt

OH20912

Fasten seat belt as follows:

1. Grasp both free ends of the belt making certain that belt webbing is not twisted
or entangled.
2. With back straight in the seat, couple the retractable end (male end) of the belt
into the receptacle (buckle) end of the belt.
3. With belt buckle positioned as low on the body as possible, pull the retractable
end of the belt away from the buckle until it is tight across the lap.
4. To release belt latch, depress red button on the buckle and pull free end from
buckle.

31200148

3-13

Section 3 - Controls and Indicators

3.4

BOOM ANGLE AND EXTENSION INDICATORS

1

50

60

70

80

40

-10

10

20

30

OX0540

The boom angle indicator (1) is located on the left side of the boom. Use this
indicator to determine the boom angle when using the capacity chart (see Use
of the Capacity Chart on page 5-4).
The boom extension indicators (2) are located on the left side of the boom. Use
these indicators to determine boom extension when using the capacity chart
(see Use of the Capacity Chart on page 5-4).

3.5

MIRROR

OW0500

Keep all windows and mirror(s) clean and unobstructed.

Adjust mirror(s) as required for maximum visibility, before and during operation.

3-14

31200148

Section 4 - Operation

SECTION 4 - OPERATION
4.1

ENGINE

Starting the Engine

This machine can be operated under normal conditions in temperatures of 0F to
104F (-20C to 40C). Consult JLG for operation outside this range or under
abnormal conditions.
1. Make sure all controls are in Neutral and all electrical components (lights,
heater, defroster, etc.) are turned off. Set parking brake.
2. Turn ignition switch to START to engage starting motor. Release key
immediately when engine starts. If engine fails to start within 20 seconds,
release key and allow starting motor to cool for a few minutes before trying
again.
3. After engine starts, observe oil pressure gauge. If gauge remains on zero for
more than ten seconds, stop engine and determine cause before restarting
engine. Reference engine manual for minimum pressure at operating
temperature.
4. Warm up engine at approximately 1/2 throttle.

Note: Engine will not start unless transmission control lever is in Neutral and park
brake switch is applied.

WARNING
UNEXPECTED MOVEMENT HAZARD. Always ensure that transmission control
lever is in neutral and the service brake is applied before releasing park brake.
Releasing park brake in either forward or reverse could cause the machine to
move abruptly, causing an accident.

31200148

4-1

Section 4 - Operation
Cold Weather Starting Aids
JLG approved starting aids employ ether. If your telehandler is equipped with an
ether starting aid, the following applies:
Injection of ether is triggered by temperature sensor located on engine.
At start-up, temperature sensor on engine will detect if ether is needed. Follow
normal start-up procedure.
Ether will be automatically injected if needed, to keep engine running.
A second battery is added for additional cold-cranking capacity.

WARNING
ENGINE EXPLOSION. If your telehandler is equipped with a cold start aid, do
not spray additional ether into air cleaner. If machine is not equipped with cold
start aid, follow instructions listed in the engine manual supplied with the
telehandler.

4-2

31200148

Section 4 - Operation
Battery Boosted Starting

OW0530

If battery-boost starting (jump-start) is necessary, proceed as follows:

Never allow vehicles to touch.
Connect the positive (+) jumper cable to positive (+) post of discharged battery.
Connect the opposite end of positive (+) jumper cable to positive (+) post of
booster battery.
Connect the negative (-) jumper cable to negative (-) post on booster battery.
Connect opposite end of negative (-) jumper cable to ground point on machine
away from discharged battery.
Follow standard starting procedures.
Remove cables in reverse order after machine has started.

WARNING
BATTERY EXPLOSION HAZARD. Never jump start or charge a frozen battery
as it could explode. Keep sparks, flames and lighted smoking materials away
from the battery. Lead acid batteries generate explosive gases when charging.
Wear safety glasses.

31200148

4-3

Section 4 - Operation
Normal Engine Operation
Observe gauges frequently to be sure all engine systems are functioning
properly.
Be alert for unusual noises or vibration. When an unusual condition is
noticed, park machine in safe position and perform shut-down procedure. Report
condition to your supervisor or maintenance personnel.
Avoid prolonged idling. If the engine is not being used, turn it off.

Shut-Down Procedure
When parking the telehandler, park in a safe location on flat level ground and away
from other equipment and/or traffic lanes.
1. Apply the park brake.
2. Shift the transmission to Neutral.
3. Lower forks or attachment to the ground.
4. Operate engine at low idle for 3 to 5 minutes. DO NOT over rev engine.
5. Shut off engine and remove ignition key.
6. Exit telehandler properly.
7. Block wheels (if necessary).

4-4

31200148

Section 4 - Operation
4.2

OPERATING WITH A LOAD

Lift Load Safely

You must know the weight and load center of every load you lift. If you are not
sure of the weight and load center, check with your supervisor or with the
supplier of the material.

WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
Know the rated load capacities (refer to Section 5) of the telehandler to
determine the operating range in which you can safely lift, transport and place a
load.

Picking Up a Load
Note the conditions of the terrain. Adjust travel speed and reduce amount of load
if conditions warrant.
Avoid lifting double-tiered loads.
Make sure load is clear of any adjacent obstacles.
Adjust spacing of forks so they engage the pallet or load at maximum width. See
Adjusting/Moving Forks on page 5-9.
Approach load slowly and squarely with fork tips straight and level. NEVER
attempt to lift a load with just one fork.
NEVER operate telehandler without a proper and legible Capacity Chart in the
operators cab for the telehandler/attachment combination you are using.

31200148

4-5

Section 4 - Operation
Transporting the Load

OW0540

After engaging the load and resting it against the backrest, tilt the load back to
position it for travel. Travel in accordance with the requirements set forth in Section
1 - General Safety Practices and Section 5 - Attachments.

Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Move boom/attachment to 4 ft (1,2 m) off ground.
4. Observe level indicator to determine whether machine must be leveled prior to
lifting load.

Important things to remember:

Never raise the boom/attachment more than 4 ft (1,2 m) above ground unless
telehandler is level.
The combination of sway and load could cause the telehandler to tip over.

The telehandler is designed to permit swaying the main frame 8 to left or right to
compensate for uneven ground conditions.

4-6

31200148

Section 4 - Operation
Placing the Load
Before placing any load be sure that:
The landing point can safely support the weight of the load.
The landing point is level; front to back and side to side.
Use the capacity chart to determine safe boom extension range. See Use of the
Capacity Chart on page 5-4.
Align forks at the level load is to be placed, then position boom slowly until load is
just above area where it is to be placed.
Lower the boom until the load rests in position and the forks are free to retract.

Disengaging the Load

Once the load has been placed safely at the landing point, proceed as follows:
1. With the forks free from the weight of the load, the boom can be retracted
and/or the telehandler can be backed away from under the load if surface will
not change level condition of telehandler.
2. Lower the carriage.
3. The telehandler can now be driven from the landing location to continue work.

31200148

4-7

Section 4 - Operation
4.3

OPERATING WITH A SUSPENDED LOAD

Lift Load Safely

You must know the weight and load center of every load you lift. If you are not
sure of the weight and load center, check with your supervisor or with the
supplier of the material.

WARNING
TIP OVER HAZARD. Exceeding lift capacity of the telehandler could damage the
equipment and/or cause tip over.
Know the rated load capacities (refer to Section 5) of the telehandler to
determine the operating range in which you can safely lift, transport and place a
load.

Picking Up a Suspended Load

Note the conditions of the terrain. Adjust travel speed and reduce amount of load
if conditions warrant.
Avoid lifting double-tiered loads.
Make sure load is clear of any adjacent obstacles.
NEVER operate telehandler without a proper and legible capacity chart in the
operator cab for the telehandler/attachment combination you are using.
Only use approved lifting devices rated for the lifting of the load.
Identify the proper lifting points of the load, taking into consideration the center of
gravity and load stability.
Ensure to always properly tether loads to restrict movement.
Refer to See Use of the Capacity Chart on page 5-4. for proper lifting guidelines
in addition to the appropriate capacity chart in the operator cab.

4-8

31200148

Section 4 - Operation
Transporting a Suspended Load

OZ3160

OW0130

Travel in accordance with the requirements set forth in Section 1 - General

Safety Practices and Section 5 - Attachments.
For additional requirements, refer to the appropriate capacity chart in the
operator cab.

Important things to remember:

Ensure the boom is fully retracted.
Never raise the load more than 11.8 in (300 mm) above ground surface or the
boom more than 45.
The combination of frame leveling and load could cause the telehandler to tip
over.
The guide men and operator must remain in constant communication (verbal or
hand) and be in visual contact with the operator at all times.
Never place the guide men between the suspended load and the telehandler.
Only transport the load at walking speed, 0.9 mph (0.4 m/s), or less.

Leveling Procedure
1. Position machine in best location to lift or place load.
2. Apply parking brake and move transmission control lever to NEUTRAL.
3. Move boom so load is no more than 11.8 in (300 mm) above ground surface
and boom/or boom is raised no more than 45.
4. Observe level indicator to determine whether machine must be leveled prior to
lifting load. Level machine with frame level joystick.
The telehandler is designed to permit leveling the main frame 8 to left or right to
compensate for uneven ground conditions.

31200148

4-9

Section 4 - Operation
Placing a Suspended Load
Before placing any load be sure that:
The landing point can safely support the weight of the load.
The landing point is level; front to back and side to side.
Use the capacity chart to determine safe boom extension range. See Use of the
Capacity Chart on page 5-4.
Align load at the level load is to be placed, then position boom slowly until load is
just above area where it is to be placed.
Ensure that the guide men and operator remain in constant communication
(verbal or hand) when placing the load.

Disengaging a Suspended Load

Never place the guide men between the suspended load and the telehandler.
Once at the destination of the load, ensure to bring the telehandler to a complete
stop and apply the park brake prior to disengagement of the lifting devices and
tethers.

4-10

31200148

Section 4 - Operation
4.4

LOADING AND SECURING FOR TRANSPORT

Tiedown
Front

Rear

OX0381

1. Level the telehandler prior to loading.

2. Using a spotter, load the telehandler with boom as low as possible.
3. Once loaded, apply parking brake and lower boom until boom or attachment is
resting on deck. Move all controls to Neutral, stop engine and remove ignition
key.
4. Secure machine to deck by passing chains through the designated tiedown
points as shown in the figure.
5. Do not tiedown front of boom.
Note: The user assumes all responsibility for choosing the proper method of
transportation and tie-down devices, making sure the equipment used is capable of
supporting the weight of the vehicle being transported and that all manufacturers
instructions and warnings, regulations and safety rules of their employer, the
Department of Transportation and/or any other state or federal laws are followed.

WARNING
TELEHANDLER SLIDE HAZARD. Before loading telehandler for transport,
make sure deck, ramps and telehandler wheels are free of mud, snow and ice.
Failure to do so could cause telehandler to slide.

31200148

4-11

Section 4 - Operation
Lifting
When lifting machine, it is very important that the lifting device and equipment is
attached only to designated lifting points. If machine is not equipped with lifting
lugs contact JLG Product Safety for information.
Make adjustments to the lifting device and equipment to ensure the machine will
be level when elevated. The machine must remain level at all times while being
lifted.
Ensure that the lifting device and equipment is adequately rated and suitable for
the intended purpose. See Section 9 - Specifications for machine weight.
Remove all loose items from machine prior to lifting.
Lift machine with smooth, even motion. Set machine down gently. Avoid quick or
sudden motions that could cause shock loads to machine and/or lifting devices.

4-12

31200148

Section 5 - Attachments

SECTION 5 - ATTACHMENTS
5.1

APPROVED ATTACHMENTS

To determine if an attachment is approved for use on the specific telehandler you are
using, perform the following prior to installation.
Before S/N 0160037689
The attachment model/option number on the attachment identification plate must
match the attachment number on a capacity chart located in the operator cab.
The model on the capacity chart must match the model telehandler being used.
The load center of the fork (if equipped) must match the load center as indicated
on the capacity chart.
Hydraulically powered attachments must only be used on machines equipped
with auxiliary hydraulics.
Hydraulically powered attachments that require auxiliary electrics must only be
used on machines equipped with auxiliary hydraulics and electrics.
S/N 0160037689 & After
The attachment type, weight, dimensions and load center must be equal to or
less than the data shown on a capacity chart located in the operator cab.
The model on the capacity chart must match the model telehandler being used.
Hydraulically powered attachments must only be used on machines equipped
with auxiliary hydraulics.
Hydraulically powered attachments that require auxiliary electrics must only be
used on machines equipped with auxiliary hydraulics and electrics.

If any of the above conditions are not met, do not use the attachment. The
telehandler may not be equipped with the proper capacity chart or the attachment
may not be approved for the model telehandler being used. Contact JLG or a local
distributor for further information.

31200148

5-1

Section 5 - Attachments
5.2

UNAPPROVED ATTACHMENTS

Do not use unapproved attachments for the following reasons:

Range and capacity limitations for will fit, homemade, altered, or other
non-approved attachments cannot be established.
An overextended or overloaded telehandler can tip over with little or no warning
and cause serious injury or death to the operator and/or those working nearby.
The ability of a non-approved attachment to perform its intended function safely
cannot be assured.

WARNING
Use only approved attachments. Attachments which have not been approved for
use with your telehandler could cause machine damage or an accident.

5-2

31200148

Section 5 - Attachments
5.3

TELEHANDLER/ATTACHMENT/FORK CAPACITY
1
3

2
OW0550

Prior to installing the attachment verify it is approved and the telehandler is equipped
with the proper capacity chart. See Approved Attachments on page 5-1.
To determine the maximum capacity of the telehandler and attachment, use the
smallest of the following capacities:
Capacity stamped on the attachment identification plate (1).
Fork capacities and load centers are stamped on the side of each fork (2)
(if equipped). This rating specifies the maximum load capacity that the individual
fork can safely carry at the maximum load center (3). Total attachment capacity is
multiplied by the number of forks on the attachment (if equipped), up to the
maximum capacity of the attachment.
Maximum capacity as indicated on the proper capacity chart. See Approved
Attachments on page 5-1.
When the load rating of the telehandler differs from the capacity of the forks or
attachment, the lower value becomes the overall load capacity.
Use the proper capacity chart to determine maximum capacity at various machine
configurations. Lifting and placing a load may require use of more than one capacity
chart based on machine configuration.
Other than block forks, all forks should be used in matched pairs, block forks used in
matched sets.

WARNING
Never use an attachment without the appropriate JLG approved capacity chart
installed on the telehandler.

31200148

5-3

Section 5 - Attachments
5.4

USE OF THE CAPACITY CHART

To properly use the capacity chart (see page 5-5), the operator must first determine
and/or have the following:
1. A JLG approved attachment. See Approved Attachments on page 5-1.
2. The proper Capacity Chart(s).
3. Weight of the load being lifted.
4. Load placement information:
a. HEIGHT where the load is to be placed.
b. DISTANCE from the front tires of the telehandler where the load is to be
placed.
5. On the Capacity Chart, find the line for the height and follow it over to the
distance.
6. The number in the load zone where the two cross is the maximum capacity for
this lift. If the two cross at a division between zones, the smaller number must
be used.
The number in the load zone must be equal to or greater than the weight of the load
to be lifted. Determine the limits of the load zone on the Capacity Chart and keep
within these limits.

Capacity Indicator Locations

Boom
Angle
Indicator

Boom Extension
Indicator

50

60

70

80

Attachment
Identification
Plate

40
-10

10

20

30

Fork
Weight
Stamp

OX0190

5-4

31200148

Section 5 - Attachments
Sample Capacity Chart
This Capacity Chart may
be used with this model
ONLY. The model of your
telehandler is indicated
on the boom or chassis.

MODEL
XXXXX

DEDUCT 350 LBS

FROM ALL CAPACITIES
WHEN MACHINE IS
EQUIPPED WITH WINCH
48'

69

5
50

36'

12'
10

8'

3000 LBS

20

16'

11 0 0 L B S

20'

2000 LBS

30

4000 LBS

24'

9000 LB
S

40

7000 LB
S

32'
28'

Boom Angle

60

40'

5000 LBS
6000 LBS

48" & 72"

CARRIAGES

RATED CAPACITY @ 2 FT. LOAD CENTER

44'

Boom
Extension

2
1

4'
0

0'
-6

-4'
-8'

36'

32'

28'

24'

20'

16'

12'

USE WITH:
1234-5678 48" CARRIAGE
8765-4321 72" CARRIAGE

8'

4'

0'

Load zones indicate

the maximum weight
XXXX-XXXX

OWO650

These numbers must

match the model/option
Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.

WARNING
TIP OVER HAZARD. All loads shown on rated capacity chart are based on
machine being on firm ground with frame level (see page 4-6); the forks being
positioned evenly on carriage; the load being centered on forks; proper size tires
being properly inflated; and the telehandler being in good operating condition.

31200148

5-5

Section 5 - Attachments
Example
A contractor owns a model xxxxx telehandler with a 48" Carriage. He knows this
attachment may be used with his model since:
The attachment model/option number, matches the attachment number on the
capacity chart.
The capacity chart is clearly marked for model xxxxx and corresponds with
machine configuration being used.
Below are examples with various conditions the contractor may encounter and
whether or not the load may be lifted.
Load Weight

Distance

Height

OK to Lift

2000 lbs (907 kg)

20 ft (6,1 m)

12 ft (3,6 m)

Yes

3000 lbs (1361 kg)

25 ft (7,6 m)

19 ft (5,8 m)

NO

6000 lbs (2722 kg)

12 ft (3,6 m)

14 ft (4,3 m)

Yes

8000 lbs (3629 kg)

8 ft (2,4 m)

30 ft (9,1 m)

NO

MODEL
XXXXX

DEDUCT 350 LBS

FROM ALL CAPACITIES
WHEN MACHINE IS
EQUIPPED WITH WINCH
48'

69

5
50

36'

12'

Example 1

10

8'

3000 LBS

20

16'

11 0 0 L B S

20'

2000 LBS

30

9000 LB
S

24'

4000 LBS

28'

7000 LB
S

32'
40

Example 2

60

40'

5000 LBS
6000 LBS

48" & 72"

CARRIAGES

RATED CAPACITY @ 2 FT. LOAD CENTER

44'

Example 4
3

2
1

Example 3

4'
0

0'
-6

-4'
-8'

36'

32'

28'

24'

20'

16'

12'

8'

4'

0'

USE WITH:
1234- 5678 4 8 " CARRIAGE
8765- 4321 7 2 " CARRIAGE
XXXX-XXXX

OWO660

Note: This is a sample capacity chart only! DO NOT use this chart, use the one
located in your operator cab.

5-6

31200148

Section 5 - Attachments
5.5

ATTACHMENT INSTALLATION

2
3
5
4
OX0440

1. Attachment
2. Attachment Pivot Pin Recess
3. Quick Switch
4. Lock Pin
5. Retaining Pin

This installation procedure is designed for one-person operation.

1. Retract Quick Switch to provide clearance.

Check to be sure lock pin is secured in out position
with retainer pin.

OX0450

2. Align attachment pivot pin with recess in

attachment. Raise boom slightly to engage
attachment pivot pin in recess.

OX0460

31200148

5-7

Section 5 - Attachments

3. Engage Quick Switch.

OX0470

4. Shut off engine. Exit cab and remove retainer pin

and slide lock pin in fully. Secure lock pin in locked
position using retainer pin.

OX0470

5. If equipped, swing attachment saddles down and

pin in place.

OX0480

6. If equipped, connect auxiliary hydraulic hoses.

7. If equipped, connect auxiliary electric harness.

WARNING
CRUSH HAZARD. Always be certain that carriage or attachment is properly
positioned on boom and is secured by lock pin and retainer pin. Failure to ensure
proper installation could permit carriage/attachment/load to disengage.

5-8

31200148

Section 5 - Attachments
5.6

ADJUSTING/MOVING FORKS

Carriages may have different locations where forks can be positioned. Two different
methods can be used for repositioning, depending upon the carriage structure.
Note: Apply a light coating of appropriate lubricant to ease sliding of forks or fork
bar.

To slide forks:
1. Ensure attachment is properly installed. Refer to Attachment Installation on
page 5-7.
2. Elevate attachment to approximately 5 ft (1,5 m) and tilt carriage forward until
fork heel is free from attachment.
3. Stand at the side of the carriage. To slide fork toward the center of the carriage,
push the fork near the fork eye. To slide fork toward the edge of the carriage,
pull the fork near the fork eye. To avoid pinching, do not place fingers or thumb
between the fork and carriage structure.

If removing fork bar is necessary:

1. Rest forks on ground.
2. Remove fork bar.
3. Reposition forks.
4. Reinstall the fork bar and fork bar retaining mechanism(s).

31200148

5-9

Section 5 - Attachments
5.7

ATTACHMENT OPERATION

Capacities and range limits for the telehandler change depending on the
attachment in use.
Separate attachment instructions must be kept in Manual Holder in cab with this
Operation & Safety Manual. An additional copy must be kept with the attachment
if it is equipped with a manual holder.

NOTICE
EQUIPMENT DAMAGE. Some attachments may contact the front tires or
machine structure when the boom is retracted and the attachment is rotated.
Improper use of attachment may result in attachment or machine structural
damage.

NOTICE
EQUIPMENT DAMAGE. Avoid contact with any structure or object when lifting a
load. Maintain clearance around boom structure and load. Failure to maintain
clearance may result in attachment or machine structural damage.

5-10

31200148

Section 5 - Attachments
Carriage w/Forks

OY0690

Description
P/N
Carriage, 48 in .............................................................. 91405073
Carriage, 72 in .............................................................. 91405074
Carriage, Drywall .......................................................... 91405077
Fork, Cubing 2x2x48 in................................................. 91403359
Fork 1-3/4x4x48 in........................................................ 91403364
Fork, Drywall 1-3/4x4x48 in .......................................... 91403366
Fork 2x6x60 in .............................................................. 91403580
Fork 2-1/4x5x48 in........................................................ 91563141
Fork 2-1/4x6x60 in........................................................ 91563142

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

1
TILT SPEED
CONTROL

OY0332

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The tilt lever (2) controls the fork tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.

Installation Procedure:
Refer to Attachment Installation on page 5-7.

31200148

5-11

Section 5 - Attachments
Crane Hook
Description
P/N
Crane Hook................................................................... 91565094
OY0640

Use Appropriate Carriage Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

1
TILT SPEED
CONTROL

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The tilt lever (2) controls the crane hook tilt.
Move lever forward to tilt down.
Move lever back to tilt up.

Installation Procedure:
Refer to Attachment Installation on page 5-7.
Secure the crane hook to the forks by sliding the crane hook onto the parent
forks and install the retaining pin behind the vertical shank of the fork.

5-12

31200148

Section 5 - Attachments
Operation:
Pallet or lumber forks of an appropriate load rating must be used. Do not use with
cubing or block forks.
Weight of crane hook and rigging must be included as part of total load being
lifted.
Do not use crane hook with attachments capable of rotating (i.e. side tilt and
swing carriages) without disabling the rotation feature(s).

31200148

5-13

Section 5 - Attachments
Bucket
Description
P/N
Bucket 60 in - 3/4 yd3 ................................................... 91405054
Bucket 74 in - 1-1/4 yd3 ................................................ 91405055
Bucket 102 in - 1-1/4 yd3 .............................................. 91405071
OZ0730

Use Appropriate Bucket Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

1
TILT SPEED
CONTROL

OY0342

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The tilt lever (2) controls bucket tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.

Installation Procedure:
Refer to Attachment Installation on page 5-7.

5-14

31200148

Section 5 - Attachments
Equipment Damage Precautions
Drive into stockpile smoothly with boom fully retracted to load bucket. Loading
bucket with boom extended could damage boom or extension chains/cables. Do
not corner-load bucket.
Do not use bucket as a lever to pry material. Excessive prying forces could
damage bucket.
Do not use bucket for "back dragging." This could cause severe damage to quick
switch and retraction cables/chains.

Operation:
Raise or lower boom to appropriate height for loading material from stockpile.
Align telehandler with face of stockpile and drive slowly and smoothly into pile to
load bucket.
Tilt bucket up far enough to retain load and back away from pile.
Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
Tilt bucket down to dump load.

31200148

5-15

Section 5 - Attachments
Truss Boom
Description
P/N
Truss Boom 10 ft w/winch .............................................91405081
Truss Boom 10 ft...........................................................91405083
Truss Boom 15 ft w/winch .............................................91405080
Truss Boom 15 ft...........................................................91405082

OY0570

Use Truss Boom Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

TILT SPEED
CONTROL

OY0351

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
Truss Boom Control:
The rear joystick (2) controls truss boom tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.

5-16

31200148

Section 5 - Attachments
Truss Boom W/Winch Control:
The auxiliary joystick (3) controls the truss boom mounted winch.
Move joystick up to lower cable.
Move joystick down to raise cable.

Installation Procedure:
Refer to Attachment Installation on page 5-7.

WARNING
CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable
drum at all times. Failure to comply could cause object or load to fall.

31200148

5-17

Section 5 - Attachments
Boom Head-Mounted Winch
Description
P/N
Winch............................................................................91515036

OY0650

Use Carriage Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

Suspend loads in accordance with requirements set forth in Section

1 - General Safety Practices.

OY0660

The joystick (1) controls lift/lower and the extend/retract movement of the boom.

Winch Control:
The auxiliary control joystick (2) controls the winch.
Move joystick up to lower cable.
Move joystick down to raise cable.

WARNING
CRUSH HAZARD. Maintain a minimum of three wraps of wire rope on the cable
drum at all times. Failure to comply could cause object or load to fall.

5-18

31200148

Section 5 - Attachments
6 ft (1,8 m) Mast with 48 or 72 in (1,2 & 1,8 m) Carriage
Description
P/N
Mast 48 in ......................................................................91405060
Mast 72 in ......................................................................91405061
OY0580

Use 6 ft Mast Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

TILT SPEED
CONTROL

OY0360

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The rear joystick (2) controls the mast tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.
To Raise/Lower Mast:
The auxiliary control joystick (3) controls the lift/lower movement of the mast.
Move joystick up to lower forks.
Move joystick down to raise forks.

31200148

5-19

Section 5 - Attachments
Installation Procedure:
Refer to Attachment Installation on page 5-7.

WARNING
CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to
comply could cause object or load to fall.

Operation:
Lower forks fully in mast before engaging load.
Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.
Use a signal person to assist in positioning of load if necessary.

5-20

31200148

Section 5 - Attachments
6 ft (1,8 m) - 100 Swing Mast W/Side Shift
Description
P/N
Mast w/ 48 in Fork .........................................................91405070
Mast w/ 60 in Fork .........................................................91415026
GNINRAW

OY0590

Use 6 ft Swing Mast Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

T
HIF
ES
SID AST

ING

SW

+
TILT SPEED
CONTROL

T
HIF
ES
SID AST

IN
SW

+
3

T
HIF
ES
SID AST

ING

SW

+
OY0371

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The rear joystick (2) controls the mast tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.

31200148

5-21

Section 5 - Attachments
To Swing:
Pull Swing Switch (4) back, located on dash panel to activate Swing function.
With Swing Switch activated, move the auxiliary control joystick (3) down to
swing forks right or up to swing forks left.
To Raise/Lower Mast:
Pull Forks Raise/Lower Switch (5) back, located on dash panel to activate Forks
Raise/Lower function. With Forks Raise/Lower Switch activated, move the
auxiliary control joystick (3) down to raise forks or up to lower forks.
To Side Shift:
Press Side Shift Switch (6) forward, located on dash panel to activate Side Shift
function. With Side Shift Switch activated, move the auxiliary control joystick (3)
down to shift forks right or up to shift forks left.

Installation Procedure:
Refer to Attachment Installation on page 5-7.

WARNING
CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before
swinging load to side. Swinging unlevel forks could cause load to slide off forks.

WARNING
CRUSH HAZARD. Do not use mast to push or pull objects or load. Failure to
comply could cause object or load to fall.

Operation:
Always lower forks fully in mast and position forks straight ahead before
engaging load.
To drive with a load, lower forks fully in mast, keep forks pointed forward and
travel in accordance with the requirements set forth in Section 1 - General Safety
Practices.
Use a signal person to assist in positioning load if necessary.

5-22

31200148

Section 5 - Attachments
Swing Carriage
Description
P/N
100 Swing Carriage .................................................... 91405075
100 Swing Drywall Carriage ....................................... 91405078
180 Swing Carriage .................................................... 91563146
OY0670

Use Swing Carriage Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

1
3

TILT SPEED
CONTROL

OY0680

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The rear joystick (2) controls the carriage tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.

To Swing:
The auxiliary control joystick (3) controls the Swing function.
Move joystick up to swing left.
Move joystick down to swing right.

31200148

5-23

Section 5 - Attachments

WARNING
CRUSH HAZARD. Always level forks (horizontally) and telehandler frame before
swinging load to side. Swinging unlevel forks could cause load to slide off forks.

WARNING
CRUSH HAZARD. Do not use swing carriage to push or pull objects or load.
Failure to comply could cause object or load to fall.

WARNING
CRUSH HAZARD. Use retaining pin (if equipped) for locking swing frame to fixed
frame when carrying loads greater than 5000 lb. Failure to comply could cause
object or load to fall.

Operation:
To drive with a load, keep forks pointed forward and travel in accordance with the
requirements set forth in Section 1 - General Safety Practices.

5-24

31200148

Section 5 - Attachments
Side Tilt Carriage
Description
P/N
Side Tilt 48 in.................................................................91405101
Side Tilt 72 in.................................................................91405079
OY0690

Use Side Tilt Attachment Capacity Chart

To determine maximum capacity, refer to Telehandler/Attachment/Fork Capacity on
page 5-3.

TILT SPEED
CONTROL

OY0380

The joystick (1) controls lift/lower and the extend/retract movement of the boom.
The rear joystick (2) controls the mast tilt.
Move joystick forward to tilt down.
Move joystick back to tilt up.
To Side Tilt:
The auxiliary control joystick (3) controls the carriage side tilt.
Move joystick up to (side) tilt carriage left.
Move joystick down to (side) tilt carriage right.

31200148

5-25

Section 5 - Attachments
Installation Procedure:
Refer to Attachment Installation on page 5-7.

Operation:
Approach load with forks centered on load and stop telehandler.
Level telehandler before side tilting carriage to engage load.
Side tilt carriage to left or right to align forks with load and engage load.
Raise load slightly and then level carriage side to side.
Travel in accordance with requirements set forth in Section 1 - General Safety
Practices.

5-26

31200148

Section 5 - Attachments
Personnel Work Platform
The operator and personnel in platform must read and understand the
separate personnel work platform manual prior to installing and using a
platform.

Preparation and Setup

1. Check to ensure the personnel platform is securely attached at the Quick
Switch or is securely attached to the forks and/or carriage is using a fork
mounted personnel work platform. Follow installation procedure on page 5-7 for
JLG Quick Switch mounted personnel work platforms.
2. Ensure the telehandler is on a firm surface and is level.
3. Engage the park brake. Blocking the wheels is also recommended.
4. Level the platform, both side to side (frame sway) and front to back
(attachment tilt).
5. Keep area under the platform free from personnel.
6. When personnel are on platform, the operator must remain seated in cab with
personnel in direct line of sight.
7. DO NOT lift or carry persons in the bucket or on forks.
Never tilt the platform forward, rearward, or sway the machine when the platform is
occupied. Serious injury or death could result.

31200148

5-27

Section 5 - Attachments

This Page Intentionally Left Blank

5-28

31200148

Section 6 - Emergency Procedures

SECTION 6 - EMERGENCY PROCEDURES

6.1

TOWING A DISABLED PRODUCT

The following information assumes the telehandler cannot be moved under its
own power.

Before moving the telehandler, read all of the following information to understand
options available. Then select the appropriate method.
The steering system permits manual steering if engine or power assist feature
fails; however, steering will be slow and will require much greater force.
DO NOT attempt to tow a telehandler that is loaded or the boom/attachment is
raised above 4 ft (1,2 m).

Moving Short Distances

If it is only necessary to move telehandler a short distance, less than 100 ft
(30 m), it is permissible to use a vehicle of sufficient capacity to tow the unit with
no previous preparation.

Moving Longer Distances

If the telehandler must be moved longer distances, it must be loaded onto a
trailer of sufficient capacity.

Contact your local Authorized Distributor for specific instructions if neither of

these methods are applicable.

31200148

6-1

Section 6 - Emergency Procedures

6.2

EMERGENCY LOWER OF BOOM

In the event of total loss of engine power or hydraulic pump failure with an elevated
load, the situation must be properly evaluated and dealt with on an individual basis.
Contact your local Authorized Distributor for specific instructions.
Secure the telehandler using the following procedures:
1. Clear the area around telehandler of all personnel.
2. Engage the parking brake. Place the transmission control lever in NEUTRAL.
3. Block all four wheels.
4. Section off a large area under the boom with string or tape to restrict any
personnel from entering this area.

6.3

EMERGENCY EXIT FROM ENCLOSED CAB

IIn an emergency, an escape hammer, located directly below the rear window in an
enclosed cab, can be used to exit the telehandler.

ANGUS-PALM 005413

OWO740

6-2

31200148

Section 7 - Lubrication and Maintenance

SECTION 7 - LUBRICATION AND MAINTENANCE

7.1

INTRODUCTION

Service the product in accordance with the maintenance schedule on the following
pages.
Service intervals are based on machine usage of 1500 hours annually. Use of your
product may vary significantly and you must adjust service frequency for your usage
to obtain maximum service life.

A
A

1
VIEW A-A

OX0370

The Service Instruction Plate (1) is located as indicated in figure. It contains general
service instructions that must be followed to keep this product in good operating
condition. The Operation & Safety Manual and Service Manual contain more
detailed service information with specific instructions.

Clothing and Safety Gear

Wear all the protective clothing and personal safety devices issued to you or
called for by job conditions.
DO NOT wear loose clothing or jewelry that can get caught on controls or moving
parts.

31200148

7-1

Section 7 - Lubrication and Maintenance

7.2

GENERAL MAINTENANCE INSTRUCTIONS

Prior to performing any service or maintenance on the telehandler, follow the

shut-down procedure on page 4-4 unless otherwise instructed. Ensure
telehandler is level, for proper fluid readings.
Clean lubrication fittings before lubricating.
After greasing telehandler, cycle all functions several times to distribute
lubricants. Perform this maintenance procedure without attachment installed.
Apply a light coating of engine oil to all linkage pivot points.
Intervals shown are for normal usage and conditions. Adjust intervals for
abnormal usage and conditions.
Drain engine and gear cases after operating when oil is hot.
Check all lubricant levels when lubricant is cool. For ease of filling hydraulic
reservoir, use a funnel with a hose or flexible tube for best results.
Note: Be certain to check boom cable adjustment every 5 weeks or 250 hours and
adjust as required. Cable damage can occur if cable is not adjusted properly.

WARNING
CUT/CRUSH/BURN HAZARD. Do not perform service or maintenance on the
machine with the engine running, with the exception of the transmission level and
hydraulic return filter indicator checks.

7-2

31200148

Section 7 - Lubrication and Maintenance

7.3

SERVICE AND MAINTENANCE SCHEDULES

10 & 1st 50 Hour Maintenance Schedule

EVERY

10

Check Fuel
Level

Check Tire
Pressure

Air Filter
Restriction
Indicator

Check Engine
Oil Level

Check Hydraulic
Oil Level

Check Hydraulic
Return Filter
Indicator

1st

50

LB/F
T (N
m)

Change
Axle Oil

Change Wheel
End Oil

Change Engine
Oil & Filter

Check Wheel
Lug Nut
Torque

Check Boom
Cable Tension

OX0201

31200148

7-3

Section 7 - Lubrication and Maintenance

50, 250 & 500 Hour Maintenance Schedule

EVERY

50

Drain Fuel/
Water
Separator

Check Engine
Coolant Level

Check
Battery

Lubrication
Schedule

EVERY

250

Change Engine
Oil and
Filter*

Check Front
Axle
Oil Level

Check Front &

Rear Wheel
End Oil Levels

Check Boom
Cable
Tension

Check Boom
Bearing
Pads

Check
Rear Axle
Stabilization

Air Filter
Vacuator
Valve

Check
Fan Belt

EVERY

500

LB/F
T (N
m)

Change Fuel
Filter

Check Wheel
Lug Nut
Torque
OX0530

Note: Engine oil & filter service interval can be extended, see page 7-12 for details.

7-4

31200148

Section 7 - Lubrication and Maintenance

1000 & 1500 Hour Maintenance Schedule

EVERY

1000

Change Front
Axle Oil

Change Front &

Rear Wheel
End Oil

Change
Hydraulic Tank
Breather

EVERY

1500

Change
Engine Coolant

Change
Hydraulic
Fluid & Filters
OY1041

31200148

7-5

Section 7 - Lubrication and Maintenance

7.4

LUBRICATION SCHEDULES

50 Hour Lubrication Schedule

EVERY

Mystik Tetrimoly Grease

(NLGI 2 GC-LB)

50

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282

** unknown **
** unknown **
2
NO

DIESEL FUEL IS FLAMMABLE

EXTINGUISH ALL OPEN FLAME AND
SMOKING MATERIALS WHEN REFUELING
INJURY OR DEATH COULD RESULT
FROM FIRE.

9114-3286

7733-3027

NO RIDERS PERMITTED ON HANDLER.

OPERATOR ONLY IN MACHINE
WHILE RUNNING.
RIDERS COULD FALL OFF MACHINE
CAUSING SERIOUS INJURY OR DEATH.

9114-3283

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282

DO NOT GO NEAR LEAKS

* High pressure oil easily punctures skin causing serious injury, gangrene or death.
* If injured, seek emergency medical help. Immediate surgery is required to remove oil.
* Do not use finger or skin to check for leaks.
* Lower load or relieve hydraulic pressure before loosening fittings.
10814B

OY0280

7-6

31200148

Section 7 - Lubrication and Maintenance

250 Hour Lubrication Schedule

EVERY

250

Mystik Tetrimoly Grease

(NLGI 2 GC-LB)

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282

** unknown **
** unknown **
2
NO
1

7733-3027

STAY CLEAR OF PINCH POINT AREA

ANYTIME ENGINE IS RUNNING.
BEING IN PINCH POINT AREA COULD
CAUSE SERIOUS INJURY OR DEATH.
9114-3282

DO NOT GO NEAR LEAKS

* High pressure oil easily punctures skin causing serious injury, gangrene or death.
* If injured, seek emergency medical help. Immediate surgery is required to remove oil.
* Do not use finger or skin to check for leaks.
* Lower load or relieve hydraulic pressure before loosening fittings.
10814B

OY0290

31200148

7-7

Section 7 - Lubrication and Maintenance

7.5

OPERATOR MAINTENANCE INSTRUCTIONS

Fuel System

10

A. Fuel Level Check

OW0970

OW0990

1
FUEL F

80

240

16

100

10

TEMP

OIL

VOLT

OY0070

1. Check fuel gauge (1) located on instrument panel in cab.

2. If fuel is low, proceed to fuel source and perform Shut-Down Procedure on
page 3-5.
3. Locate fuel tank (2), turn fuel tank cap (3) and remove from filler neck (4). Add
diesel fuel as needed. Replace fuel tank cap.

Note: Replenish diesel fuel at end of each work shift to minimize condensation.

7-8

31200148

Section 7 - Lubrication and Maintenance

50

B. Drain Fuel/Water Separator

5-FRONT

OX0130

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover.
3. Loosen drain cock (4) on underside of fuel filter (5) and allow all water to drain
into a glass until clear fuel is visible. Tighten drain cock.
4. Close and secure the engine cover.

31200148

7-9

Section 7 - Lubrication and Maintenance

Air Intake System

10

A. Air Filter Restriction Indicator Check

4
1
6
3

OX0331

1. Perform Shut-Down Procedure on page 4-4.

2. Locate air cleaner (1) and check restriction indicator (2). If red band is visible,
filter(s) must be replaced.
3. Remove dust from vacuator valve (3) by squeezing bottom of valve to allow
loose particles to fall out.

Note: Only remove canister cover to service the elements as restriction indicator
indicates. Excessive access to check an element can lead to premature element
failure.

7-10

31200148

Section 7 - Lubrication and Maintenance

B. Element Change (as restriction indicator indicates)
1. Unlock air cleaner cover (4), turn counterclockwise and remove from air cleaner
canister (5).
2. Remove outer primary element (6) and inspect for damage. Damaged elements
should not be reused.
3. Thoroughly clean the interior of the air cleaner canister and vacuator valve.
4. Replace inner safety element (7) after every third primary element change. If
replacing the inner safety element at this time, carefully slide the element out
and replace with new element.
5. Slide the new primary element over the inner element making sure the sealing
edge is flush with the base of the air cleaner.
6. Position air cleaner cover in place, turn clockwise and lock into position.
7. Depress button on restriction indicator to reset.

Note: An inner safety element should never be washed or reused. Always install a
new element.

31200148

7-11

Section 7 - Lubrication and Maintenance

Engine Oil

10

A. Engine Oil Level Check

AD

2
3

OX0140

1. Perform Shut-Down Procedure on page 4-4.

2. Remove dipstick (1) and check oil mark. The oil should be between the full (2)
and add (3) marks within the crosshatched area of the dipstick. Replace
dipstick.
3. If oil is low, open the engine cover, remove oil fill cap (4) and add motor oil to
bring oil up to the full mark in the crosshatch area.
4. Replace oil fill cap.
5. Close and secure the engine cover.

Note: The standard service interval for engine oil and filter is 250 hours maximum.
If an extended service interval is desired, see the engine manual for specific
guidlines for optimizing oil change intervals.

7-12

31200148

Section 7 - Lubrication and Maintenance

Hydraulic Oil

A. Hydraulic Oil Level Check

10
7

5
6

2-FRONT

OX0180

1. Be sure all cylinders are fully retracted and machine is level.

2. Perform Shut-Down Procedure on page 4-4.
3. Check level of hydraulic oil in tank at the sight gauge (6) on the hydraulic
tank (5). The oil level should be visible in the gauge window.
4. If hydraulic oil is low, open the tank cover and remove oil fill cap (7) from filler
neck. Add hydraulic fluid to bring oil up to the upper mark on the sight gauge.
5. Replace hydraulic oil fill cap.
6. Close and secure the tank cover.

31200148

7-13

Section 7 - Lubrication and Maintenance

Tires

A. Tire Air Pressure Check

10

1. Perform Shut-Down Procedure on page 4-4.

2. Remove valve stem cap.
3. Check tire pressure using a good quality gauge.
4. Add air if required.
13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply ............................ 65 psi (4.5 bar)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply ................................. 65 psi (4.5 bar)
13.00 x 24, G-2/L-2 Radial - 1 Star ............................................. 70 psi (4.8 bar)
15.50 x 25, G-2/L-2 Bias-Ply Traction - 12 Ply ............................ 58 psi (4.0 bar)
15.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply ................................. 65 psi (4.5 bar)
15.50 x 25, G-2/L-2 Radial - 1 Star ............................................. 70 psi (4.8 bar)
5. Replace valve stem cap.

B. Tire Damage
For pneumatic tires, JLG recommends that when any cut, rip or tear is discovered
that exposes sidewall or tread area cords in the tire, measures be taken to remove
the JLG product from service immediately. Arrangements must be made for
replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG recommends that when any of the following
are discovered, measures must be taken to remove the product from service
immediately. Arrangements must be made for replacement of the tire or tire
assembly.
A smooth even cut through the cord piles which exceeds 3 in (7.5 cm) in total
length.
Any tears or rips (ragged edges) in the cord plies which exceeds 1 in (2.5 cm) in
any direction
Any punctures which exceed 1 in (2.5 cm) in diameter.
If a tire is damaged but within the above noted criteria, the tire must be inspected
daily to ensure the damage has not propagated beyond the allowable criteria.

7-14

31200148

Section 7 - Lubrication and Maintenance

C. Tire and Wheel Replacement
JLG recommends a replacement tire to be the same size, ply and brand as originally
installed. Refer to the appropriate parts manual for ordering information. If not using
a JLG approved replacement tire, JLG recommends that replacement tires have the
following characteristics:
Equal or greater ply/load rating and size of original.
Tire tread contact width equal or greater than original.
Wheel diameter, width and offset dimensions equal to the original.
Approved for the application by the tire manufacturer (including inflation pressure
and maximum tire load).
Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire
assembly with a pneumatic tire. Due to size variations between tire brands, when
selecting and installing a replacement tire ensure both tires on the axle are the
same.
The rims installed have been designed for stability requirements which consist of
track width, tire pressure and load capacity. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written factory
recommendations, may result in unsafe condition regarding stability.

31200148

7-15

Section 7 - Lubrication and Maintenance

E. Wheel Installation
Torque lug nuts before first use and after each wheel removal.
Note: If machine is equipped with directional tire assemblies, the wheel and tire
assemblies must be installed with the directional tread pattern arrows facing in the
direction of forward travel.
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on
threads or nuts.
2. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to
350-400 lb-ft (475-543 Nm).

10

9
8

2
6

4
OY1220

WARNING
TIP OVER HAZARD. Lug nuts must be installed and maintained at the proper
torque to prevent loose wheels, broken studs and possible separation of wheel
from the axle.

7-16

31200148

Section 7 - Lubrication and Maintenance

Hydraulic Return Filter

10

A. Hydraulic Return Filter Indicator Check

OX0170

1. Apply park brake, shift transmission to "Neutral" and lower forks or attachment
to horizontal position.
2. Check hydraulic return filter indicator with engine at normal operating
temperature.
3. Have an assistant open the tank cover.
4. With the engine at full throttle and the assistant observing the indicator (2)
located on the hydraulic return filter (1), extend and retract the boom 10-12 ft
(3,0-3,7 m). The gauge should be within the green area.
5. Replace filter before the gauge reaches the red area on the indicator. If it
reaches the red area, the filter is too dirty and hydraulic oil is bypassing the
filter.
6. Close and secure the tank cover.

31200148

7-17

Section 7 - Lubrication and Maintenance

Engine Cooling System

50

A. Engine Coolant Level Check

OX0160

1. Perform Shut-Down Procedure on page 4-4.

2. Open the engine cover.
3. When coolant is cool, remove cap (1). Check coolant level in radiator.
4. If coolant is low, add coolant (50/50 mixture of ethylene glycol and water) as
required.
5. Replace radiator cap.
6. Close and secure the engine cover.

7-18

31200148

Section 7 - Lubrication and Maintenance

Battery

50

A. Battery Check

2-FRONT

CLM
05-09-97
4
YES
.
.
1
.
9114-9206
.

OX0150

1. Perform Shut-Down Procedure on page 4-4.

2. Remove the front cover.
3. Wearing eye protection, visually inspect the battery (2). Check terminals for
corrosion. Replace battery if it has a cracked, melted or damaged case.
4. Replace the front cover.

31200148

7-19

Section 7 - Lubrication and Maintenance

This Page Intentionally Left Blank

7-20

31200148

Section 8 - Additional Checks

SECTION 8 - ADDITIONAL CHECKS

This Page Intentionally Left Blank

31200148

8-1

Section 8 - Additional Checks

This Page Intentionally Left Blank

8-2

31200148

Section 9 - Specifications

SECTION 9 - SPECIFICATIONS
9.1

PRODUCT SPECIFICATIONS

Fluid and Lubrication Capacities

Engine Crankcase Oil
Capacity with Filter Change ...................................................15.5 quarts (14,7 liters)
Type of Oil ................................................................................................ 15W-40 CD
Fuel Tank
Capacity .................................................................................38 gallons (143,8 liters)
Type of Fuel.................................................................................................. #2 Diesel
Cooling System
System Capacity ....................................................................15.5 quarts (14,7 liters)
Type of Coolant ............................................................ 50/50 ethylene glycol & water
Hydraulic System
System Capacity .......................................................................43 gallons (163 liters)
Reservoir Capacity to Full Mark ...............................................20 gallons (75,7 liters)
Type of Oil ........................................Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46)
Axles
Housing Capacity (Front Axle) ...................................................5 gallons (18,9 liters)
Hubs (Rear Axle).....................................................................3 pints each (1,6 liters)
Type of Fluid ...................................... Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46

31200148

9-1

Section 9 - Specifications
Tires
Pressure
13.00 x 24, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic ......................................................................................65 psi (4.5 bar)
542 lb (246 kg) Foam .....................................................................60 psi (4.1 bar)
13.00 x 24, G-3/L-3 Bias Ply Rock - 12 Ply
Pneumatic ......................................................................................65 psi (4.5 bar)
542 lb (246 kg) Foam .....................................................................65 psi (4.5 bar)
13.00 x 24, G-2/L-2 Radial - 1 Star
Pneumatic ......................................................................................70 psi (4.8 bar)
542 lb (246 kg) Foam .....................................................................70 psi (4.8 bar)
15.50 x 25, G-2/L-2 Bias-Ply Traction - 12 Ply
Pneumatic ......................................................................................58 psi (4.0 bar)
600 lb (272 kg) Foam .....................................................................58 psi (4.0 bar)
15.50 x 25, G-3/L-3 Bias Ply Rock - 12 Ply
Pneumatic ......................................................................................65 psi (4.5 bar)
600 lb (272 kg) Foam .....................................................................65 psi (4.5 bar)
15.50 x 25, G-2/L-2 Radial - 1 Star
Pneumatic ......................................................................................70 psi (4.8 bar)
600 lb (272 kg) Foam .....................................................................70 psi (4.8 bar)
Wheel Lug Nut
Torque.............................................................................. 350-400 lb-ft (475-542 Nm)

Performance
Maximum Lift Capacity ..................................................................6,600 lb (2.994 kg)
Maximum Lift Height....................................................................... 42.79 ft (13,04 m)
Capacity at Maximum Height.........................................................6,000 lb (2.722 kg)
Maximum Forward Reach................................................................. 28.14 ft (8,58 m)
Capacity at Maximum Forward Reach..............................................1,000 lb (454 kg)
Reach at Maximum Height ................................................................. 5.05 ft (1,54 m)
Carriage Rotation ....................................................................................128 degrees
Maximum Travel Speed ............................................................20.5 mph (33.0 kmph)
Towing Capacity ..............................................................................18,000 (8.165 kg)
Frame Leveling ............................................................................................8 degrees

9-2

31200148

Section 9 - Specifications
Dimensions
Overall Height..............................................................................95.40 in (2.423 mm)
Overall Width...............................................................................96.23 in (2.444 mm)
Cab Width............................................................................................37 in (940 mm)
Track Width..................................................................................82.24 in (2.089 mm)
Wheelbase .....................................................................................128 in (3.251 mm)
Length at Front Wheels ...............................................................183.5 in (4.661 mm)
Overall Length (less Forks) ...........................................................212.59 in (5.4 mm)
Ground Clearance ...............................................................................17 in (432 mm)
Turning Raduis Over Tires........................................................ 141.25 in (3.588 mm)
Turning Raduis at Forks ............................................................. 182.4 in (4.633 mm)
Gross Vehicle Weight with Forks................................................. 20,400 lb (9.253 kg)
Front Axle Weight .......................................................................... 9,695 lb (4.398 kg)
Rear Axle Weight ........................................................................ 10,705 lb (4.856 kg)
Maximum Ground Bearing Pressure
13.00 x 24 Foam Filled .................................................. 98.2 lbs/in (6,90 kg/cm)
15.50 x 25 Foam Filled ................................................. 70.8 lbs/in ( 4,98 kg/cm)

31200148

9-3

Section 9 - Specifications

This Page Intentionally Left Blank

9-4

31200148

Index

Index
A
Additional Checks............................. 8-1
Adjusting/Moving Forks .................... 5-9
Approved Attachments ..................... 5-1

Driving Hazards on Slopes ...............1-9

E
Electrical Hazards .............................1-2

Attachment Installation ..................... 5-7

Emergency Exit from

Enclosed Cab....................................6-2

Attachment Operation .................... 5-10

Emergency Lower of Boom...............6-2

Attachment Tilt Lever ....................... 3-6

Emergency Procedures ....................6-1

Attachments ..................................... 5-1

Engine...............................................4-1
Normal Operation ........................4-4
Starting ........................................4-1

Auxiliary Control Joystick ................. 3-7

Axles................................................. 9-1

Engine Crankcase Oil .......................9-1

Engine Oil Level..............................7-12

Battery ............................................ 7-19

Battery Boosted Starting .................. 4-3

Boom Angle Indicator ..................... 3-14

Fall Hazard......................................1-12

Boom Extension Indicator .............. 3-14

Fork Positioner................................5-11

Boom Head-Mounted Winch .......... 5-18

Frame Sway Lever............................3-6

Boom Joystick .................................. 3-5

Fuel Level .........................................7-8

Bucket ............................................ 5-14

Fuel Tank ..........................................9-1

Fuel/Water Separator........................7-9

C
Capacities......................................... 9-1

Capacity ........................................... 5-3

General Maintenance........................7-2

Capacity Chart.................................. 5-4

Example ...................................... 5-6
Sample........................................ 5-5

H
Hazard Classification System ...........1-1

Capacity Indicator Locations ............ 5-4

Heater .............................................3-10

Chemical Hazards .......................... 1-13

Hydraulic Oil Level ..........................7-13

Controls ............................................ 3-2

Hydraulic Return Filter ....................7-17

Coolant Level ................................. 7-18

Hydraulic System ..............................9-1

Cooling System ................................ 9-1

Crane Hook .................................... 5-12

Ignition ..............................................3-4

Dash Controls and Indicators ........... 3-8

Leveling Procedure ....................4-6, 4-9

Decals .............................................. 2-3

Lifting Personnel ...............................1-8

Dimensions....................................... 9-3

Load Falling Hazard..........................1-7

Disengaging a Suspended
Load ............................................... 4-10

Lubrication and Maintenance............7-1

Disengaging the Load ...................... 4-7

31200148

Index
Lubrication Schedule ........................ 7-6
250 Hour ..................................... 7-7
50 Hour ....................................... 7-6

1st 50 Hour ..................................7-3

250 Hour ......................................7-4
50 Hour ........................................7-4
500 Hour ......................................7-4

Shut-Down Procedure.......................4-4

Mast w/ Carriage ............................ 5-19

Side Tilt Carriage ............................5-25

Specifications ....................................9-1

Operating with a Load ...................... 4-5

Swing Carriage................................5-23

Operating with a Suspended

Load.................................................. 4-8

Swing Mast w/Side Shift..................5-21

Operational Check............................ 2-8

Operator Cab.................................... 2-9
Operator Maintenance
Instructions ....................................... 7-8
Operator Seat ................................. 3-11

P
Park Brake........................................ 3-9
Parking Procedure............................ 3-9
Personnel Work Platform................ 5-27
Picking Up a Load ............................ 4-5

T
Tip Over Hazard................................1-3
Tires ................................................7-14
Air Pressure ...............................7-14
Damage .....................................7-14
Pressure ......................................9-2
Replacement..............................7-15
Towing...............................................6-1
Transmission Control Lever ..............3-3
Transport.........................................4-11
Lifting .........................................4-12
Tiedown .....................................4-11

Pinch Points and Crush Hazards.... 1-10

Transporting a Suspended
Load ..................................................4-9

Placing a Suspended Load............. 4-10

Transporting the Load .......................4-6

Placing the Load............................... 4-7

Travel Hazard....................................1-6

Pre-Operation Check
and Inspection .................................. 2-1

Truss Boom.....................................5-16

Walk-Around Inspection ....................2-6

Restriction Indicator........................ 7-10

Warm-Up Check................................2-8

Picking Up a Suspended Load ......... 4-8

S
Safety Decals ................................... 2-3
Safety Practices................................ 1-1

Weights .............................................9-2
Wheel Lug Nut ..................................9-2
Wheel Replacement........................7-15

Safety Signal Words ......................... 1-1

Seat Belt ......................................... 3-13
Service and Maintenance
Schedule........................................... 7-3
10 Hour ....................................... 7-3
1000 Hour ................................... 7-5
1500 Hour ................................... 7-5

31200148

Inspection, Maintenance and Repair Log

Inspection, Maintenance and Repair Log

Serial Number ______________________________

Date

Comments

Inspection, Maintenance and Repair Log

Date

Comments

TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company

To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. For the purpose of receiving safety-related
bulletins, it is very important to keep JLG Industries, Inc. updated with the current
ownership of all JLG products. JLG maintains owner information for each JLG product
and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: _______________________________________________________________
Serial Number: ____________________________________________________________
Previous Owner: ___________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Date of Transfer: _________________________________
Current Owner: ____________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________
Title: _____________________________________________________________________

Hand Signals

OY1090

EMERGENCY STOP - With both

arms extended laterally, hands
open downward, move arms back
and forth.

OY1120

RAISE BOOM - With either arm

extended horizontally, fingers
closed, point thumb upward.

OY1150

EXTEND BOOM - With both

hands clenched, point thumbs
outward.

OY1180

TILT FORKS UP - With one arm

held at side, extend other arm
upward at about 45 degrees.

OY1100

STOP - With either arm extended

laterally, hand open downward,
move arm back and forth.

OY1130

LOWER BOOM - With either arm

extended horizontally, fingers
closed, point thumb downward.

OY1160

RETRACT BOOM - With both

hands clenched, point thumbs
inward.

OY1110

STOP ENGINE - Draw thumb or

forefinger across throat.

OY1140

MOVE SLOWLY - Place one hand

motionless in front of hand giving
motion signal. (Raise load slowly
shown)

OY1170

THIS FAR TO GO - With hands

raised and open inward, move
hands laterally, indicating distance
to go.

OY1190

TILT FORKS DOWN - With one

arm held at side, extend other arm
downward at about 45 degrees.

Special Signals - When signals for auxiliary equipment functions or conditions not
covered are required, they shall be agreed upon in advance by the operator and
signalman.

An Oshkosh Corporation Company

JLG Industries, Inc.

1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: +1-717-485-5161
Customer Support Toll Free: 1-877-554-5438
Fax: +1-717-485-6417

JLG Worldwide Locations

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: +61 265 811 111
Fax: +61 265 810 122

JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: +55 193 295 0407
Fax: +55 193 295 1025

JLG Industries (UK) Ltd

Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP
England
Phone: +44 (0)161 654 1000
Fax: +44 (0)161 654 1001

JLG France SAS

Z.I. de Baulieu
47400 Fauillet
France
Phone: +33 (0)5 53 88 31 70
Fax: +33 (0)5 53 88 31 79

JLG Deutschland GmbH

Max-Planck-Str. 21
D - 27721 Ritterhude-lhlpohl
Germany
Phone: +49 (0)421 69 350 20
Fax: +49 (0)421 69 350 45

JLG Equipment Services Ltd.

Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N.T.
Hong Kong
Phone: +852 2639 5783
Fax: +852 2639 5797

JLG Industries (Italia) s.r.l.

Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: +39 029 359 5210
Fax: +39 029 359 5845

JLG Europe B.V.

Polaris Avenue 63
2132 JH Hoofddorp
The Netherlands
Phone: +31 (0)23 565 5665
Fax: +31 (0)23 557 2493

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: +48 (0)914 320 245
Fax: +48 (0)914 358 200

JLG Industries (Scotland)

Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland
Phone: +44 (0)141 781 6700
Fax: +44 (0)141 773 1907

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: +34 93 772 4 700
Fax: +34 93 771 1762

JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
Phone: +46 (0)850 659 500
Fax: +46 (0)850 659 534

Liquid Coolant
Test Manual

John Deere Liquid Coolant Conditioner

Form No. 20004 / Original Issue 3-2000

ENGINE COOLANT SPECIFICATIONS

Engine coolants are a combination of three chemical
components: ethylene glycol, (antifreeze), inhibiting
coolant additives and quality water.
Coolant solutions of quality water, ethylene glycol
concentrate, (antifreeze), and supplemental coolant
additives, (SCAs), MUST be used year-round to protect
against freezing, boil-over, liner erosion or pitting, and
to provide a stable, non-corrosive environment for
seals, hoses and metal engine parts.
Some products, including John Deere PREDILUTED
ANTIFREEZE/SUMMER COOLANT and John Deere
COOL-GARD, are fully formulated coolants that
contain all three components in their correct concentrations. Do not add an initial charge of supplemental
coolant additives to these fully formulated products.
Some coolant concentrates, including John Deere
ANTIFREEZE/SUMMER COOLANT CONCENTRATE,
contain both ethylene glycol antifreeze and inhibiting
coolant additives. Mix these products and quality water,
but do not add an initial charge of supplemental
coolant additives.
Coolants meeting ASTM D5345, (prediluted coolant) or
ASTM D4985, (coolant concentrate), require an initial
charge of supplemental coolant additives.
Water Quality:

Ethylene Glycol Concentrate (Antifreeze):

IMPORTANT: Do not use cooling system sealing
additives or use antifreeze that contains
sealing additives.

The use of John Deere coolant products is strongly

recommended.
If John deere coolant products are not used, other low
silicate ethylene glycol base coolants for heavy-duty
diesel engines may be used when mixed with quality
water and supplemental coolant additives, (SCAs), if
they meet one of the following specifications:
*

ASTM D5345 (prediluted coolant)

*
ASTM D4985 (coolant concentrate) in a 40%
to 60% mixture of concentrate with quality water.
Coolants meeting these specifications require addition
of supplemental coolant additives, (SCAs), formulated
for heavy-duty diesel engines, for protection against
corrosion and cylinder liner erosion and pitting.
IMPORTANT: Never use automotive-type coolants, (such as
those meeting ASTM D3306 or ASTM D4656).
These coolants do not contain the correct
additives to protect heavy-duty diesel
engines. They often contain a high concentra
tion of silicates and may damage the engine
cooling system.

Water quality is important to the performance of the

cooling system. Distilled, deionized or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate. All water used in the
cooling system should meet the following minimum
specifications for quality:
Water Quality Specifications

Item

Parts
Per
Million

Chlorides (maximum).......................40
Sulfates (maximum)........................100
Total Dissolved Solids (maximum)...340
Total Hardness..............................170

Grains
Per
U.S. Gallon

2.5
5.9
20
10

pH Level................................................5.5-9.0

pg.1

ENGINE COOLANT SPECIFICATIONS--CONTINUED

Supplemental Coolant Additives (SCAs):
IMPORTANT: DO NOT over-inhibit antifreeze solutions, as
this can cause silicate-dropout. When this
happens, a gel-type deposit is created which
retards heat transfer and coolant flow,
causing engine to overheat.

NOTE: John Deere Pre-diluted Antifreeze/Summer Coolant

conccentrate, and John Deere COOL-GARD contain
supplemental coolant additives (SCAs). However, as
the coolant solution loses its effectiveness, additives
will need to be added.

Operating without proper coolant additive will result in

increased corrosion, cylinder liner erosion and pitting,
and other damage to the engine and cooling system. A
simple mixture of ethylene glycol and water WILL NOT
give adequate protection.

John Deere Liquid Coolant Conditioner

The use of supplemental coolant additives reduces

corrosion, erosion and pitting. These chemicals reduce
the number of vapor bubbles in the coolant and help
form a protective film on cylinder liner surfaces. This
film acts as a barrier against harmful effects of collapsing vapor bubbles.
Inhibit the antifreeze-coolant mix with a non-chromate
inhibitor. John Deere Liquid Coolant Conditioner is
recommended as a supplemental coolant additive in
John Deere engines.
IMPORTANT: Check inhibitors between drain intervals
every 600 hours or 12 months of operation.
Replenish inhibitors by the addition of a
supplemental coolant additive as necessary.
DO NOT use a soluble oil.

Additives eventually lose their effectiveness and must

be recharged with additional supplemental coolant
additives available in the form of liquid coolant conditioner. See TESTING DIESEL ENGINE COOLANT and
REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCAs) BETWEEN COOLANT CHANGES, as
described later in this group.

pg.2

TESTING DIESEL ENGINE COOLANT

Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect
the engine and cooling system against freezing,
corrosion and cylinder liner erosion and pitting.
Test the coolant solution at 600 hours or 12 month
interals and whenever excessive coolant is lost through
leaks or overheating to ensure the necessary protection.
Coolant Test Strips
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective
method to check the freeze point and additive levels of
your engine coolant.
Compare the results to the supplemental coolant
additive (SCA) chart to determine the amount of
inhibiting additives in your coolant and whether more
John Deere Liquid Coolant Conditioner should be
added.
COOLSCAN
For a more thorough evaluation of your coolant,
perform a COOLSCAN analysis where available. See
your John Deere distributor or servicing dealer for
information about COOLSCAN.

pg. 3

REPLENISHING SUPPLEMENTAL COOLANT ADDITIVES (SCAs) BETWEEN COOLANT CHANGES

IMPORTANT: Do not add supplemental coolant additives

when the cooling system is drained and
refilled with John Deere ANTIFREEZE/
SUMMER COOLANT or John Deere
COOL-GARD.

Through time and use, the concentration of coolant

additives is gradually depleted during engine operation.
Periodic replenishment of inhibitors is required, even
when John Deere ANTIFREEZE/SUMMER COOLANT
or John Deere COOL-GARD is used. The cooling
system must be recharged with additional coolant
additives available in the form of liquid coolant conditioner.
Maintaining the correct coolant conditioner
concentration (SCAs) and freeze point is essential in
your cooling system to protect against rust, liner pitting
and corrosion, and freeze-ups due to incorrect coolant
dilution.
John Deere LIQUID COOLANT CONDITIONER is
recommended as a supplemental coolant additive
in John Deere engines.

IMPORTANT: ALWAYS maintain coolant at correct level and

concentration. DO NOT operate engine
without coolant for even a few minutes.
If frequent coolant makeup is required, the
glycol concentration should be checked with
JT05460 Refractometer to assure that the
desired freeze point is maintained. Follow
manufacturers instructions provided with
refractometer.

Add the manufacturers recommended concentration of

supplemental coolant additive. DO NOT add more than
the recommended amount.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation of
the coolant.
If other coolants are used, consult the coolant supplier
and follow the manufacturers recommendation for use
of supplemental coolant additives.
See ENGINE COOLANT SUPPLEMENTS earlier in
this group for proper mixing of coolant ingredients
before adding to the cooling system.

Test the coolant solution at 600 hours or 12 months of

operation using either John Deere coolant test strips or
a CoolScan analysis. If a CoolScan analysis is not
available, recharge system per instructions printed on
label of john Deere Liquid Coolant Conditioner.

pg.4

OPERATING IN WARM TEMPERATURE CLIMATES

John Deere engines are designed to operate using
glycol base engine coolants.
Always use a recommended glycol base engine
coolant, even when operating in geographical areas
where freeze protection is not required.

IMPORTANT: Water may be used as coolant in emergency

situations only.
Foaming, hot surface aluminum and iron
corrosion, scaling and cavitation will occur
when water is used as the coolant, even when
coolant conditioners are added.
Drain cooling system and refill with recom
mended glycol base engine coolant as soon
as possible.

pg.5

FLUSH AND SERVICE COOLING SYSTEM

IMPORTANT: CAUTION: Explosive release of fluids form

pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing cap completely.

IMPORTANT: Air must be expelled from cooling system

when system is refilled. Follow procedure
given in your operators manual.

The ethylene glycol base, (antifreeze), can become

depleted of SCAs allowing various acids to form that
will damage engine components. In addition, heavy
metals, such as lead, copper and zinc accumulate in
the ethylene glycol base. The heavy metals come from
corrosion that occurs to some degree within a cooling
system. When a coolant is saturated to the point where
it can no longer hold heavy metals and other dissolved
solids, they settle out and act as abrasives on engine
parts.

NOTE: Refer to your operators manual for a specific

service interval.

Flush cooling system and replace thermostats as

described in your operators manual. Clean cooling
system with clean water and TY15979 John Deere
Heavy-Duty Cooling System Cleaner or an equivalent
cleaner such as FLEETGUARD RESTORE or RESTORE PLUS. Follow the instructions provided with
the cleaner. Refill the cooling system with the appropriate coolant solution. See ENGINE COOLANT SPECIFICATIONS, earlier in this group.
IMPORTANT: NEVER overfill the system. A pressurized
system needs space for heat expansion
without overflowing at the top of the radiator.
Coolant level should be at tbottom of radiator
filler neck.
Air must be expelled from cooling system
when the system is refilled. Loosen tempera
ture sending unit fitting at rear of cylinder
head or plug in thermostat housing to allow
air to escape when filling system. Re-tighten
fitting or plug when all the air has been
expelled.

After adding new coolant solution, run engine until it

reaches operating temperature. This mixes the coolant
solution uniformly and circulates it through the entire
system. After running engine, check coolant level and
entire cooling system for leaks.

Contact your authorized servicing dealer or engine

distributor if there are further questions.

pg.6

DISPOSING OF COOLANT
Improperly disposing of engine coolant can threaten the
environment and ecology.
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling center,
or from your John Deere dealer.

pg. 7

MANNESMANN
REXROTH
Brueninghaus Hydromatik

R
Reparaturanleitung
Repair Instructions

A6VM 28 ... 200

Baureihe / Series 63

RDE 91604-01-R
08.96

RDE 91604-01-R/08.96

Typschlssel

Reparaturanleitung A6VM
Repair Instructions A6VM

Type code
Typschlssel
Axialkolbenmaschine
Schrgscheibenbauart, verstellbar

A6V M

/ 6 3 W

A6V

Betriebsart
Motor

Nenngre
Schluckvolumen Vg max in cm3

28 55 80 107 140 160 200

NG 250 - 1000 siehe RD 91603

Regel- und Verstelleinrichtung

Hydraulische Verstellung, steuerdruckabhngig

HD

HD

HD

HD

28

55

80

HD1

HD2

HD1D

HD2D

HZ1

1
2
1
2

Steuerdruckanstieg p = 10 bar
Steuerdruckanstieg p = 25 bar

107 140 160 200

mit Druckregelung

Hydraulische Zweipunktverstellung

Elektrische Verstellung mit Proportionalmagnet

HZ1

HZ3

HZ2

EP

EP1

EP

EP2

EP

EP1D

EP

EP2D

EZ1

1
2
1
2

Steuerspannung 12 V
Steuerspannung 24 V

mit Druckregelung

Elektr. Zweipunktverstellung mit Schaltmagnet

EZ

EZ

EZ

EZ

HA

HA

HA

1
2
3
4

EZ2

EP3

EP4

HA1

HA2

HA3

Steuerspannung 12 V
Steuerspannung 24 V
Automatische Verstellung, hochdruckabhngig

1
2
3

Ausfhrung ohne Druckanstieg

Ausfhrung mit Druckanstieg p = 100 bar

Hydraulische Verstellung, drehzahlabhngig

HA1

HA2

HA3

ohne bersteuerung (kein Zeichen)

mit hydraulischer bersteuerung

mit elektrischer bersteuerung, 12 V

U1

mit elektrischer bersteuerung, 24 V

U2

mit el. berst. + el. Fahrtrichtungsventil, 12 V

R1

mit el. berst. + el. Fahrtrichtungsventil, 24 V

R2

pST/pHD = 5/100,hydraulisches Fahrtrichtungsventil

el. Fahrtrichtungsventil (12 V) + el. Qmax Schaltung (12 V)

DA1

DA2

DA3

DA4

el. Fahrtrichtungsventil (12 V) + el. Qmax Schaltung (12 V)

DA5

el. Fahrtrichtungsventil (24 V) + el. Qmax Schaltung (24 V)

DA6

el. Fahrtrichtungsventil (24 V) + el. Qmax Schaltung (24 V)

pST/pHD = 8/100,hydraulisches Fahrtrichtungsventil

Gleichgangkolben

bersteuerung

Brueninghaus Hydromatik

Differentialkolben

RDE 91604-01-R/08.96

Typschlssel

Reparaturanleitung A6VM

Type code

Repair Instructions A6VM

Type code
Axial piston unit
Bent axis design, variable displacement

A6V M

/ 6 3 W

A6V

Mode of operation
Motor

Size
Displacement Vg max in cm3

28 55 80 107 140 160 200

Size 250 - 1000 see RE 91603

Control and regulating device

Hydraulische Verstellung, steuerdruckabhngig

HD

HD

HD

HD

28

55

80

HD2

HD1D

HD2D

1
2
1
2

Pilot pressure increase p = 10 bar

Pilot pressure increase p = 25 bar

107 140 160 200

HD1

with constant pressure control

Hydraulic two-position control

Electrical control, with proportional solenoid

HZ1

HZ1

HZ3

HZ2

EP

EP1

EP

EP2

EP

EP1D

EP

EP2D

1
2
1
2

Control voltage 12 V
Control voltage 24 V

with constant pressure control

Electr. two-position control, w. switching solenoid

EZ

EZ

EZ

EZ

HA

HA

HA

EZ1

EZ2

EP3

EP4

HA1

HA2

HA3

Control voltage 12 V
Control voltage 24 V
Automatic control, high pressure related

1
2
3

Model without pressure increase

Model with pressure increase p = 100 bar

Hydraulic control, speed related

Override

HA1

HA2

HA3

without override (no code)

hydraulic override

electrical override, 12 V

U1

electrical override, 24 V

U2

el. override + el. valve for travel direction, 12 V

R1

el. override + el. valve for travel direction, 24 V

R2

DA1

el. valve for travel direction (12 V) + el. Qmax switch (12 V)

DA2

el. valve for travel direction (24 V) + el. Qmax switch (24 V)

DA3

DA4

el. valve for travel direction (12 V) + el. Qmax switch (12 V)

DA5

el. valve for travel direction (24 V) + el. Qmax switch (24 V)

DA6

pST/pHD = 5/100,hydraulic valve for travel direction

pST/pHD = 8/100,hydraulic valve for travel direction

Synchronizing
piston

Differential
piston

Brueninghaus Hydromatik

RDE 91604-01-R/08.96

Hinweis / Inhalt
Notice / Contents

Reparaturanleitung A6VM
Repair Instructions A6VM

HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen
entsprechen dem Informationsstand zum Zeitpunkt der
Drucklegung dieser Unterlage.
nderungen knnen den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, fr
deren Resultat wir keine Haftung bernehmen knnen.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit
Angabe der Fabrik-Nr. bestellt, sind die Basis guter
Reparaturen.
Einstell- und Prfarbeiten sind bei Betriebstemperatur
auf dem Teststand vorzunehmen.
Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.
Sachkenntnis, die Voraussetzung fr jede Servicearbeit, vermitteln wir in unseren Schulungskursen.

NOTICE
Specifications, descriptions and illustrative material
shown herein were as accurate as known at the time
this publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to
discontinue models or options at any time or to change
specifications, materials, or design without notice and
without incurring obligation.
Optional equipment and accessories may add cost to
the basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant
data sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test
bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service
work, can be obtained in our training courses.

INHALT

CONTENTS

Seite/
Page

A6VM

A6VM
Typschlssel
Hinweis / Inhalt
Schnittbild
Allgemeine Reparaturhinweise
Dichtstze und Baugruppen
Baugruppen / Steuerteile
Dichtmutter austauschen
Anschluplatte abdichten
Steuerteile abdichten
Verstellung abdichten
Anschluplatte demontieren
Stellkolben ausbauen
Triebwerk ausbauen
Triebwerk austauschen
berprfungshinweise
Triebwerk montieren
Triebwerksabstimmung
Anschluplatte mintieren
Anziehdrehmomente
Sicherheitsbestimmungen

Brueninghaus Hydromatik

2-3
4
5-8
9
10-11
12-13
14
15
16
17-18
19-21
22-23
24-25
26-27
28-29
30-34
35
36-37
38
39-40

Type code
Notice / Contents
Sectional view
General repair instructions
Seal kits and sub assembly groups
Component groups / Control components
Replace seal nut
Sealing of the cover plate
Sealing of the control parts
Sealing of the hydraulic parts
Disassembly of the port plate
Remove of the positioning piston
Remove rotary group
Exchanging of the rotary group
Inspection notes
Rotary group assembly
Rotary group adjustment
Assembly of the port plate
Tightening torques
Safety regulations

RDE 91604-01-R/08.96

Schnittbild

Reparaturanleitung A6VM

Sectional drawing

Repair Instructions A6VM

A6VM 28-200 HD./6

Index 3
Verstellmotor
Variable motor

A6VM 28-200 HD./6

Index 3
Verstellmotor mit Splventil
Variable motor with flushing valve

A6VM 28-200 HD1D/6

Index 3
Verstellmotor mit Druckregelventil
Variable motor with pressure
control valve

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RDE 91604-01-R/08.96

Schnittbild
Sectional drawing
A6VM 55-107 HZ3/6
Index 3
Verstellmotor
Variable motor

A6VM 55-107 EZ3/6

Index 3
Verstellmotor
Variable motor

A6VM 28-200 EP./6

Index 3
Verstellmotor
Variable motor

Brueninghaus Hydromatik

Reparaturanleitung A6VM
Repair Instructions A6VM

RDE 91604-01-R/08.96

Schnittbild

Reparaturanleitung A6VM

Sectional drawing

Repair Instructions A6VM

A6VM 28-200 HA2U/6

Index 3
Verstellmotor mit Bremsventil
Variable motor with braking valve

A6VM ... DA1/6

Index 3
Verstellmotor
Variable motor

A6VM ... DA3/6

Index 3
Verstellmotor
Variable motor

Brueninghaus Hydromatik

RDE 91604-01-R/08.96

Schnittbild
Sectional drawing
A6VM 28-200 HA2R/6
Index 3
Verstellmotor
Variable motor

A6VM 55-107 HA3/6

Index 3
Verstellmotor
Variable motor

A6VM 55-107 HA3U/6

Index 3
Verstellmotor
Variable motor

Brueninghaus Hydromatik

Reparaturanleitung A6VM
Repair Instructions A6VM

RDE 91604-01-R/08.96

Allgemeine Reparaturhinweise

Reparaturanleitung A6VM

General repair instructions

Repair Instructions A6VM

Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out repair
work at hydraulic aggregates!

Alle ffnungen der Hydraulikaggregate verschlieen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur original HYDROMATIK-Ersatzteile verwenden.
Replace all seals.
Use only original HYDROMATIK spare parts.

Alle Dicht- und Gleitflchen auf Verschlei prfen.

Achtung: Nacharbeiten an Dichtflchen z.B. durch
Schleifpapier kann die Oberflche beschdigen.
Check all seal and sliding surfaces for wear.
Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befllen.
Fill up hydraulic aggregates with medium
before start- up.

Brueninghaus Hydromatik

RDE 91604-01-R/08.96

Dichtstze und Baugruppen

Seal kits and sub assembly groups

Reparaturanleitung A6VM
Repair Instructions A6VM

Dichtsatz fr Triebwelle.
Seal kit for drive shaft.

uerer Dichtsatz.
External seal kit.

Gehuse
Housing

4
Pos. 2

Triebwerk komplett
Hinweis: Pos. 1 - Fr Anschluplatte mit Differentialkolben
Pos. 2 - Fr Anschluplatte mit Gleichgangkolben
Complete rotary group
Note: Pos. 1 - For port plate with differential piston
Pos. 2 - For port plate with synchronizing piston

Pos. 1

Pos. 1

Pos. 2

Anschluplatte mit Stellkolben

Hinweis: Pos. 1 - Fr Anschluplatte mit Differentialkolben
Pos. 2 - Fr Anschluplatte mit Gleichgangkolben
Port plate with control piston
Note: Pos. 1 - For port plate with differential piston
Pos. 2 - For port plate with synchronizing piston

10

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Dichtstze und Baugruppen

Seal kits and sub assembly groups

Reparaturanleitung A6VM
Repair Instructions A6VM

Proportionalmagnet (EP)
Proportional solenoid (EP)

Schaltmagnet
Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
Cover with * throttle pin.
* Throttle pin "as to order requirement".

*
*
*
9

*
*

Deckel mit Spl- und Speisedruckventil und * Drosselstift

* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve and
* throttle pin.
* Throttle pin "as to order requirement".

Brueninghaus Hydromatik

11

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Reparaturanleitung A6VM
Repair Instructions A6VM

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA

Auftragsbezogen

HA2

"as to order requirement".

12

Brueninghaus Hydromatik

HD

DA

RDE 91604-01-R/08.96

Baugruppen / Steuerteile

Reparaturanleitung A6VM

Component groups / Control components

Repair Instructions A6VM

z. B. HZ3 / EZ3

HA3 / HA3U

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13

RDE 91604-01-R/08.96

Dichtmutter austauschen
Replace seal nut

Reparaturanleitung A6VM
Repair Instructions A6VM

10

Dichtmutter austauschen.
Zuerst Einstellhhe messen und festhalten.
Replace seal nut.
First measure and record setting height.

11

Beim Anziehen Einstellschraube gegenhalten,

anschlieend Einstellhhe kontrollieren.
When tightening, counterhold setting screw, then
check setting height.

14

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Anschluplatte abdichten

Reparaturanleitung A6VM

Sealing of the cover plate

Repair Instructions A6VM

12
13

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.
Protecting the drive shaft.
Remove retaining ring and shim.

14

Blechschraube in die mit Gummi gefllten

Lcher eindrehen.
Mit Zange WDR herausziehen.
Screw in sheet metal screw into the holes
fitted with rubber.
Pull out seal with pliers.

15

Wellendichtring und Scheibe mit Montagehlse einpressen.

Einpresstiefe beachten! * Marke fr Einpresstiefe.
Sicherungsring einbauen.
Press in shaft seal ring and shim with bush to stop.
Take note of press-in depth!
Install mark for press-in depth of safety ring.

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Reparaturanleitung A6VM
Repair Instructions A6VM

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung
Attention!
Spring load
16
17

Kontrolle
Bohrung im Gehuse, O-Ring, Nut.
Inspect
Drilling in housing, O-ring, groove.

18
Einstellschraube nicht ausbauen.
Kontrolle
O-Ring, O-Ring-Nut, Gehuse
Do not remove adjustment screw.
Inspect
O-ring, O-ring groove, housing

19

Montagehilfe
Stift mit Fett einkleben.
Assembly aid
Insert pin with grease.

16

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Verstellung abdichten

Reparaturanleitung A6VM

Sealing the hydraulic control

Repair Instructions A6VM

20
21

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.
Example: A6VM ... HD control
Disassembly position:
Remove cover pos. 1

Pos.1

22

1
2

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
control components

3
23
1
5
2

1. O-Ring
2. Stelllzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. Stelllzulauf
2. Hochdruck bzw. Niederdruck
3. Hochdruck bzw. Niederdruck
4. Leckl
5. Stellkolben

1. Input flow of oil control

2. High pressure /
low pressure
3. High pressure /
low pressure
4. Leckage oil
5. Control piston

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Reparaturanleitung A6VM
Repair Instructions A6VM

Verstellung abdichten
Sealing the hydraulic control

24
25

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Ma x: Ma festhalten (Regelbeginn).
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

26
1

1. Check of O-ring

27
2

1. Hochdruck - kleine Stellkolbenseite

2. Stelldruck
3. Hochdruck - Rckschlagventil
4. Hochdruck - Rckschlagventil

18

1. O-Ring Kontrolle

1. High pressure - small control piston side

2. Control pressure
3. High pressure - check valve
4. High pressure - check valve

Brueninghaus Hydromatik

RDE 91604-01-R/08.96

Anschluplatte demontieren

Reparaturanleitung A6VM

Disassembly of the port plate

Repair Instructions A6VM

Differentialkolben:
Ma X festhalten.
Diferential piston:
Note dimension x

Bei "Demontage" der Anschluplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hngen aus der Zylinderbohrung aus.
For disassembly of the port plate, swivel
always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.

Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.
Remove Qmin-screw.
Swivel rotary group to 0o.

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RDE 91604-01-R/08.96

Anschluplatte demontieren

Reparaturanleitung A6VM
Repair Instructions A6VM

Disassembly of the port plate

Gleichgangkolben:
Ma X festhalten.
Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschluplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hngen aus der Zylinderbohrung aus.
Qmin-Schraube
Qmin-screw

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.

Qmin-Schraube und Verschluschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o

schwenken.
Swivel rotary group to zero position
with screw Qmin .

20

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Reparaturanleitung A6VM

Anschluplatte demontieren
Disassembly of the port plate

Repair Instructions A6VM

28

Anschluplatte
Lage markieren. Schrauben lsen.
Abbauen
Port plate
Mark position. Loosen screws.
Removal

29

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Treibwerk nicht ausschwenken.
Kolbenringe hngen aus der Zylinderbohrung aus.
Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

30
Steuerlinse in Gleitbahn mit Fett einkleben.
Fertigmontage in umgekehrter Reihenfolge.
Anschluplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

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RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Stellkolben ausbauen
Remove of the positioning piston

Differentialkolben

Gleichgangkolben

Differential piston

Synchronizing
piston

31
32

Befestigungsschraube lsen.
Nur Zapfenschlssel verwenden.
Loosen fixing screw.
Use only socket wrench.

22

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Reparaturanleitung A6VM

Stellkolben ausbauen
Remove of the positioning piston

Repair Instructions A6VM

33

Kolben mit Kolbenring ausbauen.

Remove piston with piston ring

34

Differentialkolben
Befestigungsschraube fr Stellzapfen ber
Bohrung erwrmen. (Schraube geklebt - herausdrehen)
Neue Schraube verwenden
Precote Beschichtung
Anziehdrehmomente beachten!

Differential piston
Warm up fixation screw for positioning plug
via boring (screw glued - to turn out).
Use new screw.
Precote coating.
Note tightening torque!

35

Gleichgangkolben
Schraube ausbauen.
Kolben ausbauen.
Einbaulage beachten.

Synchronizing piston
Remove screw.
Remove piston.
Note installation position.

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RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Triebwerk ausbauen
Remove rotary group

36
37

Gewindestift in Mittelzapfen einschrauben,

mit Scheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.
Screw in threaded pin into center pin.
Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.
Nenngre / Size

38

28 :
55 :
80 :
107 :
140 :
160 :
200 :

M4 x 58 mm
M5 x 71 mm
M6 x 82 mm
M6 x 92 mm
M8 x 105 mm
M8 x 105 mm
M8 x 109 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager
nicht schlagen.
Press out rotary group!
If the bearings are used again
do not hit on the drive shaft.

24

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Triebwerk ausbauen

Reparaturanleitung A6VM

Remove rotary group

Repair Instructions A6VM

39

Oder mit Abziehvorrichtung ausdrcken.

Or press-out with extraction device.

Brueninghaus Hydromatik

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RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in

Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Teil

Complete rotary group

Setting of hydraulic part
necessary.
40

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil:
Abstimmung notwendig *.
Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part:
Adjustment necessary

41

*
*

*
Triebwerk: Alle Bauteile
* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.
Rotary group: All parts
* Setting
Setting value, torque see service information. 42
26

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Triebwerk austauschen
Exchanging of the rotary group

Reparaturanleitung A6VM
Repair Instructions A6VM

43

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.
Remove fixing screw (cylinder).
Remove cylinder.

44

Rckzugplatte demontieren.
Schrauben sind eingeklebt.
Torx-Werkzeug verwenden.

Disassemble retaining plate.

Screws are glued.
Use Torx-tools.

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27

RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

berprfungshinweise
Inspection notes

45

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting; no damage
to splines or keyways.

46

Kolben
Riefenfrei und keine Pittings.
Pistons
No scoring and no pittings.

47
2

Mittelzapfen
Riefenfrei und keine Pittings.
Center pin
No scoring and no pittings.

48

Rckzugplatte
Riefenfrei und keine Ausbrche.
Retaining plate
No scoring and no evidence of wear

49

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmiges Tragbild, ri- und riefenfrei.
Cylinder block / control lens
1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks and scoring.

28

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berprfungshinweise
Inspection notes

Reparaturanleitung A6VM
Repair Instructions A6VM

50

Reglergehuse
Gleitbahn und Seitenfhrung riefenfrei,
nicht ausgelaufen.
Control housing
Sliding surface and side guides free of scoring
and no wear.

51

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.
Visual check:
Bearing areas free of scoring and no evidence of wear.

Brueninghaus Hydromatik

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RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part
1

Abstimmung Ma *
und Lagerdrehmomente
siehe Serviceinfo.
Adjustment dimension *
and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht berschreiten.
Press on bearing.
Do not exeed bearing torque
during press-on.

Lager mit Montagehlse vorspannen

und laufende Drehmomentenkontrolle.
Preload bearing with assembly sleeve
and steady control of the torque.

30

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Triebwerk montieren

Reparaturanleitung A6VM

Rotary group assembly

Repair Instructions A6VM

Triebwelle: mechanischer Teil

Rotary group: mechanical part

*
Sicherungsring montieren.
Ma * fr Abstimmscheibe mit
Endmaen ermitteln (berkreuz).
Assemble safety ring.
Determine dimension for
adjustment disc with final
dimensions (crossover).

Abstimmscheibe einbauen.
Sicherungsring montieren.
Triebwelle einbaufertig.
Install adjustment disc.
Assemble safety ring.
Drve shaft ready for assembly.

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Triebwerk montieren
Rotary group assembly

Reparaturanleitung A6VM
Repair Instructions A6VM

52
53

Rckzugplatte mit Kolben und Mittelzapfen einsetzen.

Schrauben mit Precote-Beschichtung verwenden.
Insert retaining plate with piston and center pin.
Use screw with Precote-coating.

54

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

55

Triebwerk max. ausschwenken und Zylinder befestigen.

Swivel cylinder block to max. and fix the cylinder.

32

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Triebwerk montieren

Reparaturanleitung A6VM

Rotary group assembly

Repair Instructions A6VM

Triebwerk komplett zum

Einbau fertig.
Rotary group completely assembled
ready for assembly.

Montagehlse montieren.
Place assembly sleeve.

Gehuse auf 80oC erwrmen.

Warm up housing to 80oC.

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Triebwerk montieren

Reparaturanleitung A6VM
Repair Instructions A6VM

Rotary group assembly

Triebwerk ins Gehuse auf

Anschlag einsetzen.
Insert rotary group into housing
to seat position.

1
2

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.
Fix zero position of cylinder
with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

34

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Triebwerksabstimmung (siehe Serviceinfo)

Reparaturanleitung A6VM

Rotary group adjustment (see service information)

Repair Instructions A6VM

56

Mit Schraube Zylinderausschwenkung

vermitteln.
Determine cylinder swivel range to
max. angle with screw.

57

* Scheibe
* Disc

58

Zentrierscheibe aufsetzen.
Place centering disc.

59

Mevorrichtung aufbauen.
Mount measuring device.

60

Ma X berprfen.
Check dimension X.

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Reparaturanleitung A6VM
Repair Instructions A6VM

Anschluplatte montieren
Assembly of the port plate

1. Anschluplatte mit Differentialkolben montieren.

Montageausfhrung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Ma * einstellen.
4. Verschluschraube einbauen.
5. Montagehlse demontieren.
1. Assemble port plate with
differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

61
62

Deckel montieren.
Assemble cover.

63

Steuerteil montieren.
Assemble control components.

36

Brueninghaus Hydromatik

RDE 91604-01-R/08.96

Anschluplatte montieren

Reparaturanleitung A6VM

Assembly of the port plate

Repair Instructions A6VM

1. Anschluplatte mit Gleichgangkolben montieren.

Montageausfhrung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Ma * einstellen.
4. Verschluschraube einbauen.
5. Montagehlse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

64
65

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehlse einpressen.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Take care of press-in depth.

Brueninghaus Hydromatik

37

RDE 91604-01-R/08.96

Anziehdrehmomente

Reparaturanleitung A6VM
Repair Instructions A6VM

Tightening torques

Anziehdrehmomente fr Schaftschrauben
(Metrisches ISO-Regelgewinde)

Tightening torques for shaft bolts

(Metric ISO Standard Thread)
Strength Classes

Festigkeitsklassen
Die nebenstehenden Werte fr Anziehdrehmomente gelten nur fr

Gewinde

8.8

10.9

12.9

The values for tightening torques

shown in the table are valid only for

Thread

8.8

10.9

12.9

gre

Anziehdrehmoment(Nm)

M3

1,1

1,6

1,9

M4

2,9

4,1

4,9

M5

8,5

10

leicht oder nicht gelte, unbehandelte

M6

10

14

Oberflchen, sowie nur bei Verwen-

M8

25

96

dung von Drehmoment- und Kraftbe-

M10

49

grenzungsschlsseln.

M12

86

M14

135

190

230

M14

99,5

140,0

169,5

M16

210

295

355

M16

154,8

217,4

261,6

Schaftschrauben mit metrischem ISORegelgewinde und Kopfauflagemaen

nach DIN 912, DIN 931 und DIN 933.
Auerdem gelten diese Werte nur fr

shaft bolts with metric ISO- standard

size

Tightening Torque (lb.ft)

M3

0,8

1,2

M4

2,1

3,0

3,6

912, DIN 931 and DIN 933. These

M5

4,4

6,3

7,4

17

values are also valid only for light or

M6

7,4

10,3

12,5

41

unoiled, untreated surface as well as

M8

18,4

25,8

30,2

69

83

for use only with torque-indicating

M10

36,1

50,9

61,2

120

145

wrenches and force limiting tools.

M12

63,4

88,4

106,9

threads and head support surface

dimensions in accordance with DIN

M18

290

405

485

M18

213,7

298,5

357,4

M 20

410

580

690

M 20

302,2

427,5

508,5

M 22

550

780

930

M 22

405,4

574,9

685,4

M 24

710

1000

1200

M 24

523,5

737,0

884,4

M 27

1050

1500

1800

M 27

773,9

1105,5

1326,6

M 30

1450

2000

2400

M 30

1068,7

1474,0

1768,8

Tightening torques for locking screws VSTI

(Metric ISO fine thread)

Anziehdrehmomente fr Verschluschrauben VSTI

(Metrisches Feingewinde)
Gewindegre

Bezeichnung

Thread size

Designation

M8x1

VSTI 8 x 1

-ED/SA

=5

M8x1

VSTI 8 x 1

-ED/SA

M 10 x 1

VSTI 10 x1

-ED

= 10

M 10 x 1

VSTI 10 x1

-ED

=7

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 20

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 15

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 30

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 22

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 30

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 22

M 18 x 1,5

VSTI 18 x 1,5

-ED/SA

= 40

M 18 x 1,5

VSTI 18 x 1,5

-ED/SA

= 29

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 50

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 37

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 60

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 44

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 70

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 51

M 27 x 2

VSTI 27 x 2

-ED

= 90

M 27 x 2

VSTI 27 x 2

-ED

= 66

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 100

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 74

M 33 x 2

VSTI 33 x 2

-ED/SA

= 120

M 33 x 2

VSTI 33 x 2

-ED/SA

= 88

M 42 x 2

VSTI 42 x 2

-ED/SA

= 200

M 42 x 2

VSTI 42 x 2

-ED/SA

= 147

M 48 x 2

VSTI 48 x 2

-ED

= 300

M 48 x 2

VSTI 48 x 2

-ED

= 220

Anziehdrehmoment(Nm)

Anziehdrehmomente fr Seal-Lock Bundmuttern

(Metrisches ISO-Regelgewinde)

Tightening torques (lb.ft)

=4

Tightening torques for seal-lock nuts

(Metric ISO-Standard Thread)

Festigkeitsklassen
Die nebenstehenden Werte fr An-

Gewinde

8.8

10.9

Strength classes
12.9

The values for tightening torques

8.8

gre

Lock Bundmuttern der Festigkeits-

M6

10

seal-lock nuts of the strength class 8.8

M6

7,4

klasse 8.8 mit metrischem ISO-Regel-

M8

22

and with metric ISO-standard thread.

M8

16,2

M 10

40

M 10

29,5

M 12

69

M 12

50,9

M 14

110

M 14

81,1

M 16

170

M 16

125,3

Anziehdrehmoment (Nm)

Anziehdrehmomente fr Linsenschrauben mit Kreuzschlitz DIN 7985

(Metrisches ISO-Regelgewinde)

shown in the table are valid only for

Thread

ziehdrehmomente gelten nur fr Seal-

gewinde.

size

ziehdrehmomente gelten nur fr Linsenschrauben mit Kreuzschlitz DIN

7985 der Festigkeitsklasse 8.8 mit
metrischem ISO-Regelgewinde

38

Gewinde

8.8

10.9

12.9

Strength classes
12.9

gre

Anziehdrehmoment(Nm)

M3

1,1

M4

2,9

M5

The values for tightening torques

shown in the table are valid only for
cross-slotted lens head screws DIN

Thread
size

8.8
0,8

M4

2,1

M5

4,4

M6

10

M6

7,4

M8

25

M8

18,4

M10

49

M10

36,1

7985 of the strength class 8.8 and with

metric ISO-standard thread.

10.9

12.9

Tightening torques (lb.ft)

M3

Brueninghaus Hydromatik

10.9

Tightening torque (lb.ft)

Tightening torques for cross-slotted lens head screws

DIN 7985
(Metric ISO- Standard Thread)

Festigkeitsklassen
Die nebenstehenden Werte fr An-

1,4

RDE 91604-01-R/08.96

Sicherheitsbestimmungen

Reparaturanleitung A6VM

Safety regulations

Repair Instructions A6VM

Allgemein

General advice

Machen Sie sich mit der Ausstattung der Maschine

vertraut.
Fahren Sie die Maschine nur, wenn Sie sich vllig
mit den Bedien- und Steuerelementen sowie der
Arbeitsweise der Maschine vertraut gemacht haben.
Benutzen Sie Ihre Schutzausrstung wie
Schutzhelm, Sicherheitsschuhe und Gehrschutz.
Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
Benutzen Sie die Maschine nur fr den ihr zugedachten Zweck.

Make yourself familiar with the equipment of the

machine.
Only operate the machine if your are completely
familiar with the operating and control elements as
well as the functioning of the machine.
Use your safety equipment like helmet, safety shoes
and hearing protection.
Make yourself familiar with your working field.
Only operate the machine for its intended purpose.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

Please observe the guidelines of the Professional

Association and the machine manufacturer.

Vor dem Start

Before starting

Beachten Sie die Bedienungshinweise vor dem

Starten.
Prfen Sie die Maschine aut auffllige Fehler.
Fahren Sie die Maschine nicht mit defekten
Instrumenten, Kontrolleuchten oder Steuerorganen.
Alle Schutzvorrichtungen mssen fest auf ihrem
Platz sein.
Nehmen Sie keine losen Gegenstnde mit bzw.
befestigen Sie diese an der Maschine.
Halten Sie die Maschine von ligem und zndfhigem Material frei.
Prfen Sie vor dem Besteigen der Maschine, ob
sich Personen oder Hindernisse neben oder unter
der Maschine befinden.
Vorsicht beim Besteigen der Maschine, bentzen
Sie Treppen und Griffe.
Stellen Sie vor dem Start Ihren Sitz ein.

Observe the operating instructions before starting.

Check the machine for remarkable faults.
Do not operate the machine with defective
instruments, warning lights or control elements.
All safety devices must be in a secure position.
Do not carry with you movable objects or secure
them to the machine.
Keep oily and inflammable material away from the
machine.
Before entering thc drivers cabin, check if persons
or obstacles are beside or beneath the machine.
Be careful when entering the drivers cabin, use
stairs and handles.
Adjust your seat before starting.

Brueninghaus Hydromatik

39

RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Sicherheitsbestimmungen
Safety regulations
Starten
Beim Starten mssen alle Bedienhebel in Neutralstellung stehen.
Die Maschine nur vom Fahrersitz aus Starten.
Prfen Sie die Anzeigeinstrumente nach dem Start,
um sicher zu gehen, da alles ordnungsgem
funktioniert.
Lassen Sie die Maschine nicht unbewacht, whrend
der Motor luft.
Beim Start mit Batterieverbindungskabeln verbinden
Sie Plus mit Plus und Minus mit Minus. Massekabel
(Minus) immer zuletzt anschliesen und zuerst abtrennen.

Start
When starting all operating levers must be in
neutral position.
Only start the machine from the drivers seat
Check the indicating instruments after start to
assure that all functions are in order.
Do not leave the machine unobserved when the
motor is running.
When starting with battery connection cables
connect plus with plus and minus with minus.
Always connect mass cable (minus) at last and cut
off at first.

Vorsicht
Auspuffgase sind lebensgefhrlich. Bei Start in
geschlossenen Rumen fr ausreichende Luftzufuhr
sorgen!

Attention
Exhaust gas is dangerous. Assure sufficient fresh
air when starting in closed rooms!

Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!

Hydraulic equipment
1. Hydraulic equipment is standing under high
pressure.

Unter hohem Druck austretende Hochdruck-

2.
3.

4.

5.

6.
7.

Flssigkeiten (Kraftstoff, Hydraulikl) knnen

die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen
Arzt aufsuchen, da anderenfalls schwere
Infektionen entstehen knnen!
Bei der Suche nach Leckstellen wegen Ver
letzungsgefahr geeignete Hilfsmittel verwenden!
Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Gerte
absenken!
Bei Arbeiten an der Hydraulikanlage unbedingt
Motor abstellen und Traktor gegen Wegrollen
sichern (Feststellbremse, Unterlegkeil)!
Beim Anschlieen von Hydraulikzylindern und
-motoren ist auf vorgeschriebenen Anschlu der
Hydraulikschluche zu achten!
Bei Vertauschen der Anschlsse umgekehrte
Funktionen (z.B. Heben/Senken) - Unfallgefahr!
Hydraulikschlauchleitungen regelmig kontrollieren und bei Beschdigung und Alterung austauschen! Die Austauschschlauchleitungen mssen den technischen Anforderungen des Gerteherstellers entsprechen!
le, Kraftstoffe und Filter ordnungsgem
entsorgen!

40

Brueninghaus Hydromatik

High pressure fluids (fuel, hydraulic oil) which

2.
3.

4.

5.

6.
7.

escape under high pressure can penetrate the

skin and cause heavy injuries.
Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
When searching leakages use appropriate auxiliary
devices because of the danger of accidents.
Before working at the hydraulic equipment, lower
pressure to zero and lower working arms of the
rnachine.
When working at the hydraulic equipment, absolutely
stop motor and secure tractor against rolling away
(parking brake, shim)!
When connecting hydraulic cylinders and motor pay
attention to correct connection of hydraulic flexible
hoses.
In case of exchanging the ports, the tunctions are
vice versa (f. ex. lift-up/lower) - danger of accidents!
Check hydraulic flexible hoses regularly and replace
them in case of dammage or wear! The new hose
pipes must comply with the technical requirements
of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!

RDE 91604-01-R/08.96

Reparaturanleitung A6VM
Repair Instructions A6VM

Hinweis!

Note!

Um eine ordnungsgeme
Abwicklung von ErsatzteilAuftrgen sicherzustellen, mu
die Bestellung folgende Angaben
enthalten:

In order to supply proper spare

parts, please provide following
specifications when ordering
spares:

Typenschlssel
Typ-Nr.
Fabrikations-Nr.
Baugruppe
Position
Benennung

Type Code
Type Number
Serial Number
Assembly Group
Item
Designation

Zur Reparatur des Gertes

empfehlen wir die Verwendung
von vormontierten und
teilgeprften Baugruppen.

In repairing the unit, we

recommend the use of
pre-assembled partially tested
assembly groups.

HYPROMATIK GmbH
Glockeraustrae 2
D-89275 Elchingen
Postanschrift: Postfach 22 60, D-89012 Ulm
Telefon (0 73 08) 8 20
Telex 712538
Telefax (0 73 08) 72 74, 72 73

Brueninghaus Hydromatik

41

Service Notes
This publication provides maintenance and service procedures for Meritor PRA 352 series planetary axles.
The information contained in this publication was current at the time of printing and is subject to revision
without notice or liability.
1. You must understand all procedures and instructions before you begin maintenance and service
procedures.
2. You must follow your companys maintenance and service guidelines.
3. You must use special tools, when required, to avoid serious personal injury and damage to components.
Meritor uses the following notations to alert the user of possible safety issues and to provide information
that will help to prevent damage to equipment and components.

WARNING

A WARNING indicates a procedure that you

must follow exactly to avoid serious personal
injury.

CAUTION

A CAUTION indicates a procedure that you

must follow exactly to avoid damaging equipment or components. Serious personal injury
can also occur.

NOTE: A NOTE indicates an operation, procedure

or instruction that is important for proper service. A NOTE can also supply information that
can help to make service quicker and easier.

T
This symbol indicates that fasteners must be
tightened to a specific torque value.

Visit Our Web Site

How to Order

Visit the Technical Library section of

www.meritorauto.com for additional product and
service information on Meritors Heavy Vehicle
Systems component lineup.

Call Meritors Customer Service Center at

800-535-5560.

Drivetrain Plus Technical

Electronic Library (TEL) on CD
The CD includes product and service information
on Meritors Drivetrain Plus component lineup.
$20. Order TP-9853.

47

PRA 352 Trumpet Variation No. 1

PRA 352 Trumpet Variation No. 1

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

Item

Description
Central Housing
Level Plug
Drain Plug
Vent Plug
Hydraulic Line Bleeder
Cover
Capscrew
Differential Case Assembly
Washer
Capscrew
Spacer
Thrust Washer
Side Gear
Thrust Washer
Pinion Gear
Spider
Spiral Gear & Pinion
Washer
Capscrew
Bearing Cone
Bearing Cup
Brake Housing
Capscrew
Adjuster Ring
Adjuster Ring Lock
Capscrew
Pinion Cage Shim
Pinion Cage Assembly
Bearing Cup
Bearing Cup
Bearing Cone
Bearing Cone
Drive Pinion Shim
Washer
Capscrew
Pinion Nut
Driven Sleeve
Drive Sleeve
Snap Ring
Motor Adapter Flange
Washer
Capscrew

II

Description

43
44
45
46
47
48
49
50
51
52
53
54

Outer Piston
Piston O-ring
Piston O-ring
Piston Brake Shim
Inner Piston
O-ring Piston
Spring
Washer
BoltReturn Spring
Spring
Brake Actuating Plate
Capscrew

55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77

Friction Disc
Stationary Disc
Brake Reaction Plate
Brake Disc Lock Pin
Sun Gear
Ring Gear
Capscrew
Planetary Pinion Spider
Planetary Pinion Shaft
Capscrew
Housing
Bearing Cone
Bearing Cone
Bearing Cup
Bearing Cup
Output Axle Shaft
Wheel Bolt
Axle Shaft Oil Seal
Adjusting Nut
Adjusting Nut Lock Capscrew
Thrust Washer
Kit Rollers
Roller Spacer

78
79
80
81
82
83
84

Planetary Pinion
Washer
Snap Ring
Stud
Capscrew
Washer
Nut

PRA 352 Trumpet Variation No. 2

35
11

10
2

4
73
3
7
65
3
4

64

2
12

63

61

10
62

11

13

67

14

59
60
59

58

66

15

69

1
71

56

68

70

46

57
32

71
31
69

47

55

49

30

53

48
50
52

51

43A
54
21

44

38
33

20

45

34

43

39
38
19

42

39

26

40

41

40

16

27
28

42

17
18
24
23
22

38
39
45
44 47 41 38
50

54
53

49
46

52

25
51

39
55

56

48

37
36

34
33

30

57

31

59

32

61A

72

29

62
58A

63

59

64
65

60

III

73

PRA 352 Trumpet Variation No. 2

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

Item

Description
Center Housing
Differential Case Assembly
Side Gear
Side Gear Thrust Washer
Pinion Gear
Pinion Gear Thrust Washer
Spider Differential
Spiral Gear Capscrew Plain Washer
Spiral Gear Capscrew
Bearing Cone
Bearing Cup
Spiral Gear & Pinion Assembly
Differential Case Plain Washer
Differential Case Capscrew
Shim Differential Case
Pinion Cage
Bearing Cup
Bearing Cone
Pinion Bearing Spacer
Bearing Cup
Bearing Cone
Universal Joint Yoke
Oil Slinger
Oil Seal
Pinion Nut
Shim Pinion Cage
Pinion Cage Washer
Pinion Cage Capscrew
Brake Housing
Brake Piston
Oil Seal Piston
Oil Seal Piston
Piston Return Spring
Return Spring Bolt
Adjuster Ring
Adjuster Ring Lock
Adjuster Ring Lock Capscrew
Stationary Disc

IV

Description

39
40
41
42
43
43A
44
45
46
47
48
49

Friction Disc
Brake Reaction Plate
Brake Disc Lock Pin
Ring Gear
Sun Gear, Short
Sun Gear, Long
Adjusting Nut
Adjusting Nut Lock Capscrew
Planetary Pinion Flange
Shaft Planetary Pinion
Planetary Pinion Axle Capscrew
Planetary Pinion Thrust Washer

50
51
52
53
54
55
56
57
58
58A
59
60
61
61A
62
63
64
65
66
67
68
69
70

Planetary Pinion
Rollers
Spacer Rollers
Planetary Pinion Plain Washer
Snap Ring
Bearing Cone
Bearing Cup
Housing
Center Housing Stud
Center Housing Stud
Washer
Center Housing Stud Nut
Center Housing Capscrew
Center Housing Capscrew
Bearing Cup
Bearing Cone
Axle Shaft Oil Seal
Axle Shaft
Center Housing Cover
Center Housing Cover Capscrew
Drain Plug
Level Plug
Vent Plug

71
72
73

Hydraulic Bleeder
Capscrew
Wheel Bolt

PRA 353/383
68
67
65
66
64
62
82

83
81
60
63
61
69

81
80

73

71
72
75
74

57

70
77

37
43

42

89 54 46
55
50

48

37
38

40

45

53

85

36

44

84
86

56
52

58

36
37

49
47

79
59

78

39

41

87

88

51

58

89

14

20

12
11 8

13
19
18
26

27
28

29

4
3

15
16
24 17

79

12

60
80
81
82

78
69
61
63

10
31

23
22

30

77
76
70
74
7
75 73
72
2
71
9
11

81
83
62
64
66

32

33

59
25

67

65

34

21

68

36
37

35

36

38

37

42

39

41

37

43

89 54
55
50

46

51

52

40
49
44

56

53

57

47
48

45

PRA 353/383
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Item

Description
Center Housing
Differential Case
Side Gear
Thrust Washer
Pinion Gear
Thrust Washer
Differential Pinion Shaft
Pinion Shaft Lock Pin
Washer
Capscrew
Bearing Cone
Bearing Cup
Spiral Gear and Pinion
Differential Case Shim
Pinion Cage
Bearing Cup
Bearing Cone
Drive Pinion Shim
Bearing Cup
Bearing Cone
Motor Adapter Flange
Driven Sleeve
Drive Sleeve
Snap Ring
Pinion Nut
Pinion Cage Shim
Washer
Capscrew
Washer
Capscrew
Brake Housing
Capscrew
Adjuster Ring
Adjuster Ring Lock
Capscrew
Stationary Disc
Friction Disc
Brake Disc Lock Pin
Brake Assembly
Pin
Circlip
Brake Control Rod
Brake Cylinder Support
Spring
Brake Piston

VI

Description

46
47
48
49
50
51
52
53
54
55
56
57

O-ring
O-ring
Brake Cylinder
Capscrew
Adjusting Nut
Nut
Brake Cylinder Cover
Capscrew
Washer
Capscrew
Capscrew
Reaction Brake Plate

58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

Ring Gear
Sun Gear
Housing
Bearing Cone
Bearing Cup
Bearing Cup
Bearing Cone
Axle Shaft
Axle Shaft Oil Seal
Wheel Bolt
Wheel Nut
Planetary Pinion Spider
Planetary Pinion Shaft
Capscrew
Thrust Washer
Planetary Pinion
Spacer
Kit Rollers
Washer
Snap Ring
Adjusting Nut
Adjusting Nut Lock Capscrew
Stud M14

81
82
83
84
85
86
87
88
89

Washer
Nut
Capscrew
Cover
Capscrew
Level Plug
Drain Plug
Vent Plug
Hydraulic Line Bleeder

PROA 352/382 (With Mechanical Drive Option)

17

16
4
36

98 99

20

18

97

43
19

24

26

27
2

14 13
32

23

15

22
37

40

94

39

12

38

99

93
11

41

21
34

95

10
35

4
28

33

43
96

30

45
42

58

31

44

57

52

56
54

59
51

55

29
85

53

77
49
60

84
50
86

62
63

46
65

61

47
66

83

67

82
68

48

79

87

64

89

100

78

72

88

64A

73

90

92
91

76

69

80
81
74
70

71

VII

PROA 352/382 (With Mechanical Drive Option)

Item

Item

Description

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Main Housing
Bushing
Trunnion Oil Seal
Differential Case Assembly
Differential Case Capscrew
Differential Case Washer
Side Gear
Friction Discs Shim Pack
Friction Drive Disc
Friction Driven Discs
Compression Discs
Thrust Washer
Pinion Gear
Pinion Gear Thrust Washer
Spider

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

Gear Capscrew Washer

Gear Capscrew
Differential Case Cone Bearing
Differential Case Cup Bearing
Gear and Pinion Assembly
Pinion Bearing Case
Shaft Side Cone Bearing
Shaft Side Cup Bearing
Pinion Bearing Spacer
Not Shown
Head Side Cup Bearing
Head Side Cone Bearing
Adapter Flange
Universal Joint Yoke
Deflector
Pinion Oil Seal
Driven Sleeve
Drive Sleeve
Snap Ring
Pinion Nut
Pinion Bearing Cage Shim
Bearing Cage Capscrew Washer
Bearing Cage Capscrew
Flange Capscrew Washer
Flange Capscrew
Brake Housing
Brake Housing Capscrew
Adjusting Ring
Adjusting Ring Lock
Lock Capscrew
Stationary Disc
Friction Disc
Brake Disc Lock Pin
Action Plate
Bolt
Medium Oil Seal

52
53
54
55
56
57
58
59
60
61
62
63
64
64A
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

VIII

Description
Spring
Return Spring Capscrew
Return Spring
Inner Piston
Shim Pack
Small Oil Seal
Outer Piston
Oil Seal
Reaction Plate
Ring Gear
Short Sun Gear
Long Sun Gear
Axle Shaft Housing
Bushing
Bearing Cone
Bearing Cup
Bearing Cup
Bearing Cone
Axle Shaft
Wheel Flange
Flange Capscrew
Axle Shaft Oil Seal
Wheel Capscrew
Wheel Nut
Not Shown
Planetary Gear Pin
Pin Capscrew
Flange Side Thrust Washer
Planetary Gear
Rollers Spacer
Rollers Kit
Thrust Washer
Snap Ring
Adjusting Nut
Adjusting Nut Lock Capscrew
Planetary Spider
Short Stud
Long Stud
Washer
Nut
Bolt
Brake Release Bolt
Main Housing Cap
Cap Capscrew
Level Plug
Drain Plug
Grease Plug
Vent Plug
Bleeder
Spacer

PROA 352/382

IX

PROA 352/382
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Item

Description
Center Housing
Bushing
Trunnion Oil Seal
Lubrication Fitting
Level Plug
Drain Plug
Vent Plug
Hydraulic Line Bleeder
Cover
Capscrew M8x1,25x16,0
Differential Case Assembly
Washer
Capscrew M10x1,5x80,0
Drive Disc
Driven Friction Disc
Clutch Disc Shim
Compression Disc
Thrust Washer
Side Gear
Thrust Washer
Pinion Gear
Spider
Spiral Gear & Pinion
Washer
Capscrew
Bearing Cone
Bearing Cup
Brake Housing
Capscrew
Adjuster Ring
Adjuster Ring Lock
Capscrew
Pinion Cage Shim
Pinion Cage
Bearing Cup
Bearing Cup
Bearing Cone
Bearing Cone
Drive Pinion Shim
Washer
Capscrew
Pinion Nut
Driven Sleeve
Drive Sleeve
Snap Ring
Motor Adapter Flange
Washer
Capscrew

Description

49
50
51
52
53
54
55
56
57
58
59
60

Brake Piston Assembly

O-ring Piston
O-ring Piston
Piston Brake Shim
Brake Piston
O-ring Piston
Spring
Washer
BoltReturn Spring
Spring
Brake Actuating Plate
Capscrew

61
62
63
64
65
66
67
68
69
70
71
71A
72
73
74
75
76
77
78
79
80
81
82

Stationary Disc
Friction Disc
Brake Reaction Plate
Brake Disc Lock Pin
Sun Gear
Ring Gear
Capscrew
Planetary Pinion Spider
Planetary Pinion Shaft
Capscrew
Housing
Bushing
Bearing Cone
Bearing Cone
Bearing Cup
Bearing Cup
Output Axle Shaft
Wheel Flange
Wheel Bolt
Capscrew
Axle Shaft Oil Seal
Adjusting Nut
Adjusting Nut Lock Capscrew

83
84
85
86
87
88
89
90
91
92
93
94

Thrust Washer
Kit Rollers
Spacer
Planetary Pinion
Washer
Snap Ring
Stud
Capscrew
Washer
Nut
Spacer
Brake Release Capscrew

Table of Contents
Section 1: Introduction
Description ......................................................................................................................................................1
Identification

Section 2: Removal and Disassembly

Remove Axle ..................................................................................................................................................2
Disassemble Ball and Ramp Brake
Disassemble Trumpet Assembly ....................................................................................................................3
Disassemble Planetary System and Axle Shaft ..............................................................................................4
Disassemble Hydraulic Apply Wet Disc Brake................................................................................................5
Disassemble Three Function Wet Disc Brake
Disassemble Main Housing ............................................................................................................................7
Disassemble Differential Case ........................................................................................................................8
Disassemble Pinion Bearing Cage ................................................................................................................10

Section 3: Prepare Parts for Assembly

Clean Ground and Polished Parts ................................................................................................................13
Clean Parts With Rough Finish
Clean Axle Assemblies
Dry Cleaned Parts
Prevent Corrosion
Inspect Parts
Inspect Tapered Roller Bearings ..................................................................................................................14
Inspect Hypoid Pinion and Ring Gear Sets ..................................................................................................15
Inspect Main Differential Assembly
Inspect Axle Shafts
Inspect Main Housing ..................................................................................................................................16
Inspect Yoke
Inspect Planetary System Parts
Inspect Brakes
Repair or Replace Parts
Repair Welding
Liquid Adhesive ............................................................................................................................................17
Disassemble Locked Sets
Cleaning
Reassembly
Application
Apply Silicone Gasket Material ....................................................................................................................18
Duo-Cone Oil Seal: Mount and Install

Section 4: Assembly and Installation

Assemble Differential Case ..........................................................................................................................23
Check Rotating Resistance of Differential Gears (Not Limited Slip) ............................................................26
Assemble Drive Pinion and Bearing Cage ....................................................................................................27
Adjust Pinion Bearing Preload (Without Press) ............................................................................................28
Adjust Thickness of Pinion Bearing Cage Shim Pack (Depth of Pinion) ......................................................29
Install Pinion Bearing Cage Assembly on Main Housing ..............................................................................31
Install Differential Housing Assembly into Main Housing (With Shims) ........................................................32
Install Differential Housing Assembly into Main Housing (With Adjusting Ring 2 Sides) ..............................33
Assemble Axle Shaft ....................................................................................................................................34
Assemble Trumpet Assembly ......................................................................................................................35

Table of Contents
Assemble Hydraulic Apply Brake Housing Assembly ..................................................................................38
Hydraulic Apply Brake Housing Functional Test
Assemble Three Function Brake Housing Assembly ....................................................................................39
Assemble Ball and Ramp Brakes, Brake Discs, Reaction Plate and Pins ....................................................42
Assemble Three Function Brake, Brake Discs, Reaction Plate and Pins ....................................................43
Install Housing Assembly into Main Housing
Assemble Three Function Brake Release Bolts and Sleeves ......................................................................44
Assemble Ball and Ramp Brake Cylinder Assembly and Install on Main Housing

Section 5: Adjustments
Check Ring Gear Runout Specification: 0.008 in. (0.20 mm)........................................................................47
Adjust Pinion and Ring Gear Backlash Specification: 0.005 in-0.015 in (0.13 mm-0.38 mm)
Teeth Contact Patterns ................................................................................................................................48
Verification Procedure
Correct Contact Patterns ..............................................................................................................................49
Incorrect Contact Patterns
High Contact Pattern
Deep Contact Pattern ..................................................................................................................................50
Variations Along Length of Gear Teeth
Replace Lubricant ........................................................................................................................................51

Section 6: Specifications
Oil Change Intervals and Specifications ......................................................................................................52
Nut Lock Special Tool ..................................................................................................................................53
Torque Charts
PROA 352/382 ..........................................................................................................................................54
PRA 352 ....................................................................................................................................................56
PROA 352 G2H/G2M ................................................................................................................................58

Section 1
Introduction
Description

Identification

The Meritor PRA 352 Series Planetary Axle is a

double reduction single speed unit that has:

A tag on the main housing correctly identifies basic

axle specifications.

A hypoid or spiral pinion and ring gear set

When ordering parts, be sure to specify information

stamped on the name plate. This information will
allow easy identification of correct parts.

A differential case assembly mounted on two

tapered roller bearings

A planetary system with 3 or 4 planetary pinion

gears

A trunnion mounting option

Bevel gears in the differential assembly with 2 or

4 differential pinion gears

An oil bath disc brake system in three different

designs:
1. Ball and Ramp
2. Hydraulic Apply Wet Disc
3. Three Function Brake

R - RIGID

P - PLANETARY

IF APPLICABLE:
O - OSCILLATING OR PIN
MOUNTING

HOUSING TYPE DESIGNATION:

A - POT OR SPLIT CARRIER

PROA 352 G2M

DIFFERENTIAL:
WHEEL END NUMBER OF
PLANETARY GEARS:

2 - SPIRAL

35 - 3 PLANETARY GEARS

3 - HYPOID

38 - 4 PLANETARY GEARS

WET DISC BRAKE DESIGNATION:

W2H - 3 FUNCTION/HYDRAULIC APPLY
G2H - HYDRAULIC BALL AND RAMP
G2M - MECHANICAL BALL AND RAMP
NOTE: ALL BRAKES ARE 9 INCH
DIAMETER (229 mm)

Section 2
Removal and Disassembly
Remove Axle

WARNING

To prevent serious eye injury, always wear safe

eye protection when you perform vehicle
maintenance or service.

WARNING

Support vehicle with safety stands. Do not work

under a vehicle only supported by jacks. Jacks
can slip or fall over and cause serious personal
injury.

NOTE
While the housing configuration of the axle you
service may differ from the figures shown,
service instructions remain the same for all axle
models addressed in this manual.
1. Make sure vehicle is on level surface.
2. Place blocks under wheels not being serviced to
keep vehicle from moving.
3. Raise vehicle so that wheels to be serviced are
off the ground. Support vehicle with safety
stands.
4. Remove axle from vehicle.
5. Plug fluid lines that were connected to axle.

Disassemble Ball and Ramp

Brake
NOTE

Identify all parts before disassembly to ensure

proper reassembly.

To disassemble hydraulic apply wet disc

brake, go to page 5.

To disassemble three function brake, go to

page 5.

Figure 2.2.
Figure 2.2
CAP
ADJUSTING
NUT

LOCK NUT

SPRING
PISTON

O-RING

O-RING
WITHOUT
HYDRAULIC
PRESSURE
BRAKE
CYLINDER
SUPPORT

BRAKE
CYLINDER

6. Place axle in appropriate repair stand. Center

main housing on stand. Figure 2.1.
7. Remove drain plugs from brake housing and
main housing with 12 mm Allen wrench. Drain
axle oil.
Figure 2.1

The PROA 352 axle is shown to illustrate

procedures in this maintenance manual
2

1. Remove brake cylinder cover.

2. Remove nut and nut lock.
3. Loosen brake cylinder capscrews.
4. Remove brake cylinder assembly from main
housing.

Section 2
Removal and Disassembly
!

CAUTION

Loosen and remove brake cylinder capscrews

alternately to avoid spring load damage to parts.
5. Disassemble brake cylinder assembly. Remove
brake release capscrew. Loosen and remove
brake cylinder capscrews alternately to avoid
spring load to be supported by only one capscrew.
6. Remove spring, piston and O-ring seals. Do not
cut or scratch them.
7. Clean cylinder and brake support surfaces. Do
not damage ground surfaces.
8. Put parts of each brake cylinder assembly in
separate plastic bags to avoid mixing them.

Disassemble Trumpet
Assembly

WARNING

To avoid serious personal injury and possible

damage to components, be very careful when
using lifting devices during removal and
disassembly procedures.

Inspect to make sure that neither lifting strap is

damaged.

Do not subject lifting straps to any shock or

drop loading.

NOTE
For three function brake design: If bleeder and
pressure ports of brake piston are open, the
trumpet assemblies and ring gear will come off
the center section easily without using puller
holes. Cover pressure ports with rags to avoid
contact with escaping oil.
3. Use two puller holes in trumpet flange to remove
trumpet assembly from main housing.

NOTE
Use steps 1 through 3 to remove second trumpet
assembly.
4. Remove ring gears from both sides through the
two threaded puller holes.
(Thread: M14 x 1.5 x 6 g).

WARNING

Do not hit steel parts with a steel hammer during

removal and disassembly procedures. Parts can
break and cause serious personal injury.
5. From main housing, remove sun axle shaft,
spacers (if used), compression plates, stationary
discs, friction discs, lock pins and expansive
plate assemblies. To make lock pin removal
easier, hit main housing with brass hammer.
Figure 2.4.
Figure 2.4

1. Support trumpet to be serviced with lifting device.

Figure 2.3.
2. Loosen and remove trumpet nuts and bolts.
Figure 2.3

Section 2
Removal and Disassembly
Disassemble Planetary System
and Axle Shaft
NOTE
Before removing planetary gears, place housing
in horizontal position or place cloth between
pinion gear flange and housing flange to keep
rollers from falling down into housing. To avoid
mixing them, be sure to put rollers and spacers
of each planetary gear in separate plastic bags.

4. Remove pinion gear flange. Lift it through

planetary gear pins.
5. Remove axle shaft assembly and cone bearing.
If necessary, use press. Figure 2.7.
Figure 2.7

1. With pliers, remove snap rings. Disassemble

planetary gears and rollers.
Figure 2.5.
Figure 2.5

6. If necessary to change bearing cups, remove

them with correct puller.
7. If necessary to replace DUO-CONE oil seal or axle
shaft roller bearing cone, use correct puller.
Figure 2.8.
Figure 2.8
2. Remove axle shaft adjusting nut lock.
3. Remove axle shaft adjusting nut lock with special
tool, illustrated in Section 6. Figure 2.6.

Figure 2.6

DUO-CONE
OIL SEAL

Section 2
Removal and Disassembly
Disassemble Hydraulic Apply
Wet Disc Brake

Disassemble Three Function

Wet Disc Brake

1. Remove piston return spring capscrews.

NOTE

2. Remove return springs.

Do not disassemble brake piston unless

necessary.

3. Remove brake piston assembly. Figure 2.9.

Figure 2.9

1. Remove return spring capscrews with 4 mm

Allen wrench. Remove return springs and
washers. Figure 2.11.
Figure 2.11

CAUTION

Ground oil seal surfaces must be properly

protected to avoid damage. Whenever necessary,
use No. 600 sandpaper to correct any damage.
4. If necessary, replace brake piston oil seals.
Figure 2.10.

2. Remove brake piston assembly from brake

housing as shown in Figure 2.12 or place brake
housing on a bench with the opening turned
down. Inject 80 psi (5.5 bar) compressed air
through inlet of service brake to eject brake
piston.

Figure 2.10

3. Remove shims.
Figure 2.12

5. Follow steps 1 through 4 to disassemble the

second brake piston.

Section 2
Removal and Disassembly
!

WARNING

Use a special tool or press to compress the

brake assembly to avoid serious personal
injury from the spring pressure.

Observe all WARNINGS and CAUTIONS

provided by the press manufacturer
concerning press operation to avoid serious
personal injury and damage to components.

CAUTION

Before removing action plate and other parts,

mark the original assembly positions of all brake
piston assembly parts. This procedure will make
reassembly easier.
6. Remove action plate and springs. Figure 2.15.
Figure 2.15

4. Compress brake piston assembly as shown in

Figure 2.13; or place assembly in press and
apply 1000 lbs. (450 kg) pressure.
5. Remove action plate capscrews. Figures 2.13
and 2.14.
Figure 2.13

7. Remove internal piston by placing brake piston

assembly on bench with action plate support
surface turned down. Tap internal piston with
rubber mallet. Figure 2.16.
Figure 2.16

Figure 2.14

PRESS

Section 2
Removal and Disassembly
8. Use sand paper on piston surfaces if they have
nicks or hits. Figure 2.17.

5. Depending on ring gear position, remove pinion

bearing cage capscrews.

Figure 2.17

6. Remove pinion bearing cage assembly from

main housing. Figure 2.19.
7. Remove drive sleeve and snap ring. Figure 2.19.

Figure 2.19

Disassemble Main Housing

1. Remove adjusting nut capscrew lock.
2. Remove adjusting nut capscrew and
adjusting nut.

DRIVE SLEEVE & SNAP RING

8. Remove differential case assembly. Figure 2.20.

Figure 2.20

3. Remove brake housing capscrews that are set

deep in brake housing flange. Use long 6mm
Allen wrench.
4. Remove brake housing from main housing. Hit
brake housing with brass hammer or use two
slots to remove it from main housing. Be careful
not to hit ring gear. Figure 2.18.
Figure 2.18

9. Remove main housing cover.

Section 2
Removal and Disassembly

1. Before disassembling differential case, mark

position of both halves and spider cross for
easier reassembly. Figure 2.21.

5. If differential case is integral, remove

differential pinion axle lock capscrew and
differential pinion axle. Then turn side gears and
remove differential pinions, side gears and
washers. Figures 2.23, 2.24 and 2.25.

Figure 2.21

Figure 2.23

Disassemble Differential Case

2. Remove differential case capscrews.

Figure 2.24

3. Separate differential case halves. If necessary

use a brass or rubber hammer to separate
halves.
4. Remove spider cross, differential pinions, side
gears and washers. If differential case is
Limited Slip, remove friction disc pack.
Figure 2.22.
Figure 2.22

Figure 2.25

Section 2
Removal and Disassembly
6. If necessary, separate ring gear from differential
case. Remove capscrews and washers that
fasten ring gear. With brass hammer, tap ring
gear to separate it from differential case.
Figures 2.26 and 2.27.

7. If differential case has two halves, remove ring

gear with a press after capscrews have been
removed (Figure 2.26). Use appropriate metal
or wood supports. Figure 2.28.
Figure 2.28

Figure 2.26

SUPPORTS

Figure 2.27

8. If necessary, remove cone bearings from

differential case. Use appropriate puller or
press. Figures 2.29, 2.30 and 2.31.
Figure 2.29

WARNING

Observe all WARNINGS and CAUTIONS provided

by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during removal
and disassembly procedures.

Figure 2.30

Figure 2.31

Section 2
Removal and Disassembly
Disassemble Pinion Bearing
Cage
1. If pinion bearing cage was not removed, hold
yoke, flange or splined sleeve with appropriate
holder to remove pinion nut. Figure 2.32
If pinion bearing cage was already removed,
place it on main housing and fasten with two
capscrews.

CAUTION

To avoid oil leaks, be careful not to damage the

mounting surface of the bearing cage.
3. Remove pinion oil seal. Pry at several points
around circumference between seal, flange and
bearing cage. Figure 2.34.
Figure 2.34
OIL SEAL

Figure 2.32

4. Remove capscrews and washers that fasten pinion

bearing cage on main housing. Figure 2.35.

Figure 2.35

CAUTION

Do not use a hammer or mallet to loosen or

remove yoke, flange or splined sleeve. The
hammer or mallet can damage the parts or cause
alignment problems. Do not damage the oil seal
surface area.
2. Remove yoke, flange or splined sleeve from drive
pinion with appropriate puller tool. Figure 2.33.
Figure 2.33

10

Section 2
Removal and Disassembly
!

CAUTION

Figure 2.37

Do not use pry bar to remove bearing cage from

carrier. A pry bar can damage bearing cage,
shims and main housing.
5. Remove pinion bearing cage and shims from
main housing. If bearing cage is tight within the
main housing, hit bearing cage at several points
around flange area with leather, plastic or rubber
mallet. Figure 2.36.
Figure 2.36

NOTE
The inner bearing cone and bearing spacer will
remain on the pinion shaft.
9. If pinion bearing needs to be replaced, remove
inner and outer bearing cups from inside of
cage. Use a press and sleeve, bearing puller or
small drift and hammer. Figures 2.38 and 2.39.
Figure 2.38

6. If shims are in good condition, keep them

together for use later when main housing is
reassembled.
7. Before damaged shims are discarded, measure
and record total thickness of the pack. The
dimension will be needed to calculate depth of
drive pinion in main housing when gear set is
installed.
8. Place drive pinion and bearing cage in press with
pinion shaft toward top assembly. Support
bearing cage under flange area with metal or
wood blocks. Press drive pinion through bearing
cage. Figure 2.37.

Figure 2.39

11

Section 2
Removal and Disassembly
10. If pinion bearings need to be replaced, remove
inner bearing cone from drive pinion with press
or bearing puller. Puller must fit under inner face
of cone to remove cone correctly without
damage. Figure 2.40.
Figure 2.40

NOTE
If bearing cup is changed, the bearing cone must
also be replaced. The cup and cone must come
from the same manufacturer.

12

Section 3
Prepare Parts for Assembly
Clean Ground and Polished
Parts

WARNING

Clean Axle Assemblies

A complete axle assembly can be steam cleaned

on the outside to remove dirt.

Before the axle is steam cleaned, close or put a

cover over all openings in the axle assembly.
Examples of openings are breathers and
hydraulic inlets.

To prevent serious eye injury, always wear safe

eye protection when you perform vehicle
maintenance or service.

Dry Cleaned Parts

WARNING

If you use cleaning solvents, hot solution tanks or

alkaline solutions incorrectly, serious personal
injury can occur. To prevent serious personal
injury, follow the instructions supplied by the
manufacturer of these products. Do not use
gasoline to clean parts. Gasoline can explode and
cause serious personal injury.

Use a cleaning solvent to clean ground or polished

parts or surfaces. Kerosene or diesel fuel oil can be
used for this purpose. NEVER USE GASOLINE.

Remove gasket material from parts. Be careful not

to damage ground surfaces.

DO NOT clean ground or polished parts in a hot

solution tank, water, steam or alkaline solution.

Clean Parts With Rough Finish

Dry the parts immediately after cleaning and

washing.

Dry the parts with soft clean paper or rags.

CAUTION

Damage to bearings can be caused if dried by

rotating with compressed air.

Except for bearings, parts can be dried with

compressed air.

Prevent Corrosion

Apply axle lubricant to cleaned and dried parts

that are not damaged and are to be assembled.

Apply a special material that prevents corrosion to

all surfaces. If parts are to be stored, wrap the
parts in special paper that prevents rust
and corrosion.

Parts with a rough finish can be cleaned with

cleaning solvent or in a hot solution tank with a
weak alkaline solution.

Parts must remain in hot solution tanks until

completely cleaned and heated.

Inspect Parts

Parts must be washed with water until the alkaline

solution is removed.

It is very important to inspect all parts carefully and

completely before the axle or carrier is assembled.
Check all parts for wear and replace damaged parts.
Replacement of damaged or worn parts will prevent
breakdown of assembly later.

13

Section 3
Prepare Parts for Assembly
Inspect Tapered Roller
Bearings
Inspect the cup, cone, rollers and cage of all tapered
roller bearings in the assembly. If any of the
following conditions exist, the bearing must be
replaced:

The center of the large diameter end of the rollers

are worn level with, or below the surface.

The center of the large diameter end of the rollers

are worn to a sharp edge. Figure 3.1.

Deep cracks or breaks in the cup, cone inner race

or roller surfaces.

Bright wear marks on the outer surface of the roller

cage. Figure 3.3.

Figure 3.3

Figure 3.1
WORN RADIUS
WEAR MARKS

Damage on rollers and on surfaces of the cup and

cone inner race that touch the rollers. Figure 3.4.

Figure 3.4
ETCHING & PITTING

WORN SURFACE

A visible roller groove in the cup or cone inner

race surfaces. The groove can be seen at the
small or large diameter end of both parts.
Figure 3.2.

Figure 3.2

CRACK

14

WEAR GROOVES

Section 3
Prepare Parts for Assembly

Damage on the cup and cone inner race surfaces

that touch the rollers.Figure 3.5.

Figure 3.5

SPALLING & FLAKING

Inspect Main Differential

Assembly
Parts that are damaged must be replaced. Inspect
the following parts for wear or stress. Figure 3.6.
Figure 3.6

Inspect Hypoid Pinion and

Ring Gear Sets

CAUTION

Hypoid drive pinions and ring gears are

machined in matched sets. When a drive
pinion or ring gear of a hypoid set needs to be
replaced, both drive gear and pinion must be
replaced at the same time.
Inspect hypoid pinions and gears for wear and
damage. Gears that are worn or damaged
must be replaced. Also verify the cone bearing
seats and spline in the pinion shaft.

Inside surfaces of both case halves

Both surfaces of all thrust washers
Four trunnion ends of spider cross
Teeth and splines of both side gears
Teeth and bore of all differential pinions
Friction disc packs if used

CAUTION

Always replace old or worn thrust washers,

differential side gears and pinion gears in sets to
avoid higher stress and early damage to parts.

Inspect Axle Shafts

For wear and cracks at flange, shaft and splines.

Replace axle shaft if required.

15

Section 3
Prepare Parts for Assembly
Inspect Main Housing

For fractures and burrs in machined areas.

Inspect Yoke

For wear at seal journal area. Replace yoke,

flange or sleeve if either shows too much wear at
seal journal area.

Inspect Planetary System

Parts

For existence of cracks, pitting, breaks or sharp

edges on planetary gear teeth, planetary gear
axles and rollers.

Inspect Brakes

For condition of friction discs, brake piston springs

and internal brake housing surfaces.

Repair or Replace Parts

General Information
Replace worn or damaged parts of an axle assembly.
The following are some examples to check for repair
and possible replacement:

Replace any fastener if corners of the head are

worn.

Replace washers if damaged.

Clean parts and apply new liquid gasket material

where required when axle is assembled.

Remove nicks, marks and burrs from parts having

machined or ground surfaces. Use a fine file, India
stone, emery cloth or crocus cloth for this purpose.

Clean and repair threads of fasteners and holes.

Use a die or tap of the correct size or a fine file for
this purpose.

Replace gaskets, oil seals or grease seals at the

time of axle repair.

16

CAUTION

Threads must be without damage and clean so

that accurate adjustment and correct torque
values can be applied to fasteners and parts.

Tighten all fasteners to correct torque values. See

chart in Section 6 for fastener torque values.

WARNING

Do not repair axle housings by bending or

straightening. Repair of axle housings by
bending or straightening can cause poor
performance and possible unsafe operation of
the axle. This can cause serious personal injury.

Repair Welding
In the interest of safety and preserving the service
life of drive axle assemblies, Meritor recommends
that assemblies are not repair welded. Repair
welding can detract from the structural integrity of a
component, particularly to heat treated parts where
the benefit of heat treatment may be nullified by
welding.
Since it can be extremely hazardous and detrimental
to repair weld components of any kind, repair welding
can be approved only where stringent controls are
imposed and equipment, customarily located at
manufacturing facilities, is employed, so as to
minimize the potentially detrimental effects of repair
welding.

Section 3
Prepare Parts for Assembly
Liquid Adhesive

Reassembly

Meritor uses the following liquid adhesives to retain

threaded fasteners:

Check the type of liquid adhesive to be used and

where the adhesive is to be applied.

In threaded holes where fasteners did not require

removal, check each one for tightness by applying
the minimum amount of specified torque.

If fasteners do not rotate, they are tightened

properly.

If fasteners rotate to any degree, they must be

removed and liquid adhesive must be applied.

Product

Type

Color

Cure Time

Loctite

271 High
241 Medium
221 Low

Red
Blue
Violet

2 hours
6 hours
6 hours

Three Bond
1305 High
1334 Medium
1341 Low

Red
Green
Blue

5 hours
5 hours
10 hours

Application
1. Apply liquid adhesive to:

Disassemble Locked Sets

Bolt threads when component has open hole.

Before installing bolts, visually check to make
sure that liquid adhesive has filled gap
between threads.

Threaded hole when component has blind

hole. Allow 4 to 6 drops to run down side of
each hole. If liquid adhesive is applied to bolt,
trapped air in hole will create back pressure
and blow out liquid adhesive as bolt
advances. Figure 3.7.

CAUTION

Do not use impact wrenches or strike components

with a hammer.
To disassemble sets originally locked with liquid
adhesive, use the regular mechanical disassembly
procedure.
If the removal of a capscrew, for example, becomes
difficult due to a worn head or unusually high
breakaway torque, the locking strength can be
reduced by heating the threaded area to
approximately 300F (150C). Heat slowly to avoid
thermal stresses on the differential case and gears.

Figure 3.7

Cleaning

WARNING

To avoid serious personal injury, trichloroethylene

must not come in contact with your skin. Do not
smoke and avoid breathing vapors in closed
rooms without ventilation. Do not use
trichloroethylene near flames, welding operations
or hot surfaces exceeding 900F (482C).
Clean capscrew, nut or bolt tapped hole and fastener
thread carefully. Use a cleaning solvent such as
trichloroethylene or equivalent to remove dirt, oil,
grease or moisture.

2. Tighten fasteners with recommended torque.

17

Section 3
Prepare Parts for Assembly
Apply Silicone Gasket Material
Liquid gasket material used by Meritor:

Loctite FAG 3

5. Assemble components quickly to permit gasket

material to compress evenly between parts.
Figure 3.8

Neutral Silicon, Dow Corning 768 or Rhodia

567/666

0.125" (3.18 MM)

DIAMETER
SILICONE GASKET
MATERIAL BEAD

Three Bond 1134

Loctite 515

WARNING

Small amounts of acid vapor are present when

applying some gasket materials. To prevent
possible serious personal injury, make sure
there is good ventilation in the work area. If
liquid gasket material gets in your eyes, flush
eyes with water for 15 minutes. Have eyes
checked by doctor.

CAUTION

6. Tighten fasteners with required torque. See Torque

Chart, Section 6. T

The amount of liquid gasket material applied must

not exceed 0.125 in. (3.18 mm) diameter bead. Too
much gasket material can block lubrication
passages and result in damage to component.

DUO-CONE Oil Seal:

Mount and Install

1. Remove all old gasket material from both surfaces.

Always follow correct procedures when

mounting and installing DUO-CONE oil seals.
Many DUO-CONE oil seal leaks result from
errors made during mounting or installation of
oil seal components.

Never let oil touch Toric ring or lodging ramps

before both oil seal rings are installed in their
mounting position.

NOTE

2. Clean the surfaces where liquid gasket material will

be applied. Remove all oil, grease, dirt and moisture.
3. Thoroughly dry both surfaces.
4. Apply according to the following procedures:

Three Bond 1134 or Loctite 515: Apply

approximately a 0.125 inch (3.18 mm) diameter
continuous bead of liquid gasket material around one
surface.

Loctite FAG 3: Apply to one surface with a paint

brush.
Also apply all gasket material around edge of all
fastener holes on that surface. Figure 3.8.

18

Section 3
Prepare Parts for Assembly
!

WARNING

To avoid serious personal injury, trichloroethylene

must not come in contact with your skin. Do not
smoke and avoid breathing vapors in closed
rooms without ventilation. Do not use
trichloroethylene near flames, welding operations
or hot surfaces exceeding 900F (482C).
1. Remove any dust, oil or foreign material from
Toric ring (2), lodging ramps (4, 7), ring retention
lips (3, 8), oil seal ring (1) and ring bore (5). Clean
components with trichloroethylene and a clean
cotton cloth or a paper towel. Figures 3.9
and 3.10.
Figure 3.9

CAUTION

Make sure that Toric ring (2) is seated in oil seal

ring (1). Be careful when you work with Toric
ring. Cuts and scratches in Toric ring may cause
leaks. Figure 3.11.
Figure 3.11
1

2
3
2

4
1 OIL SEAL RING
2 TORIC RING
3 BORE RETENTION LIP
4 BORE RAMP
5 RING BORE

2. Place Toric ring (2) in oil seal ring (1) in button of

ring ramps (7) and against ring retention lip (8).
Figure 3.12.

Figure 3.12

Figure 3.10

6
9
2
7

8
6 RING FACE
7 BORE RAMP
8 RING RETENTION LIP
9 INSTALLATION TOOL

19

Section 3
Prepare Parts for Assembly
5. Verify mounting distance (A) in at least four
places spaced 90 degrees apart. The difference
in the mounting distance (A) around ring cannot
be more than 0.04 inches (1 mm). Figure 3.15.

NOTE
Do not use any liquid that leaves a film of oil or
does not evaporate quickly.
3. Place installation tool (9) under oil seal ring with
Toric ring (2). Submerge ring in receptacle filled
with trichloroethylene until entire surface of Toric
ring is wet. Figure 3.13.

Figure 3.15

Figure 3.13
9
1
(A) 0.04 in (1 mm)
2

6. If adjustments are necessary, use installation tool

(9) to push ring. Do not use your hands.
Figure 3.16.
4. With Toric ring surface wet (2), use installation
tool (9) to install oil seal ring and Toric ring
perpendicular to ring bore. Use a rapid and
uniform pressure to push Toric ring under ring
retention lip. Figure 3.14.

Figure 3.16
1
9

Figure 3.14
9
1

20

7. Toric ring may become distorted if not entirely wet

or if there is a sharp edge on the retention lip and
bore.

Section 3
Prepare Parts for Assembly
!

CAUTION

Misalignment or a twisted Toric ring may cause

leakage in the DUO-CONE oil seal. If installation
was not correct, remove oil seal from bore and
repeat steps 3-6.

A Toric ring must never slide on any ramp of oil

seal ring or bore. To prevent sliding, wait at
least two minutes for trichloroethylene to
evaporate before continuing with installation.
When in the correct position, Toric ring must
roll only on ramps.

A small piece of lint can separate the oil seal

surfaces and cause leaks. Figure 3.17.

10. Make sure both bores are correctly aligned and

concentric. Move slowly and carefully.
Figure 3.19.
Figure 3.19

Figure 3.17

CAUTION

Do not force rings abruptly against each other. A

strong impact may break the oil seal
components. When seal is installed properly,
fasten all components well.
If DUO-CONE oil seal is installed incorrectly, these
conditions can result:

8. Clean oil seal surfaces with lint-free cloth or paper.

Toric ring can warp. Figure 3.20.

Figure 3.20

9. Apply a thin, uniform film of clean oil on oil seal

surfaces with cloth or clean finger. Do not get oil
on Toric ring. Figure 3.18.
Figure 3.18
5
1

21

Section 3
Prepare Parts for Assembly

Warped ring can cause irregular pressure on ring

surface resulting in oscillating movements of oil
seal.

Different pressures on oil seal surfaces can cause

seepage, wear and leaks.

Oscillating oil seals allow dirt to enter.

Figure 3.21 shows an incorrect installation of an oil

seal in its mounting position. The upper bore is
stopped and the lower lodge is rotating.
Figure 3.21
CL

Figure 3.22 shows the same lower bore after

rotation of 180 degrees. In this position, high
pressure occurs on points A and Y. This high
pressure variation may damage rings. Points B and
X will develop low pressure and possible leakage.
Figure 3.22

CL

22

Section 4
Assembly and Installation
Assemble Differential Case

WARNING

To prevent serious eye injury, always wear safe

eye protection when you perform vehicle
maintenance or service.

4. Apply Loctite 271 or Three Bond 1305 adhesive

to ring gear fasteners. See Section 3, Liquid
Adhesive. Install ring gear fasteners and fasten
with the specified torque, 66-75 lb-ft
(90-100 Nm). Figure 4.1. T
Figure 4.1

1. Apply specified lubricant on all parts of differential

case assembly before installation.

CAUTION

Never attempt to press a cold ring gear on the

flanged half of the differential case. A cold ring
gear will damage the case because of the tight fit.
The tight fit can cause misalignment or excessive
runout and will make final backlash and teeth
contact adjustments very difficult.

WARNING

Wear safe clothing and gloves to protect yourself

from serious personal injury when you touch the
hot ring gear.
2. Expand ring gear bore by heating ring gear in tank
of water heated 160F to 180F (71C to 82C) for
10 to 15 minutes. DO NOT USE AN OPEN
FLAME SUCH AS A TORCH FOR THIS
PROCEDURE.

5. Assemble new cone bearings in both halves of

differential case or in both sides if it is an integral
differential case. Figure 4.2.
6. Install side gear in flanged case half.
Figure 4.2

PRESS

3. Install ring gear on case half or in the integral

differential case.

WARNING

To avoid serious personal injury be careful when

using Loctite or Three Bond adhesive during
assembly and installation procedures. Follow the
manufacturers instructions for safe use to
prevent irritation to eyes and skin. Wash after
skin contact. If the Loctite or Three Bond
adhesive gets in the eyes, flush the eyes with
water for 15 minutes. Have eyes checked
by doctor.

23

Section 4
Assembly and Installation
NOTE
For limited slip differential, go to step 12.
7. Install spider cross, differential pinions and
washers on original assembly position. Figure 4.3.

d. Install differential pinion axle and lock

capscrew. Fasten capscrew to specified torque
17-23 lb-ft (23-31 Nm). T
8. Install other side gear over spider and differential
pinions. Figure 4.5.
Figure 4.5

Figure 4.3
SPIDER

a. If you have an integral differential case, install

side gears and washers in each original
assembly side.
b. Install differential pinions in the correct position
by turning side gears until pinion holes are
aligned with differential pinion axle holes.
Figure 4.4.

9. Place plain half of differential over flanged half.

Rotate plain half as needed to align match marks.
Figure 4.6.
Figure 4.6

c. Install differential pinion washers.

Figure 4.4

24

MARKS

Section 4
Assembly and Installation
10. Apply Loctite 271 or Three Bond 1305 liquid
adhesive to capscrews. Install four capscrews
into case halves equally spaced and tighten to
48-64 lb-ft (64-87 Nm). T
11. Install other capscrews into case halves. Tighten
the capscrews to 48-64 lb-ft (64-87 Nm).
T
12. Assemble Limited Slip Differential Case.

d. Place disc pack stack in vise. Use micrometer

to determine D, the height (thickness) of
limited slip disc stack (includes thrust washer
and compression disc). Take four readings,
one at each of four points. Average readings
to determine D. Figures 4.8 and 4.9.
Figure 4.8

a. Follow steps 1 to 5.
b. Place flanged case half on bench.
c. Begin stacking of the disc pack with a drive disc
followed by driven friction discs. Make sure
lubrication grooves are aligned. Figure 4.7.
Figure 4.7

Figure 4.9

TOP

PLAIN HALF
SIDE GEAR
PLAIN HALF SIDE
GEAR MOVED TO
DETERMINE A

SPIDER

LUBRICATION GROOVES

DIFF CASE
FACE
(DATUM)

Maintain the following sequence:

D

1) Drive disc
2) Driven friction disc
3) Drive disc
4) Driven friction disc
5) Drive disc
6) Driven friction disc
7) Drive disc
8) Shims (Do not stack until measurements are
complete.)
9) Compression disc
10) Thrust washer (on side gear side)

LIMITED
SLIP PACK

PLAIN HALF
DIFF GEAR
PLAIN HALF
SIDE GEAR

A: Differential case half flange to back of

differential side gear distance.
B: Differential case face to side gear seat.
C: Differential case half depth.
D: Stack height (thickness).
e. Use depth gauge to determine C, depth of
differential case half. Take four readings.
Average readings for result. Figure 4.9.

25

Section 4
Assembly and Installation
f. Place removed plain half side gear on top as
shown in Figure 4.10. Use depth gauge to
determine A, distance from differential case
half flange to backside of differential side gear.
Take four readings. Average readings for
result. Figure 4.10.
g. Determine clearance dimension: B-A=(C-D)-A.
Clearance dimension must be greater than
0.05 mm and less than 0.15 mm.
h. Use proper shim thickness to achieve
clearance specified in step G.
i. Assemble friction discs in differential case
using sequence in step C including shims.
Make sure discs are lubricated.

Check Rotating Resistance

of Differential Gears
(Not Limited Slip)
NOTE
Make tool to check rotating resistance of the
differential gears, 50 lb-ft (68 Nm). The tool can
be made from a sun gear that matches the spline
of the differential side gear. Figure 4.11.
Figure 4.11

APPROXIMATELY
12 INCHES (304.6 mm)

j. Drop side gear spline through disc pack.

k. Repeat steps A through I for the plain
differential case half.
l. Follow steps 9 through 11 to assemble
differential case.
Figure 4.10

TOP

PLAIN HALF
SIDE GEAR
PLAIN HALF SIDE
GEAR MOVED TO
DETERMINE A

SPIDER

C
D

LIMITED
SLIP PACK

26

DIFF CASE
FACE
(DATUM)
PLAIN HALF
DIFF GEAR
PLAIN HALF
SIDE GEAR

1. Place differential case assembly in a vise with soft

metal covers on the vise jaws. Install the tool into
differential until splines of tool and one side gear
are engaged. Figure 4.12.
Figure 4.12

Section 4
Assembly and Installation
2. Attach torque wrench to the tool nut and rotate
differential gears. As differential rotates, read
torque value indicated on dial. Figure 4.13. T
Figure 4.13

2. Support bearing cage with metal or wood blocks.

3. Press the bearing cup into bore of bearing cage
until cup is flat against bottom of bore. Use correct
size sleeve to install bearing cup.

NOTE
Use same procedure for both bearing cups.
4. Put drive pinion in press. The gear head (teeth)
must face toward the bottom.
5. Press inner bearing cone on shaft of drive pinion
until cone is flat against gear head. Use a sleeve
of the correct size against bearing inner race.
Figure 4.15.
Figure 4.15

3. If torque value exceeds specification of 50 lb-ft

(68 Nm), disassemble gears from differential
case. T

SLEEVE

4. Check differential case halves, spider, gears and

thrust washers for problem that causes excessive
torque value. Repair or replace parts.
5. After parts are repaired or replaced, assemble
parts and repeat steps 1 to 4.

Assemble Drive Pinion

and Bearing Cage

6. Apply axle lubricant on bearing cups in cage and

bearing cones.
7. Install drive pinion into bearing cage.
8. Install bearing spacer(s) in pinion shaft against
inner bearing cone. Figure 4.16.

WARNING

Observe all WARNINGS and CAUTIONS provided

by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during
assembly and installation procedures.
1. Place bearing cage in press. Figure 4.14.
Figure 4.14.
SLEEVE

NOTE
Spacer(s) controls preload adjustment of drive
pinion bearings.
Figure 4.16
OUTER
CONE
BEARING

BEARING CUP

BEARING
SPACER
BEARING CAGE
DRIVE PINION

INNER
BEARING
CONE

27

Section 4
Assembly and Installation
9. Install outer bearing cone on pinion shaft against
spacer. Figure 4.16.

NOTE
Do not install pinion oil seal in bearing cage
before bearing preload adjustment. Continue
adjusting preload of pinion bearings.

5. Use appropriate tool to fasten pinion through

yoke, flange or splined sleeve. Figure 4.17.
Figure 4.17

10. Press outer cone bearing with 10 ton force and

check preload of bearings. Figure 4.16.

Adjust Pinion Bearing Preload

(Without Press)
NOTE

If the preload value is below the specified

range, install a thinner bearing spacer.

If the preload value is over the specified range,

install a thicker bearing spacer.

Calculation Example:
Data:
Radius:
Load:

9.3 cm (3.65 in)

2.3 Kg (5.0 lbs)

Calculation Procedure:
2.3 Kg x 9.3 cm = 21.4 Kg-cm
5.0 lb x 3.65 in = 18.25 lb-in.
Conversion to Nm:
21.4 x 0.098 = 2.1 Nm
18.25 x 0.113 = 2.1 Nm

6. Tighten pinion nut with minimum torque value of

465 lb-ft (630 Nm). T
7. Rotate pinion bearing cage several times so
bearings make normal contact.
8. Attach torque wrench on drive pinion nut. Rotate
pinion and check if preload is in specified range.
Make the reading during the rotation, not the
starting value. Figure 4.18.
Figure 4.18

NOTE

To convert lb-in to Nm:

multiply by 0.113

Kg-cm to Nm:
multiply by 0.098

1. Lubricate bearing cups and cones with

specified oil.
2. Install yoke or flange without pinion oil seal.
3. Install pinion bearing cage assembly on main
housing without bearing cage shims.
4. Fasten bearing cage assembly on main housing
with two capscrews. Apply minimum specified
torque of 67 lb-ft (90 Nm). T

28

9. If the pinion bearing preload torque value is under

or above the specified preload torque of 5-20 lb-in
(0.55-2.2 Nm), change shims to thick or thinner
size as necessary. Repeat pinion bearing
preload check. T

Section 4
Assembly and Installation
10. After getting specified preload, remove bearing
cage from main housing and disassemble yoke or
input flange.

CAUTION

Make sure oil seal lips are clean and free from
dirt. Dirt can cause leakage between seal and
yoke or flange.
11. Install pinion oil seal with the appropriate tool:
a. Apply extreme pressure lithium soap grease to
oil seal lips. Figure 4.19.

d. Install yoke or flange and pinion nut

into pinion.
e. Tighten pinion nut to specified torque after
installing pinion bearing cage into main
housing of 465-570 lb-ft (630-775 Nm). T

Adjust Thickness of Pinion

Bearing Cage Shim Pack
(Depth of Pinion)
NOTE
Use this procedure if a new drive pinion and ring
gear set is installed or if the depth of the drive
pinion has to be adjusted. Figure 4.21.

Figure 4.19

INDUSTRIAL
ADHESIVE

Figure 4.21
BEARING CAGE
SHIM PACK

b. Apply 3M Industrial Adhesive or equivalent to

oil seal outer surfaces. Figure 4.19.
c. Press oil seal into bearing until seal flange is
flat against top of bearing cage. Use the
correct size sleeve or seal driver that fits
against metal flange of seal. The diameter of
the sleeve must be larger than diameter of
flange. Figure 4.20.
Figure 4.20

MAIN
HOUSING

1. Use a micrometer to measure the thickness of the

old shim pack that was removed from under the
pinion cage. Record the measurement for later
use. Figure 4.22.
Figure 4.22

29

Section 4
Assembly and Installation
2. Record the pinion cone (PC) variation number on
the old drive pinion that is being replaced. If the
PC variation number cannot be located, assemble
the gear set with the shim pack found in step 1.
Figure 4.23.
Figure 4.23

7. If the new pinion cone number is a minus (),

subtract the number from the standard shim pack
thickness that was calculated in step 3 or 4.

NOTE
The value calculated in step 6 or 7 is the thickness of a new shim pack that will be installed.
EXAMPLES

Inches

mm

Old shim pack thickness

0.030
Old PC number, PC+2 (+0.05mm) 0.002

0.76
0.05

Standard shim pack thickness

0.028
New PC number, PC+5 (+0.13mm) +0.005

0.71
+0.13

1.

New shim pack thickness

0.033

0.84

NOTE
The pinion cone number (PC) can be either
1,000ths of an inch (0.000 inch) or 100ths of a
millimeter (0.00 mm). Examples:

2.
Old shim pack thickness
0.030
Old PC number, PC2 (0.05mm) +0.002

0.76
+0.05

PC+3, PC3, +3 OR -3 = .003 inch (.076 mm)

PC+.03, PC.03MM , + .03 OR .03 = .03 mm

Standard shim pack thickness

0.032
New PC number, PC+5 (+0.13mm) +0.005

0.81
+0.13

To change inches to millimeters, multiply

inches by 25.40

New shim pack thickness

To change millimeters to inches, multiply

millimeters by 0.039.

3.

3. If the old pinion cone number is a plus (+),

subtract the number from the old shim pack
thickness that was measured in step 2.
4. If the old pinion cone number is a minus (), add
the number to the old shim pack thickness that
was measured in step 2.

0.037

0.94

Old shim pack thickness

0.030
Old PC number, PC+2 (+0.05mm) 0.002

0.76
0.05

Standard shim pack thickness

0.028
New PC number, PC5 (0.13mm) 0.005

0.71
0.13

0.023

0.58

NOTE

4.

The value calculated in step 3 or 4 is the thickness of the standard shim pack without a
variation.

Old shim pack thickness

0.030
Old PC number, PC2 (0.05mm) +0.002

0.76
+0.05

Standard shim pack thickness

0.032
New PC number, PC5 (0.13mm) 0.005

0.81
0.13

5. Look at the pinion cone (PC) variation number on

the new drive pinion that will be installed. Record
the number for later use.
6. If the new pinion cone number is a plus (+), add
the number to the standard shim pack thickness
that was calculated in step 3 or 4.

30

New shim thickness

New shim pack thickness

0.027

0.68

Section 4
Assembly and Installation
Install Pinion Bearing Cage
Assembly on Main Housing
NOTE
Use minimum of three shims in pack. If pack is
made from different thickness shims, install
thinnest shims on both sides of pack for
maximum sealing.

3. Install two capscrews and washers that fasten

bearing cage. Tighten to minimum torque of
67 lb-ft (90 Nm). Figure 4.26.

Figure 4.26

1. Install correct shim pack between bearing cage

and main housing. Figure 4.24.
Figure 4.24

4. Install yoke or flange and pinion nut. Fasten yoke

or flange with appropriate tool. Tighten pinion nut
to minimum specified torque of 465-570 lb-ft
(630-775 Nm). Figure 4.27. T
CAPSCREW
SHIM PACK

Figure 4.27

WARNING

Do not hit steel parts with a steel hammer during

assembly and installation procedures. Parts can
break and cause serious personal injury.
2. Install drive pinion and bearing cage into carrier. If
necessary, use rubber, plastic or leather mallet to
tap assembly into position. Figure 4.25.
Figure 4.25

CAUTION

The fit between input yoke or flange splines and

drive pinion is tight. To install yoke or flange into
pinion, use pinion nut and appropriate tool to
fasten it. Never use hammer or mallet. A hammer
or mallet will damage yoke or flange.

31

Section 4
Assembly and Installation
5. If ring gear is mounted on opposite brake housing
side, loosen two capscrews that fasten pinion
bearing cage. Remove cage and mount it after
differential case is assembled.

4. Install differential case assembly. Figure 4.29.

Figure 4.29

If ring gear is mounted on brake housing side,

install other capscrews that fasten pinion bearing
cage. Tighten the capscrews to a torque of
67-91 lb-ft (91-120 Nm). T

Install Differential Housing

Assembly into Main Housing
(With Shims)
1. The preload of differential bearings is adjusted by
selecting proper shim pack to obtain a torque of
15-35 lb-in (1.7-4.0 Nm). T
2. Install shims. Combine two shims to obtain
desired thickness. Figure 4.28.

5. Install brake housing and other differential case

bearing cup. Figure 4.30.
Figure 4.30

Figure 4.28
NUT
COUNTER NUT

NOTE
Usually a 0.102-0.104 inch (2.60-2.65 mm) shim
pack thickness is enough to obtain specified
backlash and differential bearing preload.
3. Install differential case bearing cup, axle shaft
housing and brake housing studs into main
housing until the thread is completely attached.
Apply Three Bond 1134 liquid gasket material on
stud threads. Figure 4.28.

32

6. Install three bolts to adjust differential on brake

housing. Tighten to a torque of 19-26 lb-ft
(26-36 Nm). Figure 4.31. T
Figure 4.31

Section 4
Assembly and Installation
7. Install differential case bearing adjusting nut on
brake housing. Figure 4.31.
8. Install pinion bearing cage assembly and
shim pack.
9. Check backlash, differential preload and teeth
contact. See Section 5, Adjustments.

Install Differential Housing

Assembly into Main Housing
(With Adjusting Ring 2 Sides)
1. Install adjusting ring into main housing.
2. Install bearing cup.

WARNING

Small amounts of acid vapor are present when

applying some liquid gasket materials during
assembly and installation procedures. To prevent
possible serious personal injury, make sure there
is good ventilation in the work area. If the liquid
gasket material gets in eyes, flush eyes with
water for 15 minutes. Have eyes checked
by doctor.

3. Install differential case assembly into main

housing. Figure 4.33.
Figure 4.33

10. If all adjustments are within specifications,

remove brake housing. Apply liquid gasket
material to main housing surface.
11. Install three bolts into the brake housing to adjust
differential. Tighten them to 19-26 lb-ft
(26-36 Nm). T
12. Apply medium torque liquid adhesive, Loctite
241 or Three Bond 1334, to lock capscrews.
Install adjusting nut lock and capscrews. Tighten
capscrews to 80-115 lb-in (9-13 Nm).
Figure 4.32. T
Figure 4.32

4. Install brake housing and other differential case

bearing cup. Figure 4.30.
5. Install three bolts to adjust the differential on
brake housing. Tighten to 19-26 lb-ft (26-36 Nm).
Figure 4.31. T
6. Install differential case bearings adjusting nut into
brake housing. Figure 4.31.

33

Section 4
Assembly and Installation
7. Install pinion bearing cage assembly and shim
pack. Figure 4.34. See Install Pinion Bearing
Cage Assembly on Main Housing, page 31.
Figure 4.34

9. Check backlash, differential preload and teeth

contact. See Section 5, Adjustments.
10. If all adjustments are within specifications,
remove brake housing. Apply liquid gasket
material to main housing surface.

WARNING

To avoid serious personal injury, be careful when

using Loctite. Follow the manufacturers
instructions for safe use to prevent irritation to
eyes and skin. Wash after skin contact. If the
Loctite gets in eyes, flush with water for 15
minutes. Have eyes checked by a doctor.
11. Apply high torque liquid adhesive, Loctite 271 or
Three Bond 1334, on stud threads.

8. Adjust adjusting rings with the following

procedure. Figure 4.35.
Figure 4.35

12. Install studs that fasten brake housing and axle

shaft housing to main housing. Tighten studs
until resistance is met.
13. Install bearing cup and brake housing into main
housing. Align holes at mark made during
disassembly.
14. Install 3 bolts into the brake housing to adjust
differential. Tighten them to 19-26 lb-ft
(26-36 Nm). Figure 4.31. T
15. Apply medium torque liquid adhesive, Loctite
241 or Three Bond 1334, to lock capscrews.
Install adjusting nut lock and capscrews. Tighten
capscrews to 80-115 lb-in (9-13 Nm). T

Assemble Axle Shaft

a. Tighten ring gear side adjusting ring to

eliminate backlash between ring gear
and pinion.
b. Unfasten same adjusting ring from four to
five slots.
c. Tighten opposite side adjusting ring to obtain a
preload of 15-35 lb-ft (1.7-4.0 Nm). Discount
pinion bearing preload measured before. T

34

1. Use correct size sleeves to install cups into

bores in axle shaft housing until cups are flat
against bottom of bores. Figure 4.36.
Figure 4.36

Section 4
Assembly and Installation
2. Install Duo-Cone oil seal into axle shaft and into
axle shaft housing bore as specified on page 18.
Figure 4.37.

Figure 4.39

44.60
44.80

Figure 4.37

DUO-CONE
OIL SEAL

!
3. With a correct size sleeve, use a press to install
flange side cone bearing. Install axle shaft into
axle shaft housing. Figure 4.37.

Assemble Trumpet Assembly

WARNING

WARNING

To avoid serious personal injury, be careful when

using Loctite. Follow the manufacturers
instructions for safe use to prevent irritation to
eyes and skin. Wash after skin contact. If the
Loctite gets in eyes, flush with water for 15
minutes. Have eyes checked by a doctor.
2. Apply Medium Torque liquid adhesive, Loctite 241
or Three Bond 1334, to threads of planetary gear
axle lock capscrews. Install and tighten to
17-23 lb-ft (23-31 Nm). T

Observe all WARNINGS and CAUTIONS provided

by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components during
assembly and installation procedures.
1. Use press to install new planetary pin into spider.
Make sure proper dimensions are used and holes
are aligned. Figures 4.38 and 4.39.
Figure 4.38

ALIGNED
HOLES

35

Section 4
Assembly and Installation
!

CAUTION

Rollers must come from the same manufacturer

and have the same tolerance range. Replace
spacers and washers when a new roller is used.
3. Apply grease, Shell-71032 Alvania EP-2 or
Texaco - 995 Multifak EP-2, on each gear hole.
Install rollers and spacers into planetary gears.
Figure 4.40.

5. Install planetary spider and axle shaft bearing

adjusting nut.
6. Measure trumpet flange radius. With a spring
scale, check the trumpet assembly preload before
tightening adjusting nut.
The value will be obtained by multiplying the
number read on the spring scale dial by the flange
radius. Make note of the value. Figure 4.42.
Figure 4.42

Figure 4.40

4. Install bearing cone. Figure 4.41.

Figure 4.41

7. Tighten adjusting nut with special tool shown on

page 60. At the same time, manually rotate the
trumpet to assure a correct fit between bearing
cups and cones and get desired preload.
Figure 4.43.
Figure 4.43

36

Section 4
Assembly and Installation
8. Check trumpet assembly preload and subtract
value obtained before tightening adjusting nut.
Value must be 15-35 lb-in (1.7-4 Nm). T
9. Apply Medium Torque liquid adhesive, Loctite
241 or Three Bond 1334, on adjusting nut lock
capscrew threads. Install adjusting nut lock
capscrew. Tighten to 17-23 lb-ft (23.0-30.5 Nm).

13. Apply liquid gasket material on contact surfaces

of trumpet and ring. Figure 4.46.
Figure 4.46

10. Install inner washer, planetary gears and rollers

into flange. Figure 4.44.
Figure 4.44

GASKET

14. Install ring gear into trumpet. Use reference

marks made during disassembly to align holes
and contact surface. Figure 4.47.
Figure 4.47

11. Install outer washers.

12. With correct pliers, install snap rings.
Figure 4.45.
Figure 4.45

37

Section 4
Assembly and Installation
Assemble Hydraulic Apply
Brake Housing Assembly
NOTE

To assemble three function brake, see

page 39.

To assemble ball and ramp brake, see page 43.

6. Apply high torque liquid adhesive, Loctite 271 or

Three Bond 1305, to capscrew threads. Install
return springs and return spring capscrews.
Tighten to 80-115 lb-in (9.0-13.0 Nm). T
Figure 4.49.
Figure 4.49

1. Check to see if the piston lodging surfaces on

brake housing is free of sharp edges, nicks and
burrs. Repair any damage if possible or replace
the part.
2. Repeat Step 1 on outer surfaces of brake piston.
3. Apply a thin film of oil, SAE W140 or SAE 90, to
piston and bore. Apply a dense layer of oil to
brake housing chamfer.
4. Carefully install piston oil seals.

NOTE
Before pressing piston into brake housing, rotate
piston 15 to 20 degrees. If piston does not turn
easily, disassemble the piston and find the cause
of the interference.

Hydraulic Apply Brake

Housing Functional Test

5. With a manual press, carefully install piston into

brake housing. Do not damage oil seals. If there
is resistance in installing the piston, do not
proceed. Figure 4.48.

This test procedure is only for the hydraulic

apply brake system.

To perform this test, it is necessary to use a

device which permits the observation of
possible leaks through oil seals and if the
piston return system is working. For an
accurate evaluation, the device must allow
piston displacement of 0.157 to 0.197 inch
(4-5 mm).

Figure 4.48

BRAKE
HOUSING

SPRING
CAPSCREW
RETURN
SPRING

NOTE

1. Connect brake housing assembly into hydraulic

system equipped with 1000 psi (69 bar)
manometer.
BRAKE
PISTON

2. Activate the cylinder at least five times with 600

psi (41.4 bar). Check for leaks.
OIL
SEAL

If there are no leaks, proceed to Step 3.

If there are leaks, disassemble brake housing
assembly, find and correct the problem.

3. Wait five minutes, then apply 600 psi (41.4 bar) to

the cylinder again.

38

Section 4
Assembly and Installation

If there are no leaks, proceed to Step 4.

Figure 4.51

If there are leaks, disassemble brake housing

assembly, find and correct the problem. Repeat
Steps 1 to 3.

4. Wait five minutes, then apply 75 to 110 psi

(5.1 to 7.6 bar) to the cylinder again.
B

If there are no leaks, the assembly is

assembled correctly.

If there are leaks, find and correct the problem.

Repeat the test again.

Assemble Three Function

Brake Housing Assembly

c. The shim pack thickness is the difference

between dimension B and dimension A
minus 0.06 in. (1.5 mm):

NOTE
Before assembling brake housing assembly,
make sure that all surfaces and bores of brake
housing and piston are free of dirt, burrs
and nicks.
1. Select piston shim pack with the following
procedure:
a. Position parts of piston assembly in a press.
Measure the dimension A under 441 lb
(200 Kg) pressure. Figure 4.50.
b. Measure the dimension B. Figure 4.51.

B-A-0.06 in. (1.5 mm) = shim pack thickness

d. If brake piston is assembled, the shim pack
thickness, under press pressure of 441 lbs
(200 Kg), is the difference between dimension
B minus the sum of dimensions C and D
minus 0.06 in. (1.5 mm):
B-(C+D) -0.06 (0.15) = shim pack thickness.
Figure 4.52.
Figure 4.52
600 lb (300 Kg)

Figure 4.50

441 lb (200 Kg)

250 lb (113 Kg)

BRAKE
DISCS

PISTON
WITHOUT
SPRINGS

C
D

ACTION PLATE
A

BRAKE DISCS

PLATE

REACTION
PLATE

39

Section 4
Assembly and Installation
2. Lubricate internal brake housing surfaces, inner
and outer piston surfaces and oil seal bores with
SAE 90 oil. Figure 4.53.

Figure 4.55

Figure 4.53
MEDIUM
OIL SEAL

INNER
PISTON

5. Install springs into bores in inner piston.

Figure 4.55. For brake with 12 springs, jump one
bore each three. Figure 4.55.

OUTER
PISTON
LARGE
OIL
SEAL

SMALL
OIL SEAL

OIL
SAE 90

NOTE
Each piston assembly has three different sizes of
oil seals: three large, one medium, one small.
3. Install medium oil seal into inner piston bore and
install the small oil seal into the outer piston bore.
Figure 4.53.
4. ONLY use a manual press to install inner piston
into outer piston. Be careful not to damage oil
seals. Do not force the inner piston assembly.
Figure 4.54.

6. Install compression plate on piston. Correctly

align the fastener holes. Use marks on piston and
lock pin slot. Figure 4.56.
Figure 4.56
PISTON

COMPRESSION
PLATE

MARKS

Figure 4.54

MARKS

PRESS

7. Apply pressure to the compression plate until it is

flat against the piston.

NOTE
Rotate pistons until marks are aligned. If inner
piston does not rotate easily, disassemble it and
find the cause. Figure 4.54.

40

Section 4
Assembly and Installation
!

10. Install shim pack into brake housing. Use bolts

to align holes. Figure 4.59.

WARNING

To avoid serious personal injury, be careful when

using Loctite. Follow the manufacturers
instructions for safe use to prevent irritation to
eyes and skin. Wash after skin contact. If the
Loctite gets in eyes, flush with water for 15
minutes. Have eyes checked by a doctor.

Figure 4.59
GUIDE BOLTS

8. Apply medium torque liquid adhesive, Loctite 241

or Three Bond 1334 in threaded external piston
bolt holes. Install action plate bolts as shown in
Figure 4.57 and apply a pretorque of 30 lb-in
(3.3 Nm). Tighten to specified torque of
120-140 lb-in (13.5-16 Nm). T
SHIMS

Figure 4.57
1

11. Remove guide bolts and manually install brake

piston assembly into brake housing. Rotate
piston assembly 15 to 20 degrees. The rotation
must be easy and without resistance. If there is
any resistance, disassemble the brake piston
assembly and find the cause.
12. Use bolts as guide and align piston and holes.
Use marks made during disassembly as
reference. Figure 4.60.
Figure 4.60

9. Install three larger oil seals into outer piston. Make

sure the oil seals fit in the bores. Figure 4.58.
Figure 4.58

LARGER OIL SEALS

13. With a manual press on brake housing, apply

pressure to brake piston until the springs
compress. Make sure oil seals fit in bores.
Figure 4.60.

41

Section 4
Assembly and Installation
14. With piston still compressed, apply 350 psi
(24 bar) into parking brake to make sure oil
seals fit in bores. Figure 4.61.
Figure 4.61

Assemble Ball and Ramp

Brakes, Brake Discs, Reaction
Plate and Pins
1. Install sun gear. Figure 4.63.
Figure 4.63

350 PSI (24 BAR)

15. Keep the parking brake under 350 psi (24 bar)
pressure and remove the manual press and
guide pins.
16. Apply medium torque liquid adhesive, Loctite
241 or Three Bond 1334, to return spring holes
and bolt threads. Install return springs, washers
and return spring bolts into brake housing.
Tighten bolts to 80-115 lb-in (9-13 Nm).
Figure 4.62. T
Figure 4.62

BOLT

WASHER

350 PSI
(24 BAR)

NOTE
After assembly, friction disc lubrication holes
must be perfectly aligned.
2. Install friction and stationary discs alternately.
Make sure friction disc is against brake piston.
3. For ball and ramp brakes, discs must be installed
alternately and a friction disc must be on each
side of the expansive plate. Figure 4.64.
Figure 4.64
REACTION PLATE
EXPANSIVE PLATE

SPRING
PIN

SPACER
FRICTION DISC
FRICTION DISC

NOTE
Use same procedure to install other brake piston
assemblies into main housing.

42

STATIONARY DISC

Section 4
Assembly and Installation
4. Install stationary disc lock pins.
5. Install reaction plate with lubrication hole on down
side of axle.
6. If there is an outer spacer, install it on brake
housing surface. Use liquid gasket material.

Assemble Three Function

Brakes, Brake Discs, Reaction
Plate and Pins
1. Lubricate all brake components with same oil
specified for axle. See page 53.

Install Housing Assembly into

Main Housing
NOTE
If axle is equipped with three function brake,
keep parking brake pressurized.
1. Install housing assembly. Make sure that the
mark made during disassembly is correctly
positioned to ensure alignment of the fastener
holes. Figure 4.66.
Figure 4.66

2. Install sun gear. Figure 4.63.

3. Apply 350 psi (24 bar) into parking brake.
4. Install friction and stationary discs, guide pins and
reaction plate. Figure 4.65.
Figure 4.65

PIN

REACTION PLATE
FRICTION DISCS

STATIONARY DISCS

BRAKE HOUSING

2. Install capscrews and nuts that fasten housing to

main housing.

Tighten grade 12.9 capscrew 170-200 lb-ft

(230-271 Nm). T

Tighten grade 10.9 capscrew 135-170 lb-ft

(183-230 Nm). T

Tighten stud nuts 120-150 lb-ft

(160-205 Nm). T

3. Release pressure from parking brake.

4. Apply liquid gasket material, Loctite 515 or Three
Bond 1134, on surface of cover that fastens to
main housing and on capscrew threads. Install
cover and capscrews on main housing. Tighten
capscrews to 20-27 lb-ft (27-36 Nm). T

43

Section 4
Assembly and Installation
Assemble Three Function
Brake Release Bolts and
Sleeves

Assemble Ball and Ramp

Brake Cylinder Assembly and
Install on Main Housing

1. Apply Loctite 516 on bolt threads. Figure 4.67.

1. Apply liquid gasket material FAG-3 on brake

cylinder surface that fastens to brake cylinder
support. Assemble brake cylinder, oil seals, piston
and brake cylinder support. Tighten capscrews
that fasten brake cylinder support 19-26 lb-ft
(26-36 Nm). Figure 4.69. T

Figure 4.67
SILASTIC 780 RTV

LOCTITE 516

Figure 4.69

LIQUID
GASKET
MATERIAL
NOT
ALLOWED

2. Apply liquid gasket material, Silastic 780 RTV Dow

Corning, on non-threaded bolt shaft. Figure 4.67.
3. Install bolts and sleeves. Tighten to 25-34 lb-ft
minimum (34-46 Nm). Figure 4.68. T

Assemble 2 larger bolts, 3.346 in. (85 mm)

with larger sleeves, 1 in. (26 mm)

Assemble shorter bolt, 3.070 in. (78 mm) with

shorter sleeve, 0.750 in. (19 mm).

Figure 4.68
BRAKE HOUSING
RING
GEAR

SHORT BOLT AND

SLEEVE INTO THIS
POSITION
SLEEVE

BOLT
PIN

44

Section 4
Assembly and Installation
2. While out of the axle, connect cylinder assembly
to hydraulic system. Apply 400 psi (27.6 bar)
pressure to compress spring until piston is against
brake cylinder. Repeat this operation four to five
times to make sure there is no leakage.
Figure 4.70.

4. While the cylinder is pressurized with 400 psi

(27.6 bar), apply liquid adhesive, Loctite 221 or
Three Bond 1341, on threads of brake shaft.
Install adjusting nut until it rests against piston.
DO NOT TIGHTEN ADJUSTING NUT. Loosen
the adjusting nut one full turn. Figure 4.72.
Figure 4.72

Figure 4.70

BRAKE SHAFT

ADJUSTING NUT
RETURN 1 LAP

HYDRAULIC
PRESSURE

HYDRAULIC
PRESSURE

CAUTION

Do not use brake fluid in the hydraulic system.

Use Shell Donax TD or Shell Tellus 32 or
equivalent.
3. Install brake cylinder assembly onto main
housing. Figure 4.71.

5. Release cylinder pressure to ZERO so piston

returns back against adjusting nut. Check
dimension X as shown in Figure 4.73.
Figure 4.73
ADJUSTING NUT

BRAKE SHAFT
X=
1.47 inch
(37.0 mm)

Figure 4.71
CYLINDER
CAPSCREW

WITHOUT
PRESSURE

SUPPORT
CAPSCREW

If dimension X is smaller than 1.47 inch (37.0

mm), tighten adjusting nut until the dimension is
reached. If dimension gets larger, unfasten the
nut. This adjustment must be made with piston
activated.

45

Section 4
Assembly and Installation
6. After 1.47 inch (37.0 mm) dimension is obtained,
apply specified pressure to brake and check the
brake torque on pinion as shown in chart.
Torque
Reduction

Disc
No.

Pressure

Torque

PRA-382
17.08:1

06

275 psi min

(19 bar min)

950-1200 lb-ft
(1288.01559.0 Nm)

PRA-353
46.00:1

06

275 psi min

(19 bar min)

350-500
(474.5678.0 Nm)

NOTE
To obtain the desired brake torque, fasten or
unfasten the adjusting nut. For each 0.04 inch
(1 mm) turned on dimension X, the variation in
torque is 4%.
7. After obtaining the desired brake torque, install nut
lock as shown in Figure 4.74. Tighten to 60-90
lb-in (80-120 Nm).
T
Figure 4.74
LOCK NUT
DIM. Y

ADJUSTING
NUT

X=
1.47 inch
(37.0 mm)

WITHOUT
PRESSURE

46

8. Install cover. Figure 4.75.

Figure 4.75
COVER
ADJUSTING NUT

LOCK NUT

SPRING
PISTON

O-RING

O-RING

WITHOUT
PRESSURE

CYLINDER
SUPPORT

CYLINDER

9. The dimension Y must be equal with 0.02 inch

(0.5 mm) on each side. If dimension is larger on
one of the sides after adjustment, disassemble
and find the cause.

NOTE
Do not check the brake torque before the wheel
has turned at least two times with the brake
activated.

Section 5
Adjustments
Check Ring Gear Runout
Specification: 0.008 inch
(0.20 mm)

Adjust Pinion and Ring Gear

Backlash Specification:
0.005-0.015 inch
(0.13-0.38 mm)

WARNING

1. Attach dial indicator on mounting flange of

carrier.

To prevent serious eye injury, always wear safe

eye protection when you perform vehicle
maintenance or service.

2. Set dial indicator so plunger is against a tooth

surface. Figure 5.2.

1. Attach magnetic base dial indicator to mounting

flange of main housing. Figure 5.1.

3. Set dial indicator to ZERO.

Figure 5.1

Figure 5.2

2. Set dial indicator so plunger or pointer is against

back surface or ring gear. Figure 5.1.

NOTE

3. Set dial indicator to ZERO.

When you adjust backlash, only move ring

gear. Do not move drive pinion.

If you are using old ring gear and pinion, it is

recommended that you maintain original
backlash.

4. Rotate differential and ring gear assembly while

you read dial indicator. Ring gear runout must not
exceed 0.008 inch (0.20 mm). If runout exceeds
specifications, remove differential and ring gear
assembly from main housing.
5. Check differential parts including carrier for
problem that caused ring gear runout to exceed
specifications. Repair or replace parts if necessary.

CAUTION

Shock load failure will distort the differential case

flange and transfer damage to ring gear. In this
case, differential carrier must be discarded.

4. Hold drive pinion in position.

5. While you read dial indicator, rotate differential
and ring gear a small amount in both directions
against teeth of the drive pinion. If backlash
reading is within specified range of
0.005-0.015 inch (0.13-0.38 mm), continue by
checking tooth contact patterns. If backlash
reading is not within specifications, adjust
backlash as needed.

6. After parts are repaired or replaced, install main

differential case and ring gear assembly into
carrier. Repeat steps 1 to 5.

47

Section 5
Adjustments
6. Loosen one bearing adjusting ring one notch,
then tighten opposite ring the same amount to
keep differential roller bearing preload.
Figure 5.3.

Verification Procedure
1. Apply a marking compound to approximately 12
teeth of ring gear. Rotate ring gear so that the 12
gear teeth are next to drive pinion. Figure 5.5.

Figure 5.3
Figure 5.5

INCREASE
BACKLASH

DECREASE
BACKLASH

NOTE
When you adjust backlash, only move ring gear.
Do not move drive pinion.

Backlash is increased by moving ring gear

away from drive pinion.

Backlash is decreased by moving ring gear

toward drive pinion.

2. Apply load on ring gear with wood pry bar.

Rotate gear forward and backward so 12 gear
teeth go past the drive pinion six times to get
contact patterns. Repeat if needed to get a more
clear pattern. Figure 5.6.

Figure 5.6

7. Repeat steps two to six until backlash is within

specifications. Record setting for use when you
adjust pinion bearing preload.

Teeth Contact Patterns

In the following procedures, movement of the contact
pattern along length of tooth is indicated as toward
the heel or toe of the ring gear.
Figure 5.4.
Figure 5.4

CONCAVE SIDE
HEEL

L
HEE
CONVEX SIDE

48

TOP
TOM
BOT

TOE
TOE

Section 5
Adjustments
3. Compare contact patterns on ring gear teeth to
good contact patterns in Figure 5.7. If contact
patterns are not satisfactory, go to Incorrect
Contact Patterns on this page.
Figure 5.7

The location of a good hand-rolled pattern for a used

gears set must match wear pattern in ring gear. The
contact pattern will be smaller in area than the wear
pattern.

Incorrect Contact Patterns

High Contact Pattern:
A high contact pattern indicated that drive pinion was
not installed deep enough into carrier. Figure 5.9.
Figure 5.9

Correct Contact Patterns

The location of a good hand-rolled contact pattern for
a new gear set is toward toe of gear tooth and in
center, between top and bottom of tooth.
Figure 5.7.
When carrier is being operated under load, pattern
will extend approximately the full length of tooth. The
top of pattern will be near top of gear tooth.
Figure 5.8.

To correct a high-contact pattern, decrease

thickness of shim pack under bearing cage. This
will move drive pinion toward ring gear.
Figure 5.10.

Figure 5.8
Figure 5.10

DECREASE SHIM
PACK THICKNESS

49

Section 5
Adjustments
Deep Contact Pattern
A deep contact pattern indicates that the drive pinion
was installed too far in the carrier.
Figure 5.11.
Figure 5.11

Variations Along Length of

Gear Teeth
Adjust backlash of ring gear within specification
range to move contact patterns to correct location
along length of gear teeth.When toe contact pattern
indicates that backlash is very low and gear is too
close to drive pinion: Figure 5.13.
Figure 5.13

To correct a deep contact pattern, increase

thickness of shim pack under bearing cage. This
will move the drive pinion away from the ring gear.
Figure 5.12.

Figure 5.12

Withdraw ring gear by decreasing shim pack

thickness or loosening the gear side adjusting ring
and tightening opposite side adjusting ring.
When heel contact pattern indicates that backlash
is very high and gear is too far away from drive
pinion: Figure 5.14.

Figure 5.14

INCREASE SHIM
PACK THICKNESS

50

Approach ring gear by increasing shim pack

thickness or loosening gear opposite side
adjusting ring and tightening gear side
adjusting ring.

Section 5
Adjustments
An acceptable contact pattern is centralized between
toe and heel along the length of gear teeth.
Figure 5.15.
Figure 5.15

Replace Lubricant
1. Install and tighten drain plug in central housing and
brake housing. T
2. Clean area around fill/level plug. Remove fill/level
plug from carrier inspection cover.

In cases where it is not possible to get a good

contact pattern, the contact pattern shown in
Figure 5.15 is acceptable. If the acceptable contact
pattern is not achieved, change the ring gear and
pinion set.
Figure 5.16 indicates a good contact pattern. It is
toward the toe and centralized between the top and
bottom of the gear teeth.

WARNING

Use only the type of fluid specified by the

equipment manufacturer. Do not use or mix
different types of fluid. The wrong fluid will
damage the rubber parts of the assemblies
which could cause loss of braking and serious
personal injury.

Do not reuse fluid. Used fluid can be

contaminated and can cause incorrect
operation which could result in serious
personal injury.

3. Add specified oil until oil level is even with bottom

of fill/level hole. See Section 6, Specifications.
4. Install and tighten fill/level plugs.

5. Road test vehicle in an unloaded condition for

one-two miles (1.6-3.2 km) at speeds not more
than 25 mph (40 kph). Check the lubricant levels
and the torque of all fasteners.

Figure 5.16

51

Section 6
Specifications
PRA 352 Series Planetary Drive Axle
Oil Change Intervals and Specifications
Initial
Oil
Change
100
operating
hours

or
1240-3100
miles
(2000-5000
km)
(whichever
comes first)

Off-Highway
Operation Intervals
Check
Petroleum
Oil
Oil
Level
Change
250
1,500
operating
operating
hours
hours

or twice a
year (whichever comes
first)

Synthetic
Oil
Change

Meritor
Specification
0-84

Military
Specification

Oil
Description
Petroleum Base
SAE 10W, 20W
or 10W/30

NOTES:
The checking interval depends on the individual operating conditions, speeds and loads. Severe operating conditions may require more
frequent intervals.
Tractor oil universal fluid, TOU types formulated for wet disc brakes, is recommended for use in the wet disc brake housing. Make sure
that the specifications of the tractor fluid are the same as the recommended specifications of the vehicle manufacturer.

CAUTION

The operating temperature of the coolant must

never reach or exceed 250F (120C). If the
operating temperature of the coolant reaches
or exceeds 250F (120C), the internal
components of the brake will be damaged. A
forced cooling system may be required to
assure the coolant temperature remains below
250F (120C).

Use only the brake hydraulic fluid specified by

the manufacturer of the vehicle. Do not use
different hydraulic fluids. The wrong fluid will
damage the seals on the piston.

52

Section 6
Specifications
Nut Lock
Special Tool
13.78 in.
(350.0 mm)
0.079 in.
(20.0 mm)

15.55 in.
(395.0 mm)

1.77 in.
(45.0 mm)
0.57 in.
(14.5mm)

0.078 in.
R 2.0
0.197 in.
(5.0 mm
x 45)

0.984 in.
R 5.0

0.79 in.
( 20.0 mm)
1.97 in.
( 50.0 mm)

THREAD: 5/8" II UNC

3.15 in.
( 80.0 mm)

0.39 in.
(10.0 mm x 45)

1.77 in.
(45.0 mm)
2.44 in.
(62.0 mm)
4.53 in.
(115.0 mm)
0.709 in.
( 18.0 mm)

0.079 in.
(2.0 mm)

in.
47 m)
0.5 .9 m
3
1
8
( 13.

3010'
3.86 in.
( 98.0 mm)

53

Section 6
Specifications
PROA 352/382 (With Mechanical Drive Option)
4

14

11
10
15

16
1

3
6
13
8

19
7
17
18

2
9

12

54

Section 6
Specifications
Torque Chart - PROA 352/382
ITEM
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION/THREAD
Pinion Nut - M24 x 1.5-6H
Nut (Stud - Center Housing) M14 x 1.5-6H
Capscrew (Differential Case) M10 x 1.5-8G
Capscrew (Spiral Gear) M10 x 1.0-6G
Capscrew (Pinion Cage) M12 x 1.75-8G
Capscrew (Lock Adjuster Ring) M6 6G
Capscrew (Adjusting Nut Lock) M8 x 1.25-6G
Capscrew (Brake Housing) M8 x 1.25-6G
Capscrew (Brake Releaser) M12 x 1.75-6G
Capscrew (Flange Adapter) .3750 x 16UNC2A
Capscrew (Center Housing Cover) M8 x 1.25-6G

TORQUE
465-570 lb-ft (630-775 Nm)
120-150 lb-ft (160-205 Nm)
48-64 lb-ft (64-87 Nm)
66-75 lb-ft (90-100 Nm)
67-91 lb-ft (91-120 Nm)
80-115 lb-in (9.0-13.0 Nm)
17-23 lb-ft (23-30 Nm)
19-26 lb-ft (26-36 Nm)
25-34 lb-ft (34-46 Nm)
39.0-53.0 lb-ft (53-72 Nm)
20-27 lb-ft (27-36 Nm)

12
13
14
15
16
17
18
19

Capscrew (Axle Shaft Flange) M20 x 1.5-6G

Drain Plug
Grease Fitting
Vent Plug
Level Plug
Capscrew (Planetary Pinion Axle) M10 x 1.5-6G
Bolt (Action Plate) M6 x 1.5-6G
Capscrew (Return Spring) M6 x 1.0-6G

470-575 lb-ft (635-780 Nm)

35 lb-ft (47 Nm)
31-40 lb-in (3.5-4.5 Nm)
15 lb-ft (20 Nm)
35 lb-ft (47 Nm)
17-23 lb-ft (23-31 Nm)
120-140 lb-in (13.5-16.0 Nm)
80-115 lb-in (9.0-13.0 Nm)

55

Section 6
Specifications
PRA 352 Trumpet Variation No. 2
5

2
4

12

13

8
11

6
7

8
9

1
10

56

Section 6
Specifications
Torque Chart - PRA 352
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13

DESCRIPTION/THREAD
Pinion Nut - M24 x 1.5-6H
Capscrew (Center Housing) - M14 x 1.5-6G
Nut (Stud - Center Housing) - M14 x 1.5-6H
Capscrew (Differential Case) - M10 x 1.5-6G
Capscrew (Spiral Gear) - M10 x 1.0-6G
Capscrew (Pinion Cage) - M12 x 1.75-6G
Capscrew (Lock - Adjuster Ring) - M6-6G
Capscrew - Adjusting Nut Lock - M8 x 1.25-6G
Bolt - Return Spring - M6 x 1.0-6G
Capscrew (Planetary Pinion Axle) - M10 x 1.5-6G
Plug - Level - M24 x 1.5

TORQUE
465-570 lb-ft (630-775 Nm)
150-185 lb-ft (205-250 Nm)
120-150 lb-ft (160-205 Nm)
48-64 lb-ft (64-87 Nm)
66-75 lb-ft (90-100 Nm)
67-91 lb-ft (90-125 Nm)
80-115 lb-in (9-13 Nm)
17-23 lb-ft (23-31 Nm)
80-115 lb-in (9.0-13.0 Nm)
17-23 lb-ft (23-31 Nm)
35 lb-ft min. (47 Nm min.)

Plug - Drain - M24 x 1.5

Plug - Vent - M12 x 1.5

35 lb-ft min. (47 Nm min.)

15 lb-ft min. (20 Nm min.)

57

Section 6
Specifications
PROA 352 G2H, G2M
5

17

16
21

20

18

8
4

19

22

7
6
10
11
1

14

13

10
11
14

15
9

2
12
13
3

17

58

Section 6
Specifications
Torque Chart - PROA 352, G2H, G2M
ITEM
1
2
3
4
5
6
7
8
9
10
11

DESCRIPTION/THREAD
Pinion Nut - M24 x 1.5-6H
Capscrew (Center Housing) M14 x 1.5-6G
Nut (Stud - Center Housing) M14 x 1.5-6H
Capscrew (Differential Case) M10 x 1.5-6G
Capscrew (Spiral Gear) M10 x 1.0-6G
Capscrew (Pinion Cage) M12 x 1.75-6G
Capscrew (Lock Adjuster Ring) M6 6G
Capscrew (Adjusting Nut Lock) M8 x 1.25-6G
Capscrew (Brake Housing) M8 x 1.25-6G
Capscrew (Brake Cylinder Support) M8 x 1.25-6G
Capscrew (Brake Cylinder) M10 x 1.5-6G

TORQUE
465.0-570 lb-ft (630-775 Nm)
180.0-215.0 lb-ft (245-290 Nm)
120-150 lb-ft (160-205 Nm)
48-64 lb-ft (64-87 Nm)
66-75 lb-ft (90-100 Nm)
67.0-91.0 lb-ft (91-120 Nm)
80.0-115.0 lb-in (9-13 Nm)
17-23 lb-ft (23-31 Nm)
19-26 lb-ft (26-36 Nm)
19-26 lb-ft (26-36 Nm)
48-64 lb-ft (64-87 Nm)

12
13
14
15
16
17
18
19
20
21
22

Cover (Brake Cylinder) M80 x 1.5-6G

Capscrew (Brake Cylinder Cover) M12 x 1.75-6G
Capscrew (Brake Releaser) M12 x 1.75-6G
Capscrew (Flange Adapter) .3750" x 16UNC2A
Capscrew (Center Housing Cover) M8 x 1.25-6G
Capscrew (Axle Shaft Flange) M20 x 1.5-6G
Drain Plug
Grease Fitting
Vent Plug
Level Plug
Capscrew (Planetary Pinion Axle) M10 x 1.5-6G

60-90 lb-ft (80-120 Nm)

22-30 lb-ft (30-41 Nm)
22-30 lb-ft (30-41 Nm)
39.0-53.0 lb-ft (53-72 Nm)
19-26 lb-ft (26-36 Nm)
470-575 lb-ft (635-780 Nm)
35.0 lb-ft (47 Nm)
10.0 lb-ft (14 Nm)
15.0 lb-ft min. (20 Nm min.)
35.0 lb-ft min. (47 Nm min.)
17.0-23.0 lb-ft (23-31 Nm)

59

MANUALE DI RIPARAZIONE
REPAIR MANUAL

ASSALE ANTERIORE - FRONT AXLE

Mod. 28.46M
Rif. CA144840

Edition date: 12/2002

P/N: CA357248

Mod. 28.46M

Indice

Index

INFORMAZIONI GENERALI . . . . . . . . . . . 1

GENERAL INFORMATION . . . . . . . . . . . 1

Utilizzo del manuale . . . . . . . . . . . . . . . . . . 2

Manual use . . . . . . . . . . . . . . . . . . . . . . . . . 2

Propriet delle informazioni . . . . . . . . . . . . . 3

Information property . . . . . . . . . . . . . . . . . . 3

Convenzioni e definizioni . . . . . . . . . . . . . . . 4

Agreements and definitions . . . . . . . . . . . . . 4

Indicazioni generali . . . . . . . . . . . . . . . . . . . 6

General description . . . . . . . . . . . . . . . . . . . 6

Indicazioni generali
per le operazioni di riparazione . . . . . . . . . . 7

Recommendations
for repair operations . . . . . . . . . . . . . . . . . . 7

INFORMAZIONI SULLA SICUREZZA . . . 9

SAFETY INSTRUCTIONS . . . . . . . . . . . . 9

Indicazioni generali per la sicurezza . . . . . 10

General safety recommendations . . . . . . . 10

Simboli di sicurezza . . . . . . . . . . . . . . . . . . 11

Safety symbols . . . . . . . . . . . . . . . . . . . . . 11

Precauzioni generali . . . . . . . . . . . . . . . . . 12

General precautions . . . . . . . . . . . . . . . . . 12

CARATTERISTICHE GENERALI . . . . . . 14

GENERAL SPECIFICATIONS . . . . . . . . 14

Usi previsti . . . . . . . . . . . . . . . . . . . . . . . . . 15

Foreseen uses . . . . . . . . . . . . . . . . . . . . . 15

Identificazione del prodotto . . . . . . . . . . . . 15

Product identification . . . . . . . . . . . . . . . . . 15

Descrizione generale . . . . . . . . . . . . . . . . . 16

General description . . . . . . . . . . . . . . . . . . 16

Caratteristiche Tecniche . . . . . . . . . . . . . . 17

Technical Features . . . . . . . . . . . . . . . . . . 17

Cambio olio e verifiche . . . . . . . . . . . . . . . 22

Oil change and checks . . . . . . . . . . . . . . . 22

Coppie di serraggio

. . . . . . . . . . . . . . . . . 26

Tightening torques . . . . . . . . . . . . . . . . . . 26

OPERAZIONI DI MONTAGGIO E
SMONTAGGIO . . . . . . . . . . . . . . . . . . . . 28

DISASSEMBLY AND ASSEMBLY

OPERATIONS . . . . . . . . . . . . . . . . . . . . 28

Gruppo flangia . . . . . . . . . . . . . . . . . . . . . . 29

Flange group . . . . . . . . . . . . . . . . . . . . . . . 29

Gruppo riduttore epicicloidale . . . . . . . . . . 32

Epicyclic reduction gear group . . . . . . . . . 32

Gruppo mozzo ruota . . . . . . . . . . . . . . . . . 36

Wheel hub group . . . . . . . . . . . . . . . . . . . . 36

Gruppo trombe trave . . . . . . . . . . . . . . . . . 41

Axle beam trumpets group . . . . . . . . . . . . 41

Freno e supporto differenziale . . . . . . . . . 45

Brake and differential support . . . . . . . . . . 45

Gruppo differenziale . . . . . . . . . . . . . . . . . 60

Differential group . . . . . . . . . . . . . . . . . . . . 60

Gruppo pignone . . . . . . . . . . . . . . . . . . . . . 64

Pinion group . . . . . . . . . . . . . . . . . . . . . . . 64

Sbloccaggio freno parcheggio . . . . . . . . . . 70

Parking brakes release . . . . . . . . . . . . . . . 70

Riattivazione freno parcheggio . . . . . . . . . 71

Re-activating parking brakes . . . . . . . . . . . 71

Prove dopo montaggio . . . . . . . . . . . . . . . 72

Testing after assembly . . . . . . . . . . . . . . . 72

LA10077

REVISION DATE:

00/00

P /N :

CA357248

PAG.

i.1

Mod. 28.46M

RICERCA GUASTI . . . . . . . . . . . . . . . . . 73

TROUBLESHOOTING . . . . . . . . . . . . . . 73

Controllo ed esame dei guasti . . . . . . . . . . 76

Troubleshooting . . . . . . . . . . . . . . . . . . . . 78

Diagnosi per problemi all'assale . . . . . . . . 80

Axle problems and diagnosis . . . . . . . . . . 81

ATTREZZATURE SPECIALI . . . . . . . . . . 82

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . 82

Attrezzature speciali . . . . . . . . . . . . . . . . . 83

Special tools . . . . . . . . . . . . . . . . . . . . . . . 83

LA10077

REVISION DATE:

00/00

P /N :

CA357248

PAG.

i.2

Mod. 28.46M

INFORMAZIONI GENERALI

GENERAL INFORMATION

REVISION DATE:

00/00

P /N :

CA357248

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

A.1 Utilizzo del manuale

A.1 Manual use

Destinatari

End users

Installatore.
Utilizzatore.
Manutentore.

Installer
User
Maintenance operator

Manutenzione

Maintenance

PRENDERE VISIONE DI TUTTO IL MANUALE poich

il buon funzionamento ed il rendimento degli organi
meccanici dipendono principalmente da una costante e
corretta manutenzione e assicurano la durata e
l'integrit del prodotto.
Nell'eventualit di guasti od anomalie il tempestivo
intervento da parte di personale specializzato
garantisce una durata pi lunga del gruppo, evitando
danni maggiori nel tempo.

CONSULT THIS MANUAL THOROUGHLY, as proper

functioning and good efficiency of mechanical organs
depends mostly on constant and correct routine
maintenance ensuring product integrity and expected
life duration.
In case of any damages or anomalies, quick intervention
of specialized personnel can avoid future impairment
and lengthen the working life.

Riparazione

Repair

Le procedure per lo smontaggio/montaggio consentono

di eseguire la revisione totale del prodotto e sono
descritte in sequenza con lausilio di illustrazioni, per
una guida completa e sicura allesecuzione di ogni
operazione.
Nella descrizione delle operazioni si presuppone che il
gruppo sia stato rimosso dal veicolo. Per la rimozione
dal veicolo si dovr consultare il manuale fornito a tale
proposito dal costruttore del veicolo stesso.
La conoscenza approfondita del prodotto consente la
corretta valutazione del tipo di intervento da eseguire,
che pu richiedere solamente lo smontaggio di alcuni
componenti operando solo parzialmente nel gruppo.

The disassembly/assembly procedures have been

outlined for a total product overhauling. They have also
been described in sequence through photographs with
relevant explanation for specific interventions, thus
obtaining a complete and safe guide for each and every
phase of an operation.
Operation description presumes that the unit has
already been removed from the vehicle. The manual
supplied by the vehicle manufacturer should be
consulted in case of a overhauling or maintenance
intervention requiring the removal of the machine.
Moreover, the attentive product inspection leads to a
correct repair work estimation that could merely require
dismounting only few components, and thus operating
partially on the group.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

A.1

PAG.2

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

A.2 Propriet delle informazioni

A.2 Information property

Questo manuale contiene informazioni di propriet

riservata. Tutti i diritti sono riservati.

This manual should be considered as CARRARO S.p.A.

confidential information. All rights reserved.

Questo manuale non pu essere riprodotto o

fotocopiato, tutto o in parte, senza il preventivo
consenso scritto di CARRARO S.p.A. Luso di questo
materiale documentale consentito solo al cliente a cui
il manuale stato fornito come corredo del prodotto, e
solo per scopi di uso, manutenzione e riparazione.

No part of this manual may be reproduced, in any form

or by any means, without prior written permission of
CARRARO S.p.A. Only the customer, whom the
manual, together with the product, has been issued to,
is allowed to use this document, and only in order to use,
maintain and repair the unit.

CARRARO S.p.A. dichiara che le informazioni

contenute in questo manuale sono congruenti con le
specifiche tecniche e di sicurezza della macchina a cui
il manuale si riferisce. Il fabbricante non si assume
alcuna responsabilit per danni diretti o indiretti a
persone, cose o animali, conseguenti alluso di questo
materiale documentale o della macchina in condizioni
diverse da quelle previste.

CARRARO S.p.A. declares that the subject of this

manual consists with the technical and safety
specifications of the machine that the manual is referred
to. The manufacturer shall not be held liable for direct
or indirect damages to persons, things or animals due
to an improper use of this document or of the machine
or to a different use of them, which does not comply with
what is provided for in this manual.

Carraro Spa
Via Olmo, 37
35011 Campodarsego (Pd) Italia
Tel. +39 049 9219111
Fax +39 049 9289111
www.carraro.com

LA10077

REVISION DATE:

00/00

P /N :

CA357248

A.2

PAG.3

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

A.3 Convenzioni e definizioni

A.3 Agreements and definitions

Convenzioni

Agreements

Le illustrazioni nel manuale NON sono in scala quindi

NON sono attendibili valutazioni delle dimensioni dei
componenti basate sulle stesse.
Le illustrazioni hanno il compito di evidenziare le corrette
procedure da condurre sulla macchina e sui suoi
componenti, per questo potrebbero non rappresentare
esattamente gli elementi di questa macchina ma
componenti meccanici simili.

Illustrations like pictures, drawings and components of

this manual are NOT in scale, because of limited space
and editing limits, therefore they are NOT reliable to
obtain values about size or weight.
Illustrations are supposed to point out the correct
methods to working on the machine and its components,
therefore they could not display exactly the same
elements.

Definizioni

Definitions

Lato sinistro: parte sinistra del gruppo vista nel senso

di marcia del veicolo.
Lato destro: parte destra del gruppo vista nel senso di
marcia del veicolo.

Left side: it is the left side of the unit considering the

vehicle running conditions.
Right side: it is the right side of the unit considering the
vehicle running conditions.

Convenzioni tipografiche

Typographic agreements

Nota: informazioni importanti, evidenziate al di fuori del

testo a cui si riferiscono.
Attenzione: procedure la cui totale o parziale
inosservanza pu produrre danni alla macchina o alle
apparecchiature ad essa collegate.
Pericolo: procedure la cui totale o parziale
inosservanza pu produrre lesioni o danni alla salute
delloperatore.

Note: The notes, pointed out externally to the text they

refer, include important information.
Warning: Warning indications point out the procedures,
whose partial or complete non-observance can damage
the machine or the connected equipment.
Danger: Danger indications point out the procedures,
whose partial or complete non-observance can injure
the operator.

Unit di misura

Measurements

Nel manuale si utilizzano le unit di misura del sistema

internazionale (SI). Per la conversione al sistema
anglosassone riferirsi alla seguente tabella.

This manual indicates all measurements in International

System (SI). Use the following conversion table to
convert Imperial Measure.

Tabella di conversione

Conversion table

S.I.
1
(mm)
10
(mm)
25.4
(mm)
6.4516
(cm)
1
(m)
16.378
(cm)
0.473
(dm)
1
(l)
1
(l)
1.772
(g)
0.4536
(kg)
0.00070308
(kg/mm)
1
(bar)
1
(kg.m)
1(daN)= 10 (N)= 1,02 (kg.f)

LA10077

REVISION DATE:

GB/USA SYSTEM
0.03937
(in)
0.3937
(in)
1
(in)
1
(sq. in)
1550
(sq. in)
1
(cu. in)
1
(U.S. pint)
61.02
(cu. in)
0.2642
(U.S. gal)
1
(oz)
1
(lb)
1
(lb/sq. in)
14.51
(psi)
7.246
(lb.ft)
2.24
(lb.f)

00/00

P /N :

CA357248

A.3

PAG.4

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

Simbologia

Symbology
DESCRIZIONE

SIMBOLI / SYMBOLS

DESCRIPTION

ATTENZIONE/PERICOLO

WARNING/DANGER

RIMOZIONE/INSTALLAZIONE
anelli-guarnizioni-filtri

REMOVE/INSTALL
seals-gaskets-filters

RIEMPIMENTO o RABBOCCO OLIO/

SCARICO OLIO

OIL FILLING OR OIL LEVEL/OIL DRAIN

LUBRIFICAZIONE/INGRASSAGGIO

LUBRICATION/GREASING

REGOLAZIONE/MISURAZIONE
coppie di serraggio-precarichi-giochi

ADJUSTMENTS/MEASUREMENTS
tightening torques-preloads-backlash

ATTREZZATURE SPECIALI

SPECIAL TOOLS

APPLICAZIONE
SIGILLANTI/COLLANTI

SEALING/LOCKING FLUIDS
APPLICATION

TRACCIATURA

MARKING

SMONTAGGIO/MONTAGGIO DI
PARTICOLARI INGOMBRI O
SOTTOGRUPPI

DISASSEMBLY/ASSEMBLY OF BULKY
PARTS OR SUBASSEMBLIES

ATTENZIONE:
rispettare il verso di montaggio

WARNING:
respect assembly orientation

PULIRE ACCURATAMENTE

CLEANING CAREFULLY

IMMETTERE FLUIDO IN PRESSIONE

APPLY PRESSURIZED FLUID

LA10077

REVISION DATE:

00/00

P /N :

CA357248

A.3

PAG.5

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

A.4 Indicazioni generali

A.4 General description

La macchina deve essere controllata e/o riparata solo

da personale tecnico specializzato che sia a
conoscenza delle sue particolari caratteristiche e delle
relative norme di sicurezza (prevenzione infortuni).

The machine should be checked and/or repaired only

by qualified technicians, acquainted with its peculiar
features and well aware of all safety instructions.

Prima di svolgere qualsiasi operazione, pulire

accuratamente il gruppo rimuovendo eventuali
incrostazioni ed accumuli di terriccio e/o grasso.

Before performing any operation it is advisable to carry

out unit cleaning accurately by removing oil/ grease
encrustations and accumulation.

Tutti gli organi meccanici smontati devono essere

accuratamente puliti con prodotti adeguati, per evitare
possibili danni. Verificarne l'integrit, sostituendoli in
caso di danni, usura, incrinature, grippaggi o difetti che
potrebbero comprometterne il buon funzionamento.
In particolar modo si deve verificare l'integrit delle parti
in movimento (cuscinetti, ingranaggi, alberi) e delle parti
di tenuta (anelli OR, anelli di tenuta), soggette a maggiori
sollecitazioni, usura, invecchiamento.
Si raccomanda di sostituire ad ogni revisione o
riparazione gli organi di tenuta.
Si ricordi che leventuale sostituzione di un componente
della coppia conica comporta la sostituzione anche
dell'altro.

All disassembled mechanical parts must be cleaned

accurately with suitable products to avoid possible
damage. Parts should be replaced if damaged, worn
out, cracked, seized, etc. as they could affect proper
working.
Rotating parts (bearings, gears, shafts) and that of
hardware/fasteners (O-Ring, oil seals) should be
examined carefully, as they are subject to major stress,
wearing and ageing.
We highly advise to replace tightening parts during every
teardown or repair.
In case of replacement of one part of the bevel gear set
this operation requires the replacement of the other part
too.

Utilizzare solo le parti di ricambio e la viteria indicate,

inoltre usare utensili metrici per la viteria metrica e inglesi
per la viteria inglese.

Use appropriate spare parts, nuts and bolts to avoid any

other problems. Moreover, use metric tools for metric
nuts and bolts and Imperial tools for the others.

Come indicato, alcune operazioni sono distruttive per

gli elementi rimossi. Leggere attentamente le descrizioni
delle varie fasi dell'intervento ed operare con attenzione
per non compromettere la funzionalit di altri elementi.

Some repairs are destructive for some axle components.

Carefully reading and thorough understanding of these
instructions will avoid damage to other components
unnecessarily.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

A.4

PAG.6

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

A.5 Indicazioni generali

per le operazioni di riparazione

A.5 Recommendations
for repair operations

Prima di iniziare le operazioni di smontaggio e

montaggio leggere attentamente le seguenti
avvertenze.

Before starting any disassembly and assembly

operations, read carefully the following
recommendations.

Anelli di tenuta per alberi

Shafts seals

Per il montaggio degli anelli di tenuta attenersi alle

seguenti raccomandazioni:
- Pulire accuratamente l'albero ed assicurarsi che non
sia danneggiato, rigato od ovalizzato nelle zone di
contatto con gli anelli.
- Montare gli anelli in modo che il labbro sia rivolto verso
il lato olio.
- Lubrificare il labbro degli anelli (usare preferibilmente
olio) e riempire per 3/4 di grasso la camera degli anelli
stessi.
- Montare gli anelli usando un appropriato calettatore.
Non usare il martello direttamente sugli anelli.
- Non danneggiare gli anelli durante il montaggio
dell'albero.

Respect the following recommendations during shaft

seal assembly:
- Clean shaft very carefully and ensure that the part in
contact with the shaft seal is not damaged, cut or out of
roundness.
- Assemble the seals so that the lip is fitted towards the
oil side.
- Lubricate seal lips (use oil) and fill 3/4 of seal cavity
with grease.
- Use appropriate drivers. Do not use a hammer directly
on the seals.
- Do not damage the seals while assembling the shaft.

Anelli OR

O-rings

Lubrificarli adeguatamente prima di inserirli nella propria

sede evitando "arrotolamenti" durante il montaggio
dell'albero.

Lubricate adequately before inserting them at the right

place and avoid o-ring rolling while inserting the shaft.

Spessori di registro

Adjusting shims

Per le registrazioni utilizzare gli appropriati spessori di

registro, misurandoli singolarmente.
La misurazione del pacco completo o la stampigliatura
riportata sugli spessori stessi pu risultare non sempre
affidabile: verificare.

Use appropriate adjusting shims and measure each one

separately.
Complete group measurement or stampings on the
shims are not always reliable: check.

Cuscinetti

Bearings

Per un corretto montaggio consigliabile riscaldarli in

forno ad una temperatura di 80C - 90C prima di
montarli sui rispettivi alberi o raffreddarli prima di inserirli
nelle relative sedi con piantaggio esterno.
Usare sempre gli estrattori idonei per rimuovere i
cuscinetti.
Prima di rimontarli, pulirli, ispezionarli e lubrificarli.

Its advisable to heat up bearings to 80C - 90C before

assembling them onto their respective shafts or to cool
them (dry ice) before inserting them into corresponding
bore.
Always use suitable extractors to remove the bearings.
Before reassembling the bearings, clean, check and
lubricate them.

Spine elastiche

Split pins

Al montaggio delle spine elastiche ad intaglio assicurarsi

che l'intaglio delle stesse sia orientato nel senso dello
sforzo sollecitante la spina. Le spine elastiche a spirale
invece non necessitano di alcun orientamento.

Before assembling elastic pins, make sure that the notch

is oriented towards the stressing force.
Spiral elastic pins do not need orientation.

Sigillante

Sealing

Usare sigillanti secondo le specifiche. Assicurarsi che

le parti da sigillare siano pulite, asciutte e
completamente prive di grasso.

Use sealing as advised by specifications. Ensure that

parts to be sealed are clean, dry and completely grease
free.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

A.5

PAG.7

INFORMAZIONI GENERALI
GENERAL INFORMATION

Mod. 28.46M

Scarico dell'olio

Oil drain

Prima di intervenire sul prodotto necessario scaricare

l'olio dal gruppo.
Attenzione: smaltire gli oli esausti nel rispetto delle
vigenti norme.

Before disassembly, oil should be drained out.

Pulizia

Cleaning

Lavare accuratamente tutte le parti in movimento

relativo (ingranaggi, cuscinetti, ecc.) utilizzando gasolio
o cherosene.
E' da evitare l'uso di benzina e soluzioni acquose
alcaline. Evitare lavaggi con vapore o acqua calda
perch sarebbe difficile eliminare completamente
l'umidit superficiale.
Asciugare accuratamente tutti i particolari mediante un
getto d'aria o stracci per evitare di rigare le superfici con
residui abrasivi.
Tutte le superfici devono essere ricoperte da un leggero
strato di lubrificante per proteggerle da eventuali
ossidazioni.

Wash all moving parts (gears, bearings, etc.) accurately

with diesel fuel or kerosene.
Avoid gasoline and watery alkaline solutions. Do not
wash with steam or hot water, as it will be very difficult
to eliminate surface humidity.
Dry all parts with a rag or air jet to avoid scratching from
abrasive residuals.
All surfaces should be covered with lubricant so as to
protect it from future oxidation.

Controlli

Checks

Verificare accuratamente tutti i cuscinetti, gli anelli

esterni eventualmente ancora piantati nelle proprie sedi
e i perni su cui rotolano i rullini. Sostituire quei particolari
che presentano tracce di usura o di danneggiamento.
Controllare che tutti gli ingranaggi non presentino avarie
od usure eccessive delle dentature: gli smussi dei denti
non devono essere deteriorati.
Controllare che tutti i tratti scanalati siano privi di usure
eccessive o di altri danneggiamenti.
Sostituire i particolari avariati con ricambi originali.
Dopo ogni smontaggio buona norma sostituire le
guarnizioni di tenuta sugli alberi rotanti.

Examine accurately all bearings, external rings which

may be still stuck in their position and pivot pins on which
rolls rotate. Replace those which are worn out or
damaged.
Gears should not be spoiled and teething should not be
excessively worn out. Teeth smoothing should not be
deteriorated.
Check all grooves: assure that they are not worn out or
damaged.
Replace spoiled parts with original spare parts.
Replace seals on rotating shafts, before reassembly.

Estremit di flange ed attrezzi

Ends of flanges and tools

Prestare la massima attenzione quando si martellano le

estremit di attrezzi o di flange per evitare di
compromettere la funzionalit e lintegrit sia degli
attrezzi che dei componenti su cui si opera.

Be careful when hammering tool or flange ends, in order

to avoid jeopardizing functionality and integrity of either
the tools or the components on which you are operating.

Metodi di riassemblaggio

Reassembly methods

Per riassemblare il gruppo si deve impiegare

unadeguata attrezzatura di sostegno.
Per posizionare il gruppo, per smontare e rimontare la
corona dentata e per sostenere la scatola ingranaggi
necessario un sistema di sollevamento.
Per facilitare le operazioni di smontaggio e montaggio
utilizzare un disegno di assieme del gruppo.

In order to reassemble the group, an appropriate fixture

must be used.
In order to position the group, to disassemble and
reassemble the ring gear and to support the gear
housing, a lifting system is needed.
To make disassembling and assembling operations
easier, use a group assembly drawing.

Impiego di lubrificante

Lubricant use

Per ottenere una corretta lubrificazione ed una esatta

temperatura di funzionamento negli assali CARRARO,
importante usare i lubrificanti raccomandati (Sez.C.4),
mantenendone il livello costante secondo quanto
indicato nel presente manuale.

In order to lubricate the CARRARO axles correctly and

to reach the exact operation temperature, it is important
to use the recommended lubricants (Section C.4),
keeping their level constant as indicated in this manual.

LA10077

REVISION DATE:

Warning: disposal of used oil must be done according

to laws.

00/00

P /N :

CA357248

A.5

PAG.8

Mod. 28.46M

B
B

INFORMAZIONI SULLA
SICUREZZA

SAFETY INSTRUCTIONS

REVISION DATE:

00/00

P /N :

CA357248

INFORMAZIONI SULLA SICUREZZA

SAFETY INSTRUCTIONS

Mod. 28.46M

B.1 Indicazioni generali per la

sicurezza

B.1 General safety

recommendations

IMPORTANTE:
Prima di iniziare qualsiasi tipo di operazione leggere
attentamente questo capitolo.

IMPORTANT:
Before proceeding with any operations please read this
chapter very carefully.

Precauzioni per la sicurezza:

Safety precautions:

Il corretto uso e la corretta riparazione dei prodotti

Carraro e dei loro componenti sono molto importanti per
la sicurezza e l'affidabilit.
Le procedure raccomandate e descritte in questo
manuale sono testate, quindi sono effettivi metodi
operativi. Seguire strettamente ogni procedura facendo
uso sia del testo che delle illustrazioni.
Alcune di queste procedure mostrano l'uso di appositi
strumenti progettati perch le operazioni vengano
condotte in modo chiaro e corretto.
Alcuni strumenti specifici devono essere usati dove
necessario per eseguire determinate operazioni.
E' impossibile trattare ogni metodo di lavoro o tutte le
possibili metodologie per svolgerlo e le rischiose
conseguenze di ognuna, perci chi usa procedure o
strumenti non consigliati deve sapere che la sicurezza
dell'operatore e del veicolo saranno messi a repentaglio.

Correct use and repair of Carraro products and of their

components is very important for safety and reliability.
Recommendations and all described procedures given
in this manual have been experimented and hence are
effective operational methods. Please follow every
procedure. Use the text as well as the illustrations.
Certain procedures show use of special tools, designed
so that the operations can be carried out in a clear and
correct manner.
Special tools must be used when a particular operation
is being carried out.
It is impossible to advise every working method or know
all possible methodologies for carrying it out or to predict
risky consequences of each operation. Hence,
performing procedures or using instruments which have
not been advised could be dangerous for the operator/
mechanic as well as the vehicle.

Pericolo

Danger

Gli occhiali di sicurezza devono essere indossati sempre

durante lesecuzione di tutte le operazioni di montaggio
o smontaggio.

Safety goggles must be worn while carrying out every

assembling or disassembling operations.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

B.1

PAG.10

INFORMAZIONI SULLA SICUREZZA

SAFETY INSTRUCTIONS

Mod. 28.46M

B.2 Simboli di sicurezza

B.2 Safety symbols

Identificazione delle informazioni sulla sicurezza

Recognize safety information

Questo il simbolo di allarme per la sicurezza; quando

lo trovate sulla macchina o sul manuale, siete avvisati
del pericolo potenziale di incidenti o danni alla persona.
Seguite i suggerimenti e le raccomandazioni per operare
in sicurezza.

This is the safety alarm symbol; whenever you find it in

the manual or see it on the machine, you are being
warned about potential danger of accidents or harm to
personnel. Follow the dos and donts to operate in total
safety.

Significato delle scritte di avvertimento

Understanding written warnings

PERICOLO

DANGER

AVVISO

WARNING

ATTENZIONE

CAUTION

Una scritta di avvertimento (PERICOLO, AVVISO o

ATTENZIONE), viene usata sulla macchina insieme al
simbolo di allarme per la sicurezza.
I segnali PERICOLO o AVVISO sono utilizzati vicino ad
aree pericolose. PERICOLO identifica la situazione pi
pericolosa.
Precauzioni generali sono invece segnalate da
ATTENZIONE.

Written warning (DANGER, WARNING or CAUTION) is

used along with an alarm symbol on the machine.
DANGER or WARNING signs are used near danger
zones, while CAUTION sign indicates general
precaution.

Seguire le istruzioni di sicurezza !

Follow safety instructions !

Leggere con cura tutti i messaggi sulla sicurezza di

questo manuale.

Read all suggestions given in this instruction manual

very carefully.

Modifiche non autorizzate possono compromettere il

funzionamento, la sicurezza d'impiego e la durata.
Se non comprendete le istruzioni del manuale,
contattate il rappresentante a voi pi vicino.

Unauthorized changes could endanger the functioning,

work safety and work span.
If you do not understand this instruction manual, contact
the nearest sales representative.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

B.2

PAG.11

INFORMAZIONI SULLA SICUREZZA

SAFETY INSTRUCTIONS

Mod. 28.46M

B.3 Precauzioni generali

B.3 General precautions

In ogni movimento dovranno essere osservate le norme

sulla prevenzione infortuni, tutte le regole generali di
sicurezza e di medicina del lavoro.
Prima di procedere nelle operazioni di manutenzione o
sistemazione di eventuali problemi, assicurarsi del buon
stato e del buon funzionamento delle attrezzature quali
banchi di sostegno, cavalletti, martelli, leve, estrattori e
chiavi apposite facilitando le operazioni da svolgere in
modo ottimale riducendo i rischi sia per gli organi ed i
componenti del prodotto che della incolumit
dell'operatore.
Tutte le modifiche arbitrarie apportate al prodotto
sollevano la CARRARO SpA da ogni responsabilit per
qualsiasi danno o incidente.
Il prodotto, se utilizzato in un impiego diverso da quello
previsto, da considerarsi soggetto a "uso non
previsto". CARRARO SpA declina ogni responsabilit
per danni o incidenti risultanti da un uso diverso da quello
previsto; tali conseguenze saranno a carico esclusivo
del cliente.

Observe safety instructions, accident prevention rules

and all general safety regulations in each and every step
at work.
Before going ahead with maintenance or repair work
ensure that all the tools, the supporting bench, stands,
levers, extractors and spanners are in good condition
so that the work can be carried out easily.
Risks to various parts and components will also be
reduced in this way and working condition for the
operator will also be safer.
CARRARO SpA declines any responsibility in case of
an accident or damage resulting due to changes made
arbitrarily on product.
The product is used for any other purpose different from
the one foreseen, than CARRARO SpA declines any
responsibility.
In this case all consequences will be at the customers
expense.

Norme per la manutenzione in sicurezza

Safety maintenance rules

1 Operare in ambiente pulito e asciutto.

2 Non lubrificare, manipolare o registrare il gruppo in
moto.
3 Tenere lontani mani, piedi, indumenti da parti in
movimento.
4 Essere sempre pronti per i principi di incendio.
Tenere a portata di mano estintore e cassetta di
pronto soccorso.
5 Tenere in evidenza il n di telefono di un medico,
ambulanza, ospedale e vigili del fuoco presso il
proprio telefono.

1 Operate in a clean and dry environment.

2 Do not lubricate, handle or adjust the group underway.
3 Keep your hands, feet and clothing away from moving parts.
4 Always be prepared for fires. Keep the extinguisher
and the first aid kit within reach.
5 Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within
reach near the telephone set.

6 Usare indumenti e protezioni adatte allo scopo

come: tuta, guanti protettivi e cuffie.
7 Usare
protezioni
auricolari
appropriate
a
salvaguardare l'udito, come tappi o cuffie per le
orecchie contro rumori molesti o fastidiosi.

6 Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices.
7 Use suitable ear protection, like ear plugs, to keep
out noise and prevent injury to the ears.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

B.3

PAG.12

INFORMAZIONI SULLA SICUREZZA

SAFETY INSTRUCTIONS

Mod. 28.46M

Una prolungata esposizione

danneggiare l'udito.

pu

A prolonged exposure to noise can damage your

hearing.

8 Le attrezzature richiedono la piena attenzione

dell'operatore. Non usare cuffie per ascoltare
musica mentre si interviene sul prodotto o gruppo.

8 The operator must be very careful with the equipment. Do not use headphones to listen music while
you are working on the product or on the group.

Eliminazione dei rischi residui

Residual risk elimination

al

rumore

Rischio di schiacciamento e cesoiamento dovuto alla

presenza di elementi in movimento.
Attenzione
Eseguire tutte le operazioni di manutenzione a
macchina ferma.
Rischio dovuto allinalazione di gas nocivi che si
possono sviluppare scaldando le vernici durante
eventuali saldature.
Attenzione
Utilizzare postazioni di lavoro dotate di sistemi di
evacuazione di polveri e fumi.
Lasciate disperdere i fumi per almeno 15 minuti prima
di saldare o riscaldare, o riprendere a lavorare sul
gruppo.
Rischio di incendio dovuto ai solventi utilizzati e
allolio presente.
Attenzione
Tenere lontano dalla zona di lavoro ogni fonte di
calore.
Quando si usano solventi o svernicianti, rimuoverli
con acqua e sapone prima di saldare.
Rimuovere i contenitori di solvente, sverniciante o
altri prodotti infiammabili dall'area di lavoro.
Rischio dovuto alla caduta, allo sganciamento o alla
violenta espulsione di oggetti od olio.
Attenzione
Questi rischi residui e le procedure per eliminarli
completamente, sono evidenziati dettagliatamente
nelle procedure di montaggio e smontaggio. Seguire
attentamente, durante la manutenzione, tutte le
procedure di sicurezza indicate nel manuale.

LA10077

REVISION DATE:

00/00

P /N :

Risk of squashing and shearing due to the presence

of moving parts.
Warning
Carry out all maintenance operations when the
machine is stationary.
Risk due to inhalation of poison gases that can be
produced by heating the varnishes during any
welding.
Warning
Use work stations equipped with dust and fume
discharging systems.
Let the fumes disperse for at least 15 minutes, before
welding or reheating, or working on the group again.
Risk of fire due to the solvents used and to the oil in
the machine.
Warning
Keep away any heat sources from the working area.
When solvents or paint removers are used, they
should be removed with soap and water, before
welding.
Remove any containers of solvent, paint remover or
any other inflammable products from the working
area.
Risk due to fall, drop or violent ejection of objects or
oil.
Warning
These residual risks and the suitable relative
procedures to eliminate them completely are pointed
out, in detail, in the assembly and disassembly
procedures. During maintenance, follow carefully all
the safety procedures indicated in the manual.

CA357248

B.3

PAG.13

Mod. 28.46M

CARATTERISTICHE GENERALI

GENERAL SPECIFICATIONS

REVISION DATE:

00/00

P /N :

CA357248

USI PREVISTI
FORESEEN USES

Mod. 28.46M

C.1 Usi previsti

C.1 Foreseen uses

Questo assale stato progettato e costruito, secondo

specifiche fornite dal cliente, per essere installato in
veicoli di tipo industriale con la funzione di trasmettere
la potenza dal motore alle ruote, consentendo anche:
laumento della forza di trazione con riduzione del
numero di giri;
la compensazione della velocit delle ruote interne
con quelle esterne durante la sterzata.

This axle has been designed and manufactured,

according to the customers technical specifications, to
be mounted on industrial machines to transmit the power
from the engine to the wheels and to allow:
increasing of tractive force, reducing the number of
revolutions
adjusting of inner wheels speed with outer wheels
speed during steering.

Non installare mai questo assale su macchine diverse

da quelle per cui e stato progettato e costruito.

Never mount this axle on machines different from the

ones for which it has been designed and manufactured

L'assale, se utilizzato in un impiego diverso da quello

previsto, da considerarsi soggetto ad "uso non
previsto".
CARRARO SpA declina ogni responsabilit per danni o
incidenti risultanti da un uso diverso da quello previsto;
tali conseguenze saranno a carico esclusivo del cliente.
Costituisce inoltre un elemento essenziale, nell'ambito
dell'uso previsto, l'osservanza scrupolosa delle modalit
di funzionamento e delle regolari manutenzioni e
riparazioni specificate da CARRARO SpA.

If the axle is used for any other purpose than the one
foreseen, CARRARO SpA declines any responsibility
regarding damages or accidents caused by it. All
consequences will be at the expense of the client.
However, when used as foreseen, operational
formalities as well as regular maintenance repair
specifications given by CARRARO SpA are to be
observed strictly.

C.2 Identificazione del prodotto

C.2 Product identification

Targhetta di identificazione dellassale

Axle serial plate

TIPO DI ASSALE
AXLE TYPE

COD. CLIENTE
CUSTOMER REF.

N/S CARRARO
CARRARO S/N

RAPPORTO DI
TRASMISSIONE TOTALE
TOTAL TRANSMISSION
RATIO

N CARRARO
CARRARO N
SENSO DI ROTAZIONE
INPUT ROTATION

TIPO DIFFERENZIALE
DIFFERENTIAL TYPE

TIPO OLIO
DIFFERENZIALE
DIFFERENTIAL OIL TYPE

QUANTIT OLIO
DIFFERENZIALE
DIFFERENTIAL OIL
CAPACITY

TIPO OLIO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR OIL TYPE

LA10077

REVISION DATE:

QUANTIT OLIO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR OIL CAPACITY

00/00

P /N :

CA357248

C.1

PAG.15

DESCRIZIONE GENERALE
GENERAL DESCRIPTION

Mod. 28.46M

C.3 Descrizione generale

C.3 General description

Lassale descritto in questo manuale costituito dai

seguenti gruppi

The axle described in this manual consists mainly of

following groups

MOZZO RUOTA: elementi di supporto della ruota e

del riduttore epicicloidale
RIDUTTORE EPICICLOIDALE: treno portasatelliti
con elementi di riduzione
TROMBE TRAVE: struttura di supporto principale
dellassale
SUPPORTO DIFFERENZIALE: struttura di supporto
del differenziale e di registrazione della coppia
conica
DIFFERENZIALE: scatola differenziale e corona
della coppia conica
GRUPPO PIGNONE: pignone con gli elementi di
registrazione e supporto
GRUPPO FRENO: componenti del freno con gli
elementi di supporto

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

GRUPPO SUPPORTO DIFFERENZIALE

DIFFERENTIAL SUPPORT GROUP
GRUPPO TROMBE TRAVE
AXLE BEAM TRUMPETS

GRUPPO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR GROUP

LA10077

WHEEL HUB: wheel support parts containing the

epicyclic reduction gears
EPICYCLIC REDUCTION GEAR: planetary carrier
with reduction/transmission parts
AXLE BEAM TRUMPETS: load-bearing shell structure of the axle
DIFFERENTIAL SUPPORT GROUP: differential
housing with ring bevel gear adjusting system
DIFFERENTIAL GROUP: differential parts with ring
bevel gear
PINION GROUP: pinion with adjusting and support
parts
BRAKE GROUP: brake parts and brake shell structure

GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP

GRUPPO FRENO
BRAKE GROUP

REVISION DATE:

00/00

P /N :

GRUPPO PIGNONE
PINION GROUP

CA357248

C.3

PAG.16

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

Mod. 28.46M

C.4 Caratteristiche Tecniche

MACCHINA

C.4 Technical Features

Assale Anteriore - Front Axle

MACHINE

CA144840

CODE

28.46M

MODEL

CODICE
MODELLO
TIPO DIFFERENZIALE

Limited slip

DIFFERENTIAL TYPE

VALORI
VALUES

DESCRIZIONE

DESCRIPTION

Riduzione coppia conica

4.777 / 1

Bevel gear ratio

Riduzione riduttore epicicloidale

6.923 / 1

Epicyclic reduction gear ratio

Riduzione totale

33.076 / 1

Total ratio

646 Kg

Dry weight

Peso a secco
Rotazione in entrata

Input rotation

SENSO ORARIO

CLOCK WISE (C.W.)

SENSO ANTIORARIO

COUNTER CLOCK WISE (C.C.W.)

Gioco di accoppiamento coppia conica

0.150.25 mm

Bevel gear set backlash

Precarico cuscinetti pignone conico

(misurato sul D=35 mm senza anelli di
tenuta)

P= 9.213.7 N

Pinion bearings preloading

(measured on D=35 mm without seals)

Precarico totale cuscinetti corona-pignone

(misurato sul D=35 mm senza anelli di
tenuta)
Spessore nominale disco differenziale
Usura max disco differenziale
(per ogni disco)

T= (P+1.9)(P+2.9) N
2.7 / 1.6 mm

Nominal differential disk thickness

0.15 / 0.30 mm

Maximum differential disk wearing

(each disk)

Spessore nominale controdisco differenziale

Tipo freno

Total pinion-ring gear bearing preloading

(measured on D=35 mm without seals)

1.3 mm

Nominal differential counterdisk thickness

A dischi in bagno dolio Type of brake

Wet discs brake

Numero dischi freno per lato

Number of brake disks each side

Spessore nominale disco freno

4.83 mm

Nominal brake disk thickness

Usura max disco freno (per ogni disco)

0.8 mm

Maximum brake disk wearing (each disk)

Spessore nominale controdisco freno

Temperatura di esercizio freni

5/10.8 mm

Nominal brake counterdisk thickness

-40 C 130 C

Brakes operating temperature

Pressione max di esercizio

44 bar

Maximum operating pressure

Pressione disinnesto freni

18 bar

Brakes disengagement pressure

Quantit olio freni

LA10077

Vedi manuale veicolo

See vehicle manual

REVISION DATE:

00/00

P /N :

Brakes oil capacity

CA357248

C.4

PAG.17

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

Mod. 28.46M

DESCRIZIONE
Specifica olio freni:
USARE I TIPI DI OLIO INDICATI
OPPORTUNAMENTE ADDITIVATI.

VALORI
VALUES

DESCRIPTION

Vedi manuale veicolo

See vehicle manual

Brakes oil specification:

USE RECOMMENDED OIL ENRICHED IN
ADDITIVES.

Quantit olio differenziale

16 litri/litres

Differential oil capacity

Quantit olio riduttore epicicloidale

per lato

1.5 litri/litres

Epicyclic reduction gear oil capacity

each side

Specifica olio:
USARE I TIPI DI OLIO INDICATI
OPPORTUNAMENTE ADDITIVATI.
Nota: NON USARE OLIO DI SINTESI O
VEGETALE SENZA IL CONSENSO DEL
COSTRUTTORE DELLASSALE
Specifica grasso

Oil specification:
USE RECOMMENDED OIL ENRICHED IN
ADDITIVES.
Note: DO NOT USE SYNTHETIC OR
VEGETABLE OIL WITHOUT CONSENT
OF THE AXLE MANUFACTURER

API GL4

TECNOLUBE SEAL
POLYMER 400/L
(DIN = KHER1R
ISO-I-XMR-XM2)

Grease specification

*usare solo per manicotto scanalato

(vedi: sezione D.1)

ROCOL SAPPHIRE-2*

Sigillante scatola (A0)

Vedi: Sigillanti e collanti

SILASTIC 30849
Housing sealant (A0)
DOW CORNING 7091 See: Sealing compounds and adhesives

LA10077

REVISION DATE:

00/00

P /N :

*use on splined sleeve only

(see: section D.1)

CA357248

C.4

PAG.18

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

Mod. 28.46M

Sigillanti e collanti

Sealing compounds and adhesives

B2
A0

A3

B2

B2
B1

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.4

PAG.19

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

Mod. 28.46M

Posizione Applicazione Adesivi/Sigillanti

Adhesive/Sealant Application Position
Applicare sulle superifici a contatto
Apply on the contact surfaces
Applicare sulla filettatura delle viti / sui perni
Apply on bolts thread / on pins
Sigillante per guarnizioni
Gasket sealant
Rif.Carraro
Carraro Ref.

Presenza
Presence

Marca e tipo di adesivo

Adhesive make and type

Caratteristiche tecniche
Technical characteristics

Resistenza
Strength

A1

Loctite 510
Superbond 529

Sigillatura superfici piane

Flat surface sealing

Alta
High

A2

Loctite 573
Superbond 519

Sigillatura superfici piane

Flat surface sealing

Bassa
Low

A3

Loctite 518
Superbond 539

Sigillatura superfici irregolari

Uneven surface sealing

Alta
High

Adesivi per frenatura organi filettati

Thread parts sealant
Rif.Carraro
Carraro Ref.

Presenza
Presence

Marca e tipo di adesivo

Adhesive make and type

Caratteristiche tecniche
Technical characteristics

Resistenza
Strength

B1

Loctite 542
Superbond 321

Frenatura organi filettati

Locking of threaded parts

Media
Medium

B2

Loctite 270
Superbond 331

Frenatura organi filettati

Locking of threaded parts

Alta
High

B3

Loctite 986/AVX
Superbond 438

Frenatura organi filettati

Locking of threaded parts

Alta, appl. speciali

High, special appl.

Adesivi per fissaggio particolari

Fixing parts sealant
Rif.Carraro
Carraro Ref.

LA10077

Presenza
Presence

Marca e tipo di adesivo

Adhesive make and type

Caratteristiche tecniche
Technical characteristics

Resistenza
Strength

C1

Loctite 405
Superbond istant 25

Adesivo per fissaggio

Fixing adhesive

Fissaggio medio
Medium bond

C2

Loctite 638
Superbond 433

Adesivo per fissaggio

Fixing adhesive

Fissaggio forte
Strong bond

C3

Loctite 542
Superbond 321

Adesivo per fissaggio

Fixing adhesive

Fissaggio medio
Medium bond

C4

Loctite 496
Superbond SB14

Adesivo per fissaggio gomma

Rubber fixing adhesive

Fissaggio forte
Strong bond

REVISION DATE:

00/00

P /N :

CA357248

C.4

PAG.20

CARATTERISTICHE TECNICHE
TECHNICAL FEATURES

Mod. 28.46M

Dimensioni dingombro

Overall dimensions

(Millimetri)

(Millimeters)

2428
538.2

M22x1.5

335

106.7

538.2

42

2100

280

385

50.9

355.6
76.3

279.4
178

542

177.8

344

239
583

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.4

PAG.21

CAMBIO OLIO E VERIFICHE

OIL CHANGE AND CHECKS

Mod. 28.46M

C.5 Cambio olio e verifiche

C.5 Oil change and checks

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the procedure is the same.

4
6

2
3
1
3

DESCRIZIONE

POSIZIONE /
POSITION

DESCRIPTION

Tappo carico e livello olio

Oil filling and level plug

Tappo scarico olio

Oil drain plug

Foro ispezione freni

Brake inspection hole

Punti di ingrassaggio

Greasing point

Sfiato olio

Oil breather

Porte ingresso olio freni

Service brakes oil port

Sfiati olio freni

Brakes bleeding plug

Tappo carico, livello e scarico

olio riduttore epicicloidale

Filling, level and drain plug

of epicyclic reduction gear oil

Sistema di sgancio freno parcheggio

Parking brake disengagement system

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.5

PAG.22

CAMBIO OLIO E VERIFICHE

OIL CHANGE AND CHECKS

Mod. 28.46M

1
Pericolo: rischio di violenta espulsione di getti dolio, seguire tutte le
procedure di sicurezza indicate in questo manuale e dal costruttore
del veicolo.
Vedi: cap.B - INFORMAZIONI SULLA SICUREZZA
Prima di scaricare lolio dal corpo dellassale, agire sullapposito sfiato
(5) per eliminare leventuale pressione interna.

Danger: risk of violent oil ejection, follow carefully all the safety
procedures indicated in this manual and in the vehicle manual.
See: cap.B - SAFETY INSTRUCTIONS
Before draining the oil from axle housing, use the breather (5) to release
possible internal pressure.
2
Per scaricare lolio dal corpo centrale svitare prima il tappo di livello
(1) e poi il tappo di scarico (2).
Pericolo: rischio di violenta espulsione di getti dolio.
Vedi: punto precedente.
Scaricare completamente lolio.
Pulire il tappo (2) e richiuderlo alla coppia prevista (Sez.C.6).

To drain the oil remove the level plug (1) and the drain plug (2).
Danger: risk of violent oil ejection.
See: the first point.
Drain all oil.
Clean the plug (2) and tighten it to the prescribed torque (Sec.C.6).

Prima di svitare il tappo di livello dellolio (1), agire sempre sullapposito

sfiato (5) per eliminare leventuale pressione interna.
Riempire con lolio prescritto a filo del foro di carico.
Attendere che lolio fluisca nellassale quindi verificare il livello e
rabboccare se necessario.
Riavvitare il tappo (1) alla coppia prevista (Sez.C.6).
Before draining the oil from the plug (1), always use the breather (5)
to release possible internal pressure.
Fill to the bottom of the fill plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check oil level and fill to
the specified level if necessary.
Close the plug (1) to the prescribed torque (Sec.C.6).

4
A

Prima di scaricare lolio dal riduttore epicicloidale, ruotarlo in modo da

portare il tappo olio (8) nel punto pi alto [posizione A].
Svitare il tappo parzialmente per eliminare leventuale pressione
interna.
Ruotare il riduttore con il tappo (8) rivolto verso il basso [posizione B].
Togliere il tappo e lasciar defluire tutto lolio.
Before draining the oil from wheel end rotate the wheel end so that the
plug (8) is at the highest position [pos.A] and partially unscrew to
release possible pressure.
Rotate the wheel end so that the plug (8) is toward the ground [pos.B].
Remove the plug and drain the oil.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.5

PAG.23

CAMBIO OLIO E VERIFICHE

OIL CHANGE AND CHECKS

Mod. 28.46M

5
C

Ruotare il riduttore fino a portare la linea livello olio parallela al suolo

[pos.C].
Riempire con olio prescritto (Sez.C.4). Il livello dellolio deve essere a
filo del foro.
Serrare il tappo alla coppia prevista (Sez.C.6).

Rotate the wheel end so that the oil level line is parallel to the ground.
Fill to the bottom of the fill plug hole with specified oil (Sec.C.4).
Tighten the plug to the prescribed torque (Sec.C.6).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.5

PAG.24

CAMBIO OLIO E VERIFICHE

OIL CHANGE AND CHECKS

Mod. 28.46M

Programma di lubrificazione

Service schedule

Gli intervalli di lubrificazione indicati sono per un impiego

normale della macchina, nel caso di impieghi
particolarmente gravosi lubrificare con maggior
frequenza.

Specified lubrication intervals are for standard-duty

use.
Severe operating conditions require shorter lubrication
intervals.

Operazione

Cambio olio assale

Primo Intervento
First time

Ad ogni stagione od
ogni 1500 ore(1)
Seasonally or every 1500
operating hours(1)

150 - 200 ore/hours

Operation

Axle oil change

Lubrication works

Operazioni di lubrificazione
Controllo e rabbocco olio

50 - 100 ore/hours

mensilmente/monthly

Check and adjust oil level

Pulizia tappo magnetico

scarico olio

150 - 200 ore/hours

ad ogni cambio olio/

every oil change

Clean magnetic oil plugs

mensilmente/monthly

Clean oil breather

Pulizia sfiato olio

Ingrassaggio

150 - 200 ore/hours

settimanalmente/weekly

Greasing

operazioni eseguibili solamente da personale

autorizzato dal costruttore
operazioni eseguibili solamente da personale
addestrato
(1) quale delle due condizioni si verifica prima

this operation must be performed only by personnel

authorized by the manufacturer
this operation must be performed only by trained
personnel
(1) which of both conditions comes first

Campi di applicazione dei lubrificanti

Lubricants application range

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.5

PAG.25

COPPIE DI SERRAGGIO
TIGHTENING TORQUES

Mod. 28.46M

C.6 Coppie di serraggio

C.6 Tightening torques

1610 Nm

79 Nm

60 Nm

25 Nm
360 Nm
60 Nm
60 Nm

155 Nm

78 Nm

LA10077

REVISION DATE:

00/00

P /N :

CA357248

C.6

PAG.26

COPPIE DI SERRAGGIO
TIGHTENING TORQUES

Mod. 28.46M

A
10 Nm

60 Nm

10 Nm
C

10 Nm

12 Nm
30 Nm

Sez. A-A

30 Nm
C

Sez. B-B

10 Nm
79 Nm

13 Nm

Sez. C-C
190 Nm

LA10077

REVISION DATE:

00/00

P /N :

CA357248

120 Nm

C.6

PAG.27

Mod. 28.46M

D
D

OPERAZIONI DI MONTAGGIO E
SMONTAGGIO

DISASSEMBLY AND ASSEMBLY

OPERATIONS

REVISION DATE:

00/00

P /N :

CA357248

GRUPPO FLANGIA
FLANGE GROUP

Mod. 28.46M

D.1 Gruppo flangia

D.1 Flange group

9
7
5

10

1
6
4

D.1.1 Smontaggio

D.1.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo pignone vedi prima
le procedure descritte alla sezione D.7.

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the pinion group see the
procedure described in the section D.7.

1
Rimuovere le viti di fissaggio (1) della flangia (2)
Sfilare la flangia (2) e recuperare la spina (4).
Rimuovere lanello OR (5) dalla flangia (2).

LA10077

Remove the fastening screw (1) of the flange (2).

Take the flange (2) out and collect the pin (4).
Remove the O-Ring (5) from the flange (2).

REVISION DATE:

00/00

P /N :

CA357248

D.1

PAG.29

GRUPPO FLANGIA
FLANGE GROUP

Mod. 28.46M

2
Rimuovere lanello di tenuta (3) dalla flangia (2).
Nota: unoperazione distruttiva per lanello di tenuta (3).

2
Remove the seal ring (3) from the flange (2).
Note: this is a destructive operation for the seal ring (3).
3
Rimuovere lanello darresto (6) dal codolo del pignone (10).
Nota: unoperazione distruttiva per lanello darresto (6).
Sfilare il manicotto (7) e recuperare lanello OR (8) e la rondella (9).

9
7
6
8

Remove the lock ring (6) from the pinion end (10).
Note: this is a destructive operation for the lock ring (6).
Take the splined sleeve (7) out, then collect the O-Ring (8) and washer
(9).

D.1.2 Montaggio

D.1.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Inserire la rondella (9) ed un nuovo anello OR sul codolo del pignone
(8).
Assemblare il manicotto scanalato (7) al codolo del pignone.
Assemblare lanello darresto (6) al codolo del pignone (10).
9
7
6
8

LA10077

Insert the washer (9) and new O-Ring (8) onto the pinion end.
Assemble the splined sleeve (7) to the pinion end.
Assemble the lock ring (6) to the pinion end (10).

REVISION DATE:

00/00

P /N :

CA357248

D.1

PAG.30

GRUPPO FLANGIA
FLANGE GROUP

Mod. 28.46M

2
Assemblare lanello di tenuta (5) nella flangia (2) con il battitoio
CA715632 ed un martello.
Nota: lubrificare lanello di tenuta (5) con grasso (Sez. C.4).
3

2
Insert the seal ring (5) into the flange (2) with the special tool CA715632
and a hammer.
Note: grease carefully the seal ring (5) (Sec. C.4).
3
Montare un nuovo anello OR (5) nella flangia (2).
Nota: lubrificare lanello OR (5) con grasso specifico (Sez. C.4).
2

Assemble a new O-Ring (5) in the flange (2).

Note: grease carefully the O-Ring (5) (Sec. C.4).
4
Assemblare la flangia (2) con la spina (4) al supporto differenziale.
Assemblare le viti di fissaggio (1) della flangia (2) alla coppia
prescritta (Sez.C.6).

2
1

LA10077

Assemble the flange (2) and the pin (4) to the differential support.
Assemble the fastening screw (1) of the flange (2) to the specified
torque (Sez.C.6).

REVISION DATE:

00/00

P /N :

CA357248

D.1

PAG.31

GRUPPO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR GROUP

Mod. 28.46M

D.2 Gruppo riduttore epicicloidale

D.2 Epicyclic reduction gear group

15
14

13
11

7
12

10
9
8

4
6

D.2.1 Smontaggio

D.2.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Scaricare completamente lolio dal riduttore epicicloidale e dal corpo
dellassale.
Vedi: sezione C.5.

Drain the oil completely from the epicyclic reduction gear and axle body.
See: section C.5.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.2

PAG.32

GRUPPO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR GROUP

Mod. 28.46M

2
Svitare le due viti di fissaggio (3) del treno portasatelliti (1).
3

3
1

Unscrew both fastening screws (3) of the planetary carrier (1).

3
1

15

Rimuovere il treno portasatelliti (1) dal mozzo ruota (15) e recuperare

il relativo anello OR (4).
Posizionare il treno portasatelliti (1) su di un piano e verificarne le
condizioni di usura.

Remove the planetary carrier (1) from the wheel hub (15) and collect
the relative O-Ring (4).
Position the planetary carrier (1) on a workbench and check its wear
conditions.

4
Rimuovere lalbero (14) dal mozzo ruota (15).

14

Remove the shaft (14) from the wheel hub (15).

5
Per eseguire leventuale sostituzione degli ingranaggi satelliti (9):
- rimuovere la vite di fissaggio (13) di ogni ingranaggio satellite (9);
- rimuovere le rondelle (12) e (10);
- estrarre i satelliti (9) dai perni;
- recuperare i relativi rullini (8) e (6) verificandone le condizioni;
- recuperare le rondelle di rasamento (7) e (5).
To carry out any possible replacements of the planetary gears (9):
- remove the fastening screws (13) on every planetary gear (9);
- remove the washers (12) and (10);
- take the planetary gears (9) out of the pins;
- collect the needle bearings (8) and (6) checking their conditions;
- collect the thrust washers (7) and (5).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.2

PAG.33

GRUPPO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR GROUP

Mod. 28.46M

D.2.2 Montaggio

D.2.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
1

13

5
10
7

12

Recuperare tutti i componenti del riduttore epicicloidale: il treno

portasatelliti (1), le ralle di rasamento (5) e (7), lingranaggio satellite
(9) ed i relativi rullini (6) e (8), le ralle (10) e (12), la vite di fissaggio
(13) di ogni perno.
Nota: con nuovi satelliti (9) consigliabile montare nuovi rullini (8) e (6).
Collect all epicyclic reduction gear parts: the planetary carrier (1), the
thrust washers (5) and (7), the planetary gear (9) with the roller bearings
(6) and (8), the washers (10) and (12), the fixing screw (13) of every
planetary carrier pin.
Note: with new planetary gears (9) it is advisable to assembly new
roller bearings (8) and (6).

2
Posizionare su un banco di lavoro il treno porta satelliti (1).
Inserire i rullini (6) e (8) con interposta la ralla di rasamento (7)
allinterno degli ingranaggi satelliti (9).
Nota: ingrassare bene i rullini (6) e (8).
Inserire nei perni del treno porta satelliti (1) le ralle di rasamento (5) e
gli ingranaggi epicicloidali (9) completi.
Position the planetary carrier (1) on a workbench.
Insert the needles bearing (6), (8) and the thrust washer (7) in the
epicyclic gears (9).
Note: grease well the needles (6) and (8).
Insert the thrust washers (5) and the assembled epicyclic gears (9) in
the planetary carrier (1) pins.
3
Montare le ralle di rasamento (10) e (12) nei perni del treno porta
satelliti (1).
Nota: la ralla intermedia (10) ha un foro che serve da centraggio con
la spina (11) piantata sui perni del treno portasatelliti (1).
Montare le relative viti di arresto (13), serrandole con chiave
dinamometrica alla coppia prevista (Sez.C.6).
11
10

LA10077

Fit the thrust washers (10) and (12) to the planetary carrier (1) pins.
Note: the intermediate thrust washers (10) has a hole for centering
with the dowel pin (11) fitted on the planetary carrier (1) pins.
Assemble the retaining screw (13), then tighten them with
dynamometric wrench to the requested torque (Sec. C.6).

REVISION DATE:

00/00

P /N :

CA357248

D.2

PAG.34

GRUPPO RIDUTTORE EPICICLOIDALE

EPICYCLIC REDUCTION GEAR GROUP

Mod. 28.46M

4
Assemblare lalbero (14) al mozzo ruota (15).

14

Assemble the shaft (14) to the wheel hub (15).

5
Inserire un nuovo anello OR (4) lubrificato sul mozzo ruota (15).
Montare il gruppo riduttore epicicloidale sul mozzo ruota (15).
Assemblare le viti di fissaggio (3) e serrarle alla coppia prevista
(Sez.C.6).

15

Assemble a new lubricated O-Ring (4) on the wheel hub (15).

Fit the epicyclic reduction gear assembly to the wheel hub (15).
Assemble the screws (3) and tighten them to the prescribed torque
(Sec.C.6).

Ripristinare lolio nel riduttore epicicloidale e nel corpo dellassale.

Vedi: sezione C.5.
Montare il tappo (2) sul treno portasatelliti (1), e serrare alla coppia
prevista (Sez.C.6) con chiave dinamometrica.

Top up the oil in the epicyclic reduction gear and axle body.
See: section C.5.
Fit the plug (2) on the epicyclic reduction gear (1) and tighten to the
prescribed torque using a torque wrench (Sec.C.6).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.2

PAG.35

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

Mod. 28.46M

D.3 Gruppo mozzo ruota

D.3 Wheel hub group

11
4
10
3

7
1

6
5

D.3.1 Smontaggio

D.3.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo mozzo ruota vedi
prima le procedure decritte alla sezione D.2.

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the wheel hub group see the
procedure described in the section D.2.

1
Rimuovere lanello darresto (1) dallestremit della tromba trave.

Remove the lock ring (1) from the beam trumpets end.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.3

PAG.36

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

Mod. 28.46M

2
Sfilare la corona dentata (2) con il mozzo fermo corona (3).
Nota: potrebbe essere necessario lutilizzo di un estrattore.

Remove the ring gear (2) and the wheel carrier (3).
Note: may be necessary the use of an extractor.
3
Rimuovere lanello darresto (4) dalla corona (2).
Separare il mozzo (3) dalla corona dentata (2).
Verificare lo stato di usura dei particolari.

3
2

4
Remove the lock ring (5) from the ring gear (2).
Disassemble the ring gear (2) from the wheel carrier (3).
Check the wear conditions of the components.
4
Svitare la ghiera (5) con la chiave speciale CA715631.
Nota: si consiglia lutilizzo di un moltiplicatore di coppia meccanico.

Remove the ring nut (5) using the special wrench CA715631.
Note: its advisable to use a mechanical torque multipliers.
5
8

Sfilare il mozzo ruota (8) facilitando lo smontaggio con leve e martello.

Nota: recuperare il cono del cuscinetto (6).

6
Remove the wheel hub (8) using levers and a hammer to facilitate the
operation.
Note: collect the bearing cone (6).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.3

PAG.37

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

Mod. 28.46M

6
Rimuovere il distanziale (7) ed il cono del cuscinetto (10) dallestremit
della tromba trave.

10
7

Remove the spacer (7) and bearing cone (6) from the beam trumpets
end.
7
8

10

11

Posizionare su di una superficie piana il mozzo ruota (8) ed estrarre

lanello di tenuta (11) con una leva.
Nota: unoperazione distruttiva per lanello di tenuta (11).
Rimuovere le coppe dei cuscinetti (6) e (10), da entrambi i lati del
mozzo ruota (8).
Togliere il cono del cuscinetto (10) dalla tromba trave, utilizzando un
estrattore da commercio.
Position the wheel hub (7) on a flat surface and take the seal ring (11)
out with a lever.
Note: this is a destructive operation for the seal ring (11).
Take the bearing cups (6) and (10) out, on both sides of the wheel hub
(8).
Remove the bearing cone (10) from the axle beam trumpet, using a
suitable extractor.

8
Esaminare le condizioni della filettatura delle colonnette (9).
Rimuovere le colonnette (9) danneggiate dal mozzo ruota (8) con un
battitoio ed un martello.
Nota: unoperazione distruttiva per le colonnette (9).

9
8

LA10077

Check the condition of the stud bolts thread.

Remove the damaged stud bolts (9) from the wheel hub (8), using a
pad and a hammer.
Note: this is a destructive operation for the stud bolts (9).

REVISION DATE:

00/00

P /N :

CA357248

D.3

PAG.38

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

Mod. 28.46M

D.3.2 Montaggio

D.3.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Assemblare le colonnette (9) al mozzo ruota (8) con un battitoio ed un
martello.

Assemble the stud bolts (9) to the wheel hub (8), using a pad and a
hammer.
2
Piantare le coppe dei cuscinetti a rulli conici (6) e (10) sul mozzo ruota
(8) utilizzando lattrezzo speciale CA715118 sotto lazione di una
pressa o di un martello.
Inserire lanello di tenuta (11) nel mozzo ruota (8) con il battitoio
CA715633 ed un martello.
7
Force both bearing cups (6) and (10) to their wheel hub (8) housings,
using the special tool CA715118 under a press or with a hammer.
Insert the seal ring (11) into the wheel hub (8) with the special tool
CA715633 and a hammer.
3

Montare il cono del cuscinetto a rulli conici (10) ed il distanziale (7) sul
codolo della tromba trave.
Assemblare il mozzo ruota (8) alla tromba trave e posizionare laltro
cono del cuscinetto (6).

Assemble the bearing cone (10) and spacer (7) on the axle beam
trumpet end.
Assemble the wheel hub (8) on the axle beam trumpet and fit the other
bearing cone (6) in position.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.3

PAG.39

GRUPPO MOZZO RUOTA

WHEEL HUB GROUP

Mod. 28.46M

4
Assemblare la ghiera (5) con la chiave speciale CA715631.
Serrare la ghiera alla coppia prevista (Sez.C.6).
Nota: si consiglia lutilizzo di un moltiplicatore di coppia meccanico.

Assemble the ring nut (5) using the special wrench CA715631.
Tighten the ring nut to the requested torque (Sec.C.6).
Note: its advisable to use a mechanical torque multipliers.
5
Preassemblare il mozzo fermo corona (3) e la corona epicicloidale (2)
con lanello darresto (4).

3
2

Preassemble the wheel carrier (3) and the epicyclic ring gear (2) with
the lock ring (4).
6
7

Montare il gruppo mozzo fermo corona sul mozzo ruota (7).

Vedi: punto successivo.
Assemblare lanello darresto (1) allestremit della tromba trave.

2
Assemble the wheel carrier group on the wheel hub (7).
See: next point.
Assemble the lock ring (1) to the beam trumpets end.
7
Nota: verificare la corretta posizione del mozzo fermo corona (3).

Note: check the wheel carrier (3) position.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.3

PAG.40

GRUPPO TROMBE TRAVE

AXLE BEAM TRUMPETS GROUP

Mod. 28.46M

D.4 Gruppo trombe trave

D.4

Axle beam trumpets group

2
3

10

11
8

D.4.1 Smontaggio

D.4.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo trombe trave vedi
prima le procedure descritte alla sezione D.3.

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the axle beam trumpets group
see the procedure described in the section D.3.

1
Estrarre le boccole (7) dalla tromba trave (6) con un punzone ed un
martello.
Nota: unoperazione distruttiva per le boccole.
7

LA10077

Take the bushes (7) out of the beam trumpet (6) with a punch and a
hammer.
Note: this is a destructive operation for the bushes.

REVISION DATE:

00/00

P /N :

CA357248

D.4

PAG.41

GRUPPO TROMBE TRAVE

AXLE BEAM TRUMPETS GROUP

Mod. 28.46M

2
Estrarre lanello di tenuta (10) dalla tromba trave (6) con una leva.
Nota: unoperazione distruttiva per lanello di tenuta.

10

Take the seal ring (10) out of the beam trumpet (6) with a lever.
Note: this is a destructive operation for the seal ring.
3
Fare dei segni di riferimento indelebili sulle trombe trave, sui cilindri
freno e sul corpo centrale trave, per identificare con sicurezza parte
destra e parte sinistra.

Put alignment marks on the beam trumpets, on the brake cylinders

and on the central body, in order to identify the right side and the left
side with certainty.
4
Attenzione: disporre lassale su supporti adatti a sostenere sia il corpo
centrale trave che le due trombe trave, anche dopo la loro separazione,
o assicurare i gruppi separatamente con funi o cinghie ad un sistema
di sollevamento.
Svitare e togliere le viti di fissaggio (8) ed il dado (9).

Warning: Position the axle on supports fitted to hold either the central
body and the two beam trumpets, even after their disjunction, or secure
the disjointed groups to a lifting device with ropes or belts.
Unscrew and remove the fastening screws (8) and nut (9).
5

10

LA10077

Staccare la tromba trave (6) e recuperare lanello OR (5).

Attenzione: rimossa la tromba trave, il gruppo freno ed il semiasse
lungo sono liberi.
Estrarre la bronzina (10) dalla tromba trave (6) solo se le condizioni di
usura lo richiedono.
Attenzione: non rovinare la sede della bronzina.
Remove the beam trumpet (6) and collect the O-Ring (5).
Warning: once the beam trumpet has been removed, the brake group
and the long half-shaft are free.
Remove the bush (10) from the beam trumpet (6) only if the wear
conditions require this.
Warning: be careful not to damage the bush housing.

REVISION DATE:

00/00

P /N :

CA357248

D.4

PAG.42

GRUPPO TROMBE TRAVE

AXLE BEAM TRUMPETS GROUP

Mod. 28.46M

6
Estrarre lalbero (2) con il manicotto scanalato (4).
Solo se necessario rimuovere lanello darresto (3) dal manicotto
scanalato.
2
3

Remove the shaft (2) and the splined sleeve (4).

Only if necessary remove the snap ring (3) from the splined sleeve.

D.4.2 Montaggio

D.4.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Verificare che lanello darresto (3) sia montato nel manicotto scanalato
(4).
Preassemblare il gruppo albero (3) / manicotto scanalato (4) ed
inserirlo nel corpo trave centrale (1).

2
3
1

Check that the snap ring (3) is already assembled on the splined sleeve
(4).
Pre-assemble the group shaft (3) / splined sleeve (4) and insert it on
the central body (1).

10

Montare nella tromba trave (6) la bronzina (10) utilizzando il battitoio

CA715531 ed un martello.
Montare un nuovo anello OR (5) nella tromba trave.
Nota: prima del montaggio, verificare i segni di riferimento eseguiti in
fase di smontaggio per il corretto posizionamento delle trombe trave.
Attenzione: sostenere opportunamente i gruppi come gi indicato
nella fase di smontaggio.
Montare la tromba trave sul corpo centrale (1), facendo attenzione
allallineamento dei fori di fissaggio.
Assemble on the beam trumpet (6) the bush (10) with the special tool
CA715531 and a hammer.
Assemble a new O-Ring (5) into the beam trumpet.
Note: in order to place precisely the beam trumpet, before assembly,
check the reference marks carried out during disassembly.
Warning: support the groups properly as already pointed out for
disassembly phase.
Assemble the beam trumpet on the central body (1), being careful to
the fastening holes alignment.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.4

PAG.43

GRUPPO TROMBE TRAVE

AXLE BEAM TRUMPETS GROUP

Mod. 28.46M

3
Avvitare il dado (9) e le viti di fissaggio (8) e serrarli alla coppia prevista
(Sez.C.6)

Screw in the nut (9) and fastening screws (8) to the requested torque
(Sec.C.6).
4
Montare un nuovo anello di tenuta (11) ben lubrificato nella tromba
trave (6) con lattrezzo CA715636 ed un martello.

Assemble a new well lubricate seal ring (11) in the beam trumpet (6)
using the special tool CA715636 and a hammer.

5
Inserire le boccole (7) nella tromba trave (6) con lattrezzo CA715635
ed un martello.

LA10077

Assemble the bushes (7) to the beam trumpet (6) with the special tool
CA715635 and a hammer.

REVISION DATE:

00/00

P /N :

CA357248

D.4

PAG.44

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

D.5 Freno e supporto differenziale

D.5 Brake and differential support

1
3
2

2
3

10

28

26

25
7

11

23

27
22
24
21

38

20
36
35
33

37

31

29

34
32
30
40
42
43

5
39
41

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.45

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

D.5.1 Smontaggio

D.5.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo freno e supporto
differenziale vedi prima le procedure descritte alla
sezione D.4.

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the brake and differential
support group see the procedure described in the
section D.4.

24

Rimuovere i componenti: controdischi freno (20) e dischi freno (21),

mozzo traino dischi freno (22), disco freno (23) e controdisco freno (24).
Nota: ricordare la posizione del mozzo scanalato per il montaggio.
23

22
20
Remove the components: brake counter plates (20) and brake plates
(21), brake disk carrier (22), brake plate (23) and brake counter plate
(24).
Note: remember the position of the the splined disk carrier, it must be
reassembled in the same position.

21
2

Svitare e togliere le viti del kit self-adjust (25) recuperandone tutti i

componenti.
Recuperare il pistone freno positivo (26).
26
25

Unscrew and remove the self-adjust kits (25) screw and collect all the
components.
Collect the brake piston positive (26).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.46

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

3
Togliere i tappi (43) e svitare completamente le viti (42) dalle viti freno
parcheggio (A, B e C).
Svitare alternativamente le viti (40) fino a rimuoverle completamente.
Recuperare gli anelli OR (41) ed i perni (39).
41
43
39
40
A

42

B
C

Remove the plugs (43) and unscrew completely the screws (42) from
the parking brake screws (A, B and C).
Unscrew alternately the screw (40) until they are completely removed.
Collect the O-Rings (41) and the pins (39).

4
Assicurare il cilindro freno (5) ad un paranco con funi o cinghie di
sicurezza.
Svitare e togliere il prigioniero (11) e la vite di fissaggio (10).
Attenzione: questa operazione libera la scatola differenziale.

Secure the brake cylinder (5) to a hoist with ropes or safety belts.
Unscrew and remove the fastening stud bolt (11) and screw (10).
Warning: the differential box is free.
5
Recuperare lanello OR (4) dal cilindro freno (5).

Collect the O-Ring (4) from the brake cylinder (5).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.47

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

6
Svitare e togliere la vite (9) ed il fermo ghiera (8) dal cilindro freno (5).
5
8

Unscrew and remove the screw (9) and the ring nut retainer (8) from
the brake cylinder (5).

7
Svitare e togliere la ghiera (7) dal cilindro freno (5) con lattrezzo
CA119030.
5
6

Unscrew and remove the adjuster ring nut (7) from the brake cylinder
(5) with the tool CA119030.
8
Estrarre la coppa del cuscinetto (6) dal cilindro freno (5) con un
battitoio.
Attenzione: non invertire le coppe dei cuscinetti se non vengono
sostituiti.
6
5
Use a driver to remove the bearing cup (6) from the brake cylinder (5).
Warning: do not mismatch the bearings cup if they are not going to
be replaced.
9

38

Posizionare il cilindro freno (5) sotto lazione di una pressa e con

lausilio dellattrezzo CA715056 togliere lanello darresto (38).
Eseguire un rilascio della spinta della pressa lento e graduale,
recuperare quindi il manicotto (37) e le molle a tazza (36).

37
36

LA10077

Position the brake cylinder (5) under a press and with the tool
CA715056 remove the snap ring (38).
Relase the load of the press slowly and gradually, them collect the
sleeve (37) and the belleville washers (36).

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.48

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

10
29
33
35

Per lestrazione del pistone freno negativo (33) utilizzare il foro di

mandata del freno applicando la minima pressione dolio o aria
necessaria per lespulsione.
Attenzione: questa operazione deve essere condotta con la massima
cautela.
Recuperare gli anelli OR (29) e (35) dal pistone freno negativo.
In order to extract the negative brake piston (33) use the hydraulic
connection applying the lowest oil or air pressure necessary to dislodge
the piston.
Warning: this operation must be performed with extreme care.
Collect the O-Rings (29) and (35) from the negative brake piston.

11

34

Togliere lanello darresto (34) dal pistone freno negativo (33) ed

estrarre il perno di spinta (31).
Recuperare gli anelli OR (30) e (32) dal perno di spinta.

32
33

31

30

Remove the snap ring (34) from the negative brake piston (33) and
extract the thrust pin (31).
Collect the O-Rings (30) and (32) fom the thrust pin.

12
Estrarre lanello di tenuta (3) dal corpo centrale (1) con una leva.
Nota: unoperazione distruttiva per gli anelli di tenuta.
Rimuovere le boccole (2).
2

LA10077

Take the seal ring (3) out of the central body (1) with a lever.
Note: this is a destructive operation for the seal rings.
Remove the bushes (2).

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.49

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

D.5.2 Montaggio

D.5.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Assemblare le boccole (2) al corpo centrale (1) utilizzando lattrezzo
speciale CA715634 ed un martello.
Nota: rispettare la posizione indicata.

1
2

45

Assemble the bushes (2) to the central body (1) with the special tool
CA715634 and a hammer.
Note: position the bushes as shown.
2
Assemblare lanello di tenuta (3) al corpo centrale (1) con lattrezzo
speciale CA715181 ed un martello.

1
3

Assemble the seal ring (3) to the central body (6) with the special tool
CA715181 and a hammer.
3
Posizionare il cilindro freno (5) su di una superficie piana e piantare la
coppa (6) del cuscinetto con il battitoio CA715583.
Attenzione: non invertire le coppe dei cuscinetti se non vengono
sostituiti.
5
Position the brake cylinder (5) on a flat surface and force the bearing
cup (6) using the special tool CA715583.
Warning: do not mismatch the bearings cup if they are not going to
be replaced.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.50

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

4
34

32
33

31
30

Montare nuovi anelli OR (30) e (32) ben lubrificati nei perni di spinta
(31).
Inserire i perni di spinta nel pistone freno negativo (33) e bloccarli con
gli anelli darresto (34).

Assemble new well lubricated O-Rings (30) and (32) to the thrust pins
(31).
Insert the thrust pins into the negative brake piston (33) and lock them
with the snap rings (34).

5
Montare nuovi anelli OR (29) e (35) ben lubrificati nel pistone freno
negativo (33).
Inserire il pistone freno negativo nel cilindro freno (5) utilizzando
lattrezzo CA715056 ed una leva come illustrato in figura.

29
33
35

Assemble new well lubricated O-Rings (29) and (35) to the negative
brake piston (33).
Insert the negative brake piston into the brake cylinder (5) using the
tool CA715056 and a lever as is shown in figure.

38
37
36

Posizionare le molle a tazza (36) ben centrate, in modo che lultima

sia concava, il manicotto (37) con la sede per lanello darresto (38)
verso lesterno, e lattrezzo CA715056 nel cilindro freno (5).
Sotto lazione di una pressa esercitare una spinta tale da poter montare
lanello darresto (38).
Pericolo: possibile rapida espulsione delle molle a tazza.
Utilizzando la pressa come potezione di sicurezza, allontanare con
cautela e solo di pochi millimetri lattrezzo CA715056 dalle molle a
tazza. Applicare olio alla pressione di circa 20 bar alla mandata olio
freno e far compiere almeno tre corse di lavoro al pistone freno (5)
verificandone la tenuta idraulica degli anelli OR ed il corretto
inserimento dellanello darresto (38).
Position the belleville washer (36) well matched, with the last disc on
top must be concave side up, the sleeve (37) with the snap ring seat
outermost, and the tool CA715056 into the brake cylinder.
Using a press, apply a pressure on the entire assembly until the snap
ring (38) can be fitted.
Danger: it is possible a rapid ejection of the belleville washer.
Using the press as safety protection, move away with caution and only
for few millimetres the special tool CA715056 from the belleville
washer. Apply an oil pressure of about 20 bar through the hydraulic
connection, in order to do at least three stroke of the brake piston (8)
and check the tightness of the O-Rings and the correct insertion of the
snap ring (38).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.51

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

39
41
10

43

40
A

42

Montare nuovi anelli OR (41) ben lubrificati nelle viti (42).

Montare i perni (39) e le viti (40) al cilindro freno (5) nelle posizioni A,
B e C.
Attraverso la mandata applicare una pressione dolio di circa 20 bar
nel cilindro freno ed avvitare le tre viti (40) fino al contatto con il pistone
freno negativo (33).
Attenzione: il piano inclinato dei perni (39) deve appoggiarsi contro il
pistone freno negativo (33), come indicato in figura.
Completare loperazione chiudendo con un ulteriore quarto di giro le
tre viti (40).
Applicare sigillante (A3) sotto la testa delle viti (42) (Sez.C.4).
Tolta la pressione, completare loperazione di assemblaggio avvitando
le viti (42) ed i tappi (43) alle coppie previste (Sez.C.6).
Assemble new well lubricated O-Ring (41) to the screws (42).
Assemble the pins (39) and the screws (40) into the brake cylinder (5)
to the positions A,B and C.
Apply an oil pressure of about 20 bar through the hydraulic connection
of the brake cylinder and screw the three screws (40) till to touch the
negative brake piston (33).
Warning: the pins ramp (39) must seat against the negative brake
piston (33), as is shown in figure.
Carry out the adjustment tightening the three screws (40) a further of
quarter turn.
Apply sealant (A3) under the screw heads (42) (Sec.C.4).
Drop the oil pressure and complete the assembly screwing and
tightening the screws (42) and the plugs (43) to the prescribed torques
(Sec.C.6).

8
Recuperare il pistone freno (26).
Spingere le boccole nelle sedi dei self-adjust con lattrezzo CA715033
ed un martello, fino a pareggiarle con la superficie interna di appoggio
del pistone.

Collect the brake piston (26).

With special tool CA715033 and a hammer, push the washers into the
self-adjust housings till they are aligned with the piston supporting
inner surface.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.52

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

9
Inserire il pistone (26) nel cilindro freno (5) e posizionare lattrezzo cod.
CA715056 o un disco piano sul pistone.
Nota: posizionare il pistone freno positivo (26) con una cava in
corrispondenza al foro di ricircolo olio del cilindro freno (5).
Con una leva ben ancorata, magari ad un golfare, esercitare una
pressione appena sufficiente ad inserire il pistone nella flangia freno.
Insert the piston (26) into the brake cylinder (5) and position the special
tool code CA715056 or a flat disk on the piston.
Note: position the positive brake piston (26) with a slot aligned with
the hydraulic connection on the brake cylinder (5).
With a lever anchored to an eyebolt, exert a pressure just enough to
insert the piston into the brake flange.
10
Montare i componenti del kit self-adjust (25) e serrare le viti alla coppia
prevista (Sez. C.6).

5
26
25

Assemble the self-adjust kit (25) and tighten the screws to the
prescribed torque (Sec. C.6).
11
Montare un nuovo anello OR (4) ben lubrificato nella sede del cilindro
freno (5).

Assemble a new well lubricated O-Ring (4) on the brake cylinder (5)
housing.
12
Montare il cilindro freno (5) sinistro sul corpo centrale (1). Serrare il
prigioniero (11) e la vite (10) di fissaggio alla coppia prevista (Sez.C.6).
Nota: verificare che i segni di riferimento fatti allo smontaggio tra il
cilindro freno (5) ed il corpo centrale (1) coincidano.

Assemble the left brake cylinder (5) on the central body (1). Tighten
the fastening stud bolt (11) and screw (10) to the requested torque
(Sec.C.6).
Note: check that the reference marks made during the disassembly
between the left brake cylinder (5) and the central body (1) coincide.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.53

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

13
Montare la scatola differenziale.
Attenzione: verificare che la corona dentata sia montata dal lato
giusto.

Assemble differential housing.

Warning: check the correct assembly side of the bevel gear.
14
Montare il cilindro freno (5) destro sul corpo centrale (1). Serrare il
prigioniero (11) e la vite (10) di fissaggio alla coppia prevista (Sez. C.6).
Nota: verificare che i segni di riferimento fatti allo smontaggio tra il
cilindro freno (5) destro ed il corpo centrale (1) coincidano.

Assemble the right brake cylinder (5) on the central body (1). Tighten
the fastening stud bolt (11) and screw (10) to the requested torque
(Sec. C.6).
Note: check that the reference marks made during the disassembly
between the right brake cylinder (5) and the central body (1) coincide.
15
Avvitare entrambe le ghiere di registrazione (7) utilizzando lattrezzo
CA119030 fino ad eliminare il gioco e precaricare leggermente i
cuscinetti del differenziale.

Screw both adjuster ring nuts (7) using the tool CA119030 till the
backlash is eliminated and the differential bearings are slightly
preloaded.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.54

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

16
Montare lattrezzo CA715146 sul codolo del pignone.
Muovere il codolo del pignone alternativamente ed annotare il gioco
fra pignone e corona, rilevato con un comparatore, in modo che il
tastatore sia a contatto ed a 90 con la superficie della staffa
dellattrezzo CA715146 in corrispondenza della tacca di riferimento.
Verificare se il valore del gioco rilevato rientra nel campo predefinito:
0.150.25 mm
Effettuare la registrazione agendo sulle due ghiere di registrazione (7)
con lattrezzo CA119030.
Assemble the tool CA715146 on the pinion end.
Move the pinion end alternatively and note the pinion-ring gear
backlash, measured with a comparator, so that the feeler stylus is in
contact and at 90 with the bracket surface of the tool CA715146 in
correspondance to the reference mark.
Check if the measured backlash value is within the requested range:
0.150.25 mm
Carry out the adjustment by operating on the two adjuster ring nuts (7)
with the tool CA119030.
17
A

Registrare le ghiere (7) ricordando che:

- se il gioco rilevato inferiore al campo di tolleranza dato, avvitare
la ghiera dal lato opposto alla corona e svitare la ghiera opposta della
stessa quantit (A);
- se il gioco rilevato superiore al campo di tolleranza dato, avvitare
la ghiera dal lato della corona e svitare la ghiera opposta della stessa
quantit (B).
Adjust the ring nuts (7), remembering that:
- if the measured backlash is less than the given tolerance range,
screw the ring nut from the side opposite to the ring gear and unscrew
the opposite one of the same measure (A);
- if the measured backlash is greater than the given tolerance range,
screw the ring nut from the side of the ring gear and unscrew the
opposite one of the same measure (B).

18
Effettuata la registrazione del gioco pignone-corona verificare anche
che ci sia un minimo di precarico sui cuscinetti della scatola
differenziale
Ripetere lintera sequenza delle operazioni citate fino al
raggiungimento delle condizioni indicate.
Once the adjustment of the pinion-bevel gear backlash has been
carried out, check also that there is a minimum preloading on the
differential housing bearings.
Repeat the whole sequence of the above mentioned operations till the
indicated conditions are reached.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.55

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

19
Stabilito il gioco pignone-corona, misurare il precarico totale T dei
cuscinetti (sistema pignone-corona), utilizzando un dinamometro con
la corda avvolta sul codolo scanalato del pignone. Il valore misurato
deve rientrare nel seguente campo:
T=(P+1.9)(P+2.9) daN
dove P il precarico effettivo misurato sul pignone.
Attenzione: tutti i precarichi vanno misurati senza anelli di tenuta.
Vedi: procedure descritte alla sezione D.7
Once the pinion-ring gear backlash has been established, measure
the total preloading T of the bearings (pinion-crown bevel gear system),
using a dynamometer whose cord is wound on the pinion splined end.
The measured value should be within the following range:
T=(P+1.9)(P+2.9) daN
where P is the effectively measured pinion preloading.
Warning: all the preloadings should be measured without the seal
rings.
See: procedure described in the section D.7.
20
A

Se la misurazione non rientrasse nel campo prescritto, controllare bene

lassemblaggio di ogni singolo componente ed intervenire sulle ghiere
di registrazione (7) del supporto differenziale:
- se il precarico totale inferiore al campo dato, avvitare della stessa
quantit le ghiere di registrazione, mantenendo inalterato il valore del
gioco pignone-corona (A);
- se il precarico totale superiore al campo dato, svitare della stessa
quantit le ghiere di registrazione, mantenendo inalterato il valore del
gioco pignone-corona (B).
If the measurement is not within the requested range, check well the
assembly of each component and operate on the adjuster ring nuts
(7) of the differential support:
- if the total preloading is less than the given range, screw in both
adjuster ring nuts by the same measure, keeping the pinion-ring gear
backlash value unchanged (A);
- if the total preloading is greater than the given range, unscrew both
adjuster ring nuts by the same measure, keeping the pinion-ring gear
backlash value unchanged (B).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.56

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

21
NOTA
Per verificare limpronta di contatto dei denti della coppia conica,
sporcare con minio la corona e rilevare il contatto.
Lesame dellimpronta di contatto deve essere eseguito sempre sui
denti della corona conica, e su ambedue i fianchi.
NOTE
To test the marks of the bevel gear teeth, paint the ring gear with red
lead paint.
The marking test should be always carried out on the ring bevel gear
teeth and on both sides.
22
OK

OK -> Contatto corretto:

Se la registrazione della coppia conica ben fatta, il contatto delle
superfici delle dentature risulter regolare.
Z -> Eccessivo contatto sulla cresta del dente:
Avvicinare il pignone alla corona ed allontanare poi la corona dal
pignone per regolare il gioco.
X -> Eccessivo contatto alla base del dente:
Allontanare il pignone dalla corona ed avvicinare poi la corona al
pignone per regolare il gioco.
OK -> Correct contact:
If the bevel gear is well adjusted, the mark on the teeth surfaces will
be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then move the ring
bevel gear away from the pinion in order to adjust the backlash.
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and then approach the
ring bevel gear to the pinion in order to adjust the backlash.

23
Spostamenti per le correzioni:
1 -> spostare il pignone per modifica contatto tipo X
2 -> spostare il pignone per modifica contatto tipo Z

Movements to correct:
1 -> move the pinion for type X contact adjustment
2 -> move the pinion for type Z contact adjustment.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.57

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

24
Dopo aver completato tutte le operazioni di registro, montare i fermi
ghiera (8) e le rispettive viti (9) serrandole alla coppia prevista
(Sez.C.6).
Attenzione: ruotare le ghiere di registrazione (7) il minimo
indispensabile per permettere il montaggio.
Once all the adjustment operations have been completed, fit the
adjuster ring nut retainers (8) and their respective screws (9), tightening
them to the requested torque (Sec.C.6).
Warning: turn the adjuster ring nuts (7) slightly in order to allow the
assembly.
25
i1

Rimuovere attacchi, sfiatatoi ed eventuali tappi dagli ingressi olio freni

(i1) e (i2).
Vedi: (6) e (7) in sezione C.5
Pericolo: possibile espulsione di olio dallassale.

i2

Remove straight threads, bleeds or plugs from the service brake oil
port (i1) and (i2).
See: (6) and (7) in section C.5
Danger: risk of ejection of oil from the axle.
26
Spingere il pistone (26) del freno in battuta utilizzando il tampone
speciale CA715056 con il manico intercambiabile CA119033 ed un
martello.
Attenzione: posizionare il tampone con cura per non danneggiare il
pistone.

Push the brake piston (26) at the end of stroke using the special pad
CA715056 and the handle CA119033 with a hammer.
Warning: position the pad with accuracy to do not damage the brake
piston.
27
Verificare che i dischi freno (21 e 23) ed i controdischi freno (20 e 24)
non presentino tracce di bruciatura; in caso contrario sostituirli.
Verificare inoltre lusura dei dischi freno (Sez.C.4) e sostituirli se
necessario.
Nota: se si installano nuovi dischi freno, prima del montaggio
immergerli nellolio prescritto (Sez.C.4).
Check that the brake plate (21 and 23) and the brake drive plate (20
and 24) do not present any sign of burning; on the contrary, replace
them. Furthermore check brake plate wear (Sec.C.4) and if necessary
replace it.
Note: if new brake plate are installed, before assembling they should
be dipped in the prescribed oil (sec.C.4).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.58

FRENO E SUPPORTO DIFFERENZIALE

BRAKE AND DIFFERENTIAL SUPPORT

Mod. 28.46M

28

24

23

22
20

21

Rimontare tutti gli elementi del gruppo freno come indicato in figura:
controdisco freno (24) e disco freno (23), mozzo traino dischi freno
(29) e controdischi freno (20) e dischi freno (21).
Attenzione: alla corretta posizione del gradino sul diametro esterno
del mozzo traino dischi freno (22).
Nota: inserire i dischi freno con i fori allineati.
Reassemble all the components of the brake grup as is shown in figure:
brake counterplate (24), brake plate (23), brake disk carrier (22), brake
counterplates (20) and brake plates (21).
Warning: to the correct position of the step on the external diameter
of the brake disk carrier (22).
Note: assemble brake disks with holes aligned.

29
Attenzione: nel caso si sostituiscano solo i dischi freno, spingere il
pistone (26) del freno in battuta utilizzando il tampone speciale
CA715056 con il manico intercambiabile CA119033 ed un martello.
Nota: posizionare il tampone con cura per non danneggiare il pistone.

Warning: when replace the brake disk only, push the brake piston (26)
at the end of stroke using the special pad CA715056 and the handle
CA119033 with a hammer.
Note: position the pad with accuracy to do not damage the brake piston.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.5

PAG.59

GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP

Mod. 28.46M

D.6 Gruppo differenziale

D.6 Differential group

14
5

11
10

14

13
9
7

15

12

7
8

10
6

11

D.6.1 Smontaggio

D.6.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo differenziale vedi
prima le procedure descritte alla sezione D.5.

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the differential group see the
procedure described in the section D.5.

1
1

LA10077

Bloccare il differenziale in una morsa.

Svitare le viti (1) di fissaggio e rimuovere la corona conica (2).
Attenzione: questa operazione libera anche le due semiscatole
differenziale (4) e (12), non disperderne i componenti.

Lock the differential with a clamp.

Unscrew the fastening screws (1) and remove the bevel gear crown (2).
Warning: this will make both differential half boxes (4) and (12) free,
so take care not to drop the internal components.

REVISION DATE:

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P /N :

CA357248

D.6

PAG.60

GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP

Mod. 28.46M

4
12

Disassemblare la scatola differenziale nelle due semiscatole (4) e (12)

complete dei rispettivi elementi.
Nota: fare dei segni di riferimento sulle due semiscatole prima di
separarle, per ripristinare la loro posizione relativa in fase di montaggio.
Disassemblare tutti i particolari.
Verificare le condizioni di funzionalit e lo stato di usura dei
componenti.
Disassemble the differential box in two half boxes (4) and (12) complete
with the relative components.
Note: mark the two half boxes before disjoining them, in order to
reassemble them in the same position as the one before
disassembling.
Disassemble all the components.
Check the operating and wear conditions of the components.

3
Per estrarre i cuscinetti (3) e (13) dalle semiscatole (4) e (12), utilizzare
due leve oppure un estrattore a tre punti di presa da commercio.

4
13

12

Take the bearings (3) and (13) out of the half boxes (4) and (12), using
two levers or a three-hold extractor.

4
4
14

14
12

LA10077

Estrarre le boccole (14) dalle semiscatole (4) e (12) solo se le condizioni

di usura lo richiedono.
Nota: unoperazione distruttiva per le boccole (5).
Attenzione: non rovinare la sede delle boccole.

Remove the bush (14) from the half boxes (4) and (12) only if the wear
conditions require this.
Note: this is a destructive operation for the bushes (14).
Warning: be careful not to damage the bush housing.

REVISION DATE:

00/00

P /N :

CA357248

D.6

PAG.61

GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP

Mod. 28.46M

D.6.2 Montaggio

D.6.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
4

Assemblare le boccole (14) alle semiscatole (4) e (12) con lattrezzo

speciale CA715637 ed un martello.

14

14
12

Assemble the bushes (14) to the half boxes (4) and (12) with the special
tool CA715637 and a hammer.

2
Montare le piste interne dei nuovi cuscinetti a rulli conici (3) e (13) sulle
semiscatole (4) e (12), utilizzando il battitoio CA119230 ed un martello.

12

Assemble the cones of the new taper roller bearings (3) and (13) on
the half boxes (4) and (12), using the special tool CA119230 and a
hammer.

13

4
12

Posizionare una semiscatola differenziale (4) o (12) sul banco di lavoro

ed assemblare con attenzione gli elementi interni (controdischi
bloccaggio differenziale (5), dischi bloccaggio differenziale (6) e (7),
ingranaggi planetari (8), perni portasatelliti (9), ingranaggi satelliti (10),
rondelle di rasamento (11)) come in figura.
Nota: il primo disco (7) deve essere orientato con il materiale dattrito
verso i dischi e la superficie liscia verso il planetario (8).
Unire le due semiscatole, allineando i riferimenti praticati sulle stesse.
Position a half box (4) or (12) on a workbench and assemble all inner
components (locking differential counterdiscs (5), locking differential
discs (6) and (7), sun gears (8), spiders (9), spider gears (10), thrust
washers (11)), as shown in figure.
Note: the first disk (7) must be assembled with friction material on the
disks side and the flat surface on the sun gear (8) side.
Join the two half boxes, aligning the reference marks made upon them.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.6

PAG.62

GRUPPO DIFFERENZIALE
DIFFERENTIAL GROUP

Mod. 28.46M

4
2
1

Posizionare la corona conica (2) sulla semiscatola differenziale (4).

Nota: verificare la posizione delle spine di centraggio (15).
Applicare sigillante (B2) sul filetto delle viti (1) (Sez.C.4) e serrarle alla
coppia prevista (Sez.C.6).

Position the bevel crown gear (2) on the half box (4).
Note: check dowel pins (15) position.
Apply sealant (B2) on the thread (Sec.C.4) and tighten the screws (1)
to the requested torque (Sec.C.6).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.6

PAG.63

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

D.7 Gruppo pignone

D.7 Pinion group

1
2
4

8
9

3
5
6
10

D.7.1 Smontaggio

D.7.1 Disassembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.
Nota: per lo smontaggio del gruppo pignone vedi prima
le procedure descritte alla sezione D.6

Some of the following pictures may not show exactly

your axle, but the process is the same.
Note: before disassemble the pinion group see the
procedure described in the section D.6.

1
Svitare la ghiera (10) di serraggio utilizzando le attrezzature CA119060
e CA715022.
Nota: operazione distruttiva per la ghiera (10).
Togliere la ghiera e recuperare la rondella fermo ghiera (9).

Unscrew the lock nut (10) using special tools CA119060 and
CA715022.
Note: this operation will irretrievably damage the lock nut (10).
Remove the lock nut and collect its retaining washer (9).

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.64

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

2
Battere con un martello di materiale tenero sul codolo per sfilare il
pignone conico (1).

Tap the end shaft with a soft hammer to remove the bevel pinion (1).
3
Tolto il pignone conico (1) recuperare le rondelle (4) e (6), il distanziale
elastico (5) ed il cono del cuscinetto (8).

Once the bevel pinion (1) has been removed, collect the washers (4)
and (6), the collapsible spacer (5) and the bearing cone (8).
4
Estrarre le coppe dei cuscinetti a rulli conici (3) e (8) con un battitoio
ed un martello.

Remove bearing cups (3) and (8) from central body with a drift and a
hammer.
5

Togliere il cono del cuscinetto (3) dal pignone conico (1) utilizzando
un estrattore di presa da commercio.
Recuperare lo spessore (2) sottostante.

LA10077

Remove the bearing cone (3) of the bevel pinion (1) with a standard
extractor.
Collect the shim (2).

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.65

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

Controllare le condizioni di tutti i particolari del pignone.

Attenzione: la ghiera (10) ed il distanziale elastico (5) in fase di
rimontaggio devono essere sostituiti.

10

Check all pinion components for wear.

Warning: the ring nut (10) and the collapsible spacer (5) must be
replaced when reassembling the unit.

D.7.2 Montaggio

D.7.2 Assembly

Alcune figure che seguono potrebbero non mostrare

esattamente il vostro assale, ma la procedura rimane la
stessa.

Some of the following pictures may not show exactly

your axle, but the process is the same.

1
Posizionare su un banco di lavoro il corpo centrale (7).
Piantare le coppe dei cuscinetti (3) e (8) nelle proprie sedi con il kit
attrezzature speciali CA715639.

Place the central body (7) on a workbench.

Fit the bearing cups (3) and (8) into their seats using the special tools
kit CA715639.
2
Inserire nelle sedi i coni dei cuscinetti (3) e (8) ed il falso pignone
CA715638.
Serrare con la ghiera (10) fino ad eliminare il gioco.

Insert into the seats the bearing cups (3) and (8) and the false pinion
CA715638.
Tighten the ring nut (10) to eliminate the backlash.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.66

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

3
Verificare il corretto posizionamento dei cilindri freno destro e sinistro
utilizzando i riferimenti riportati sui medesimi e sul corpo centrale (7).
Montare i cilindri freno fissandoli con le rispettive viti (avvitarne almeno
due diametralmente opposte per ogni cilindro).

Check the correct positioning of the right and left brake cylinder, using
the reference marks on them and on the central body (7).
Assemble the brake cylinders and fix them with their screws (screw in
at least two ones diametrically-opposed for each cylinder).
4
Introdurre nel corpo centrale (7) la falsa scatola differenziale
CA715578.
Verificare che la falsa scatola differenziale sia inserita in entrambe le
sedi dei cilindri freno.

Insert the false differential box CA715578 into the central body (7).
Check that the false differential box is inserted in both brake cylinders
housings.
5
Per registrare la coppia conica misurare con un calibro di profondit
la distanza A.
Determinare il valore X come segue:
X=(A+C)-B mm
dove B e C sono valori noti.
To adjust bevel gear/pinion measure the distance A with a depth
gauge.
Calculate the value X as follows:
X=(A+C)-B mm
where B and C are known.
6
Dal valore X sottrarre il valore V(stampigliato sulla testa del pignone)
per ottenere il valore S.
S=X-V mm
From the value X deduct the value V (stamped on the pinion head)
to get the value S.
S=X-V mm

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.67

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

7
Scegliere uno spessore di valore (S) tra la gamma di spessori a
disposizione ed inserirlo sul codolo sotto la testa del pignone.
GAMMA SPESSORI - SHIMS RANGE
Spess./Thick. (mm)

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

3.3

3.4

Q.ty

---

---

---

---

---

---

---

---

---

---

Select a shim with thickness equal to (S) among the range available
and fit it on the shaft under the pinion head.
8
Rimuovere il falso pignone CA715638, i cuscinetti (3) e (8) e la ghiera
(10) dal corpo centrale (7).
Smontare la falsa scatola differenziale CA715578 dai cilindri freno e
successivamente svitare le viti per rimuovere i cilindri freno.

Remove the false pinion CA715638, the bearings (3) and (8) and the
ring nut (10) from the central body (7).
Disassemble the false differential box CA715578 from the brake
cylinders and then unscrew the screws to remove the brake cylinders.
9
3
2

6
4

Dopo aver scelto ed inserito lo spessore (2) adatto con lo smusso

rivolto verso lingranaggio, piantare il cuscinetto (3) nellalbero del
pignone (1) sotto lazione di una pressa con il battitoio CA715433,
assicurandosi che sia ben assestato.
Inserire gli spessori (4) e (6) ed un nuovo distanziale elastico (5).
Nota: utilizzare sempre un distanziale elastico (5) nuovo.
Once you have chosen and inserted the suitable shim (2) with the
chamfer against the gear, force the bearing (3) into the pinion shaft (1)
with the special tool CA715433 under a press, making sure that it is
well set.
Insert the shims (4) and (6) and a new collapsible spacer (5).
Note: use always a new collapsible spacer (5).

10
Inserire il gruppo pignone conico (1) preassemblato nel corpo centrale
(7) ed il cuscinetto (8) sul codolo pignone, come in figura.
Per eseguire il piantaggio del cuscinetto (8), utilizzare il battitoio
CA715433 ed un martello.
Si consiglia di contrapporre unazione resistente alla forza battente ad
esempio con una mazza.
Insert the bevel pinion (1) unit into the central body (7) and the bearing
(8) into the pinion shaft, as shown in figure.
In order to force the bearing (8) into position, use the special tool
CA715433 and a hammer.
It is advisable to offer resistance, for example with a sledge, to the
beating force.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.68

GRUPPO PIGNONE
PINION GROUP

Mod. 28.46M

11
Inserire la rondella fermo ghiera (9) ed avvitare una nuova ghiera di
serraggio (10) sul codolo del pignone.
Avvitare la ghiera (10) utilizzando le chiavi per ghiera CA119060 e
fermo pignone CA715022.
Attenzione: la coppia di serraggio data dalla misurazione del
precarico sui cuscinetti (3) e (8); serrare la ghiera (10)
progressivamente.
Nota: se il serraggio eccessivo il distanziale elastico (5) dovr essere
sostituito e la procedura ripetuta.
Al momento di verificare il precarico opportuno dare piccoli colpi con
martello in materiale tenero alle estremit del pignone (1) per favorire
lassestamento dei cuscinetti (3) e (8).
Insert the ring nut washer (9) and screw a new lock ring nut (10) on
the pinion end.
Screw the ring nut (10) in, using the wrench for ring nut CA119060 and
for pinion retainer CA715022.
Warning: the torque setting is given by the preloading measurement
on bearings (3) and (8); tighten the ring nut (10) gradually.
Note: if the tightening is excessive, the elastic spacer (5) must be
replaced and the procedure repeated.
When you check the preloading, it is advisable to beat slightly both
pinion ends (1) with a soft hammer, so as to help setting the bearings
(3) and (8).
12
Effettuare la misurazione del precarico P dei cuscinetti conici (3) e (8),
utilizzando un dinamometro con la corda, avvolta sul codolo scanalato
del pignone (1).
La regolazione si effettua aumentando gradualmente il serraggio della
ghiera (10), facendo attenzione a non eccedere.
Attenzione: tutti i precarichi devono essere misurati senza anello di
tenuta.
P=9.213.7 daN
Carry out the preloading measurement P of the pinion taper roller
bearings (3) and (8), using a dynamometer whose cord is wound on
the end of pinion spline (1).
The adjustment is carried out by increasing the ring nut (10) torque
gradually, being careful not to exceed.
Warning: all preloadings must be measured without the seal ring.
13
Ottenuto il prescritto valore di precarico, cianfrinare la ghiera (10)
utilizzando martello e punzone.

Once the requested preloading value is achieved, stake the ring nut
(10), using a hammer and a chisel.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.7

PAG.69

SBLOCCAGGIO FRENO PARCHEGGIO

PARKING BRAKES RELEASE

Mod. 28.46M

D.8 Sbloccaggio freno parcheggio

D.8 Parking brakes release

ATTENZIONE

WARNING

BLOCCARE LE RUOTE. Il non farlo pu essere molto

pericoloso o addiritura mortale per loperatore. Bloccare
tutte e quattro le ruote per impedire il movimento del
veicolo una volta che il freno stato disinserito.
Per disabilitare i freni di parcheggio necessaria una
chiave a brugola da 8 mm.
Fare un segno sulla testa delle viti per poter contare il
numero di giri che ciascuna vite dovr fare mentre
eseguite la procedura.
Sdraiarsi sotto lassale ed individuate le sei viti di rilascio
(tre per ciascun lato) alla base dellassale.
Avvitare alternativamente di 1/2 giro alla volta in senso
orario le viti di rilascio freno A,B e C fino a quando si
inizia a sentire una certa resistenza.
Avvitare alternativamente di 1/2 giro alla volta le viti A,
B e C per 5 5.5 giri.
Spostarsi da sotto il veicolo e liberare larea circostante
dal personale non coinvolto dalle operazioni.
Rimuovere con attenzione i ceppi di bloccaggio dalle
quattro ruote e trainare il veicolo in un luogo sicuro.
Bloccare nuovamente le quattro ruote e continuare
con le operazioni che necessitano.

BLOCK ALL FOUR WHEELS. Failure to do so could

result in death or serious injury from vehicle roll away.
Block all four wheels to prevent the vehicle from moving
once the parking brake is disabled.
An 8 mm allen head socket will be needed to properly
disable the parking brakes.
Mark a line on the socket so you can accurately count
the number of turn each bolt makes as you perform the
procedure.
Lie down under the axle and locate the six brake release
bolts (three bolts per side) at the base of the axle.
Alternately screw 1/2 turn brake release bolts A, B & C
inxard direction (clockwise) until you first begin to feel
resistance.
Alternately screw 1/2 turn the bolts A, B and C inward
direction of 5 5.5 turns.
To get out from under the vehicle and clear the area of
any unnecessary personnel.
Carefully remove the blocking from each of the four tires
and tow the vehicle to asecure location.
Block all four wheels and continue following the
procedure.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.8

PAG.70

RIATTIVAZIONE FRENO PARCHEGGIO

RE-ACTIVATING PARKING BRAKES

Mod. 28.46M

D.9 Riattivazione freno parcheggio

D.9 Re-activating parking brakes

ATTENZIONE

WARNING

BLOCCARE LE QUATTRO RUOTE. Il non farlo pu

essere molto pericoloso o addiritura mortale per
loperatore. Bloccare tutte e quattro le ruote, sdraiarsi
sotto lassale e, utilizzando la chiave dinamometrica,
svitare alternativamente le viti di rilascio A, B e C (in
senso antiorario) di 1/2 giro.
Di nuovo svitare alternativamente di 1/2 giro le viti A, B
e C fino a quando la coppia si riduce bruscamente.
Continuare a svitare alternativamente le viti A, B e C
fino a quando si avverte che la testa della vite va a
contatto con la vite speciale. Riavvitare poi in senso
inverso le viti A, B e C di 1/4 di giro.
I freni di parcheggio sono a questo punto riattivati e le
ruote bloccate.
Rimuovere quindi i ceppi dalle quattro ruote.
Verificare lefficienza del freno di parcheggio.
Rimuovere i cartelli di pericolo o di avviso dal volante e
dalla chiave daccensione.

BLOCK ALL FOUR WHEELS. Failure to do so could

result in death or serious injury from vehicle roll away.
After you have locked all four wheels, lie down under
the axle. Using the torque wrench, alternately unscrew
brake release bolts A, B and C outward direction
(counterclockwise) 1/2 turn.
Again, alternately unscrew brake release bolts A, B and
C outward direction 1/2 turn until the torque drops off
sharply. Alternately unscrew brake release bolts A, B
and C outward direction (counterclockwise) until feel the
bolts flange begin to contact against the special screw.
Screw the bolts A, B and C inward direction 1/4 turn.
The parking brakes should now be re-activated and the
wheels are locked.
Remove the blocking from the four tires.
Verify that parking brake works properly.
Remove any warning tags from the ignition lock key and
from the steering wheel.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.9

PAG.71

PROVE DOPO MONTAGGIO

TESTING AFTER ASSEMBLY

Mod. 28.46M

D.10 Prove dopo montaggio

D.10 Testing after assembly

D.10.1Procedure di collaudo

D.10.1Testing methods

Passo 1
A motore spento, sollevare l'assale della ruota motrice
sino a che i pneumatici si siano staccati da terra.

Step 1
With engine off, lift the axle so that the tyres get away
from the ground.

Passo 2
Ingranare la marcia in modo che il pignone sia bloccato.

Step 2
Engage the gear so that the pinion gets locked.

Passo 3
Con l'aiuto di un'altra persona collocata al lato opposto,
iniziare la prova di montaggio ruotando per quanto
possibile entrambe le ruote nel senso di marcia avanti.
(Entrambe le ruote dovrebbero bloccarsi dopo poco)

Step 3
With the help of another person standing on the opposite
side, begin the assembly testing by rotating as much as
possible both the wheels forward. (Both the wheels
should get blocked after a while.)

Passo 4
Con il pignone sempre bloccato, liberare la ruota di
destra e ruotare la ruota di sinistra nel senso (marcia
avanti).
Se il montaggio corretto si dovr verificare che la ruota
giri liberamente senza eccessivi sforzi, e la ruota di
destra ruoti in senso opposto.
Ripetere l'operazione nel senso opposto (retro marcia).

Step 4
Keeping the pinion locked, free the right wheel and rotate
the left one in the line of march. Rotate the right wheels
in the opposite direction.
The wheel will move freely without difficulty and the right
wheel will move in the opposite direction if the assembly
has been carried out correctly.
Repeat the same operation in the opposite direction
(reverse gear).

SE UNA DELLE RUOTE NON GIRA LIBERAMENTE

IN ENTRAMBE LE DIREZIONI, ricontrollare passo
passo il montaggio.
Controllare anche che i freni siano regolati in modo da
consentirne il corretto funzionamento.

IF ONE WHEEL DOES NOT ROTATE FREELY IN

BOTH DIRECTIONS, then check step by step all
assembly operations.
Check and see that the brakes are regulated correctly
and functioning properly.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

D.10

PAG.72

Mod. 28.46M

RICERCA GUASTI

TROUBLESHOOTING

REVISION DATE:

00/00

P /N :

CA357248

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

PROBLEMA

POSSIBILI CAUSE
1

10 11

10 11

- Vibrazioni delle ruote; resistenza del pneumatico

anteriore; rottura del/i semiasse/i.
- Difficolt nello sterzare; il veicolo tende ad andare
dritto mentre in curva.
- Non vi azione del differenziale; inceppamento in
curva.
- Rumore eccessivo nella trasmissione.
- Usura eccessiva del pneumatico.
- Rumore di attrito.
- In marcia avanti si avvertono vibrazioni, rumore
intermittente.

PROBLEMS

POSSIBLE CAUSES
1

- Wheel vibration; front tyre resistance; halfshaft

breakage.
- Steering is difficult; vehicle goes straight while its
turning.
- No differential action; jamming while steering.
- No differential action; jamming while steering.
- Uneven wear of tyre.
- Friction noise.
- Vibration during forward drive, intermittent noise.

1 Installazione scorretta / assale difettoso

Correggere l'installazione oppure, se il differenziale
non supera una delle fasi di prova, ripararlo o
sostituirlo.

1 Incorrect installation / defective axle

Correct installation or repair or replace the differential in
case it does not survive any one of the test phases.

2 Sovraccarico / distribuzione scorretta del peso

Togliere il peso in eccesso e ridistribuire il carico,
rispettando le istruzioni relative al veicolo.

2 Overloading / incorrect weight distribution

Remove excessive weight and redistribute load,
following instructions related to the vehicle.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

PAG.74

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

3 Raggio di rotazione dei pneumatici diversi

Un pneumatico con raggio pi piccolo provoca un
parziale slittamento della ruota quando si applica
energia. L'altro pneumatico con raggio maggiore dovr
sopportare tutto il lavoro. Sostituire il pneumatico o
regolare la pressione di entrambi sino a che il raggio di
rotazione sia uguale.

3 Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial
wheel slipping when force is applied.The other tyre with
bigger radius will have to support all the work. Replace
the tyre or adjust pressure to have same radius on both
tyre.

4 Semiasse rotto
E' sconsigliato usare un veicolo con un solo semiasse.
E' possibile tuttavia spostare il veicolo a vuoto con il
differenziale bloccato per pochi metri.

4 Broken halfshaft
It is not advisable to operate the vehicle with a broken
halfshaft. It is acceptable to move the vehicle (engine
off unloaded) a few meters away only.

5 Semiasse piegato
Sostituire i semiassi.

5 Bent halfshaft
Replace halfshaft.

6 Differenziale bloccato
Funzionamento anomalo del differenziale e/o rottura
del dispositivo di comando del bloccaggio di comando.
Verificare l'installazione, eventualmente smontare e
verificare i componenti.
I veicoli impostati per angoli di sterzata ampi, possono
procedere a scatti, avere difficolt di sterzo e provocare
un consumo del pneumatico nelle curve strette.
Ridurre l'angolo di sterzata minimo e decelerare
quando il motore inizia a procedere a scatti.

6 Blocked differential
Abnormal functioning of the differential or breakage/
blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with
kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to
minimum and decelerate when the vehicle begins to
kick.

7 Allineamento scorretto della ruota

Verificare l'integrit della struttura, e cuscinetti lato
ruota.

7 Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.

8 Parti dell'assale consumate o difettose

Controllare le condizioni della corona dentata,
dell'ingranaggio del pignone, dei cuscinetti, delle
guarnizioni, ecc. Sostituire dove necessario.

8 Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings
etc. Replace when ever necessary.

9 Corpi estranei nella scatola dell'assale o

montaggio scorretto di alcune sue parti
Controllare se vi sono corpi estranei. Controllare il
montaggio delle parti dell'assale.

9 Contamination in the axle box or incorrect

assembly of parts
Look for foreign particles. Check assembly of the
various parts of the axle.

10 Regolazioni della coppia conica scorrette: parti

di trasmissione consumate
(ingranaggi di trasmissione, giunti, ecc.). Sostituire o
regolare secondo necessit.

10 Incorrect adjustment of bevel gear set: Parts of

the transmission worn out.
(transmission gears, U joints, etc.)
Replace or adjust as required.

11 Uso scorretto del prodotto

Rivedere le istruzioni rilasciate dal produttore del
veicolo.

11 Incorrect use of the product

See the vehicle producers instructions once again.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

PAG.75

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

E.1 Controllo ed esame dei guasti

Questo capitolo offre una guida descrittiva ed esplicativa di problemi che si possono comunemente riscontrare sugli
assali o di avarie che si possono verificare. La guida suggerisce anche le corrette procedure di riparazione.
Problema

Causa

Azione consigliata

Rottura verso l'estremit esterna del

dente corona dentata

1. Carico dell'ingranaggio eccessivo

rispetto a quello previsto
2. Regolazione ingranaggio scorretto
(gioco eccessivo)
3. Dado del pignone allentato.

Sostituire la coppia conica.

Seguire attentamente le operazioni
raccomandate di regolazione del gioco
della corona dentata e del pignone e per
la rilevazione dellimpronta del dente.

Rottura verso l'estremit interna del

dente corona dentata

1. Urto da carico
2. Regolazione ingranaggio scorretto
(gioco insufficiente)
3. Dado del pignone allentato

Sostituire la coppia conica.

Seguire attentamente le operazioni
raccomandate di regolazione del gioco
della corona dentata e del pignone e per
la rilevazione dellimpronta del dente

Denti del pignone e della corona dentata 1. Lubrificazione insufficiente

erosi o rigati
2. Lubrificante sporco
3. Lubrificante errato o con additivi
impoveriti
4. Cuscinetti del pignone consumati che
provocano un gioco assiale del pignone e
un contatto tra pignone e corona
scorretto.

Sostituire la coppia conica.

Sostituire i cuscinetti del pignone facendo
attenzione a sistemare correttamente la
corona, il pignone e i precarichi dei
cuscinetti.
Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Denti della corona e del pignone

surriscaldati. Guardare se i denti
dell'ingranaggio hanno perso la
colorazione

1. Funzionamento prolungato a
temperatura eccessiva.
2. Lubrificante scorretto
3. Livello dell'olio basso
4. Lubrificante sporco.

Sostituire la coppia conica.

Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Denti del pignone di comando butterati

1. Uso estremamente intenso

2. Lubrificazione insufficiente

Sostituire la coppia conica.

Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Corpo trave dell'assale piegato

1. Sovraccarico del veicolo

2. Veicolo incidentato
3. Urto da carico

Sostituire il corpo trave dell'assale

Cuscinetti consumati o butterati

1. Lubrificazione insufficiente
2. Lubrificante sporco
3. Uso estremamente intenso
4. Consumo normale
5. Dado del pignone allentato.

Sostituire i cuscinettii.
Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Le guarnizioni perdono olio

1. Funzionamento prolungato con

temperatura dell'olio eccessiva.
2. Guarnizione dell'olio montata male
3. Bordo della guarnizione tagliata o
intaccata
4. Lubrificante sporco

Sostituire la guarnizione e la superficie di

accoppiamento se danneggiata.
Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Usura eccessiva della scanalatura della

flangia di entrata.

1. Uso intenso
2. Dado del pignone allentato
3. Gioco assiale del pignone

Sostituire la flangia
Controllare che la scanalatura del
pignone non sia eccessivamente
consumata
Sostituire la coppia conica, se necessario.

Rottura per fatica del dente

dell'ingranaggio del pignone. Guardare
se la linea di frattura ad onda ben
delineata (linea di arresto).

1. Uso intenso
2. Sovraccarico continuo

Sostituire la coppia conica.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

E.1

PAG.76

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

Problema

Causa

Azione consigliata

Rottura denti pignone e corona

Carico d'urto dei componenti del

differenziale

Controllare e/o sostituire altri componenti

differenziale.

Scanalature dell'ingranaggio planetario

consumate (gioco eccessivo)

Uso intenso

Sostituire il gruppo ingranaggi

differenziale. Sostituire il semiasse, se
necessario.

Superfici della ralla di rasamento

consumate o graffiate

1. Lubrificazione insufficiente
2. Lubrificazione scorretta
3. Lubrificante sporco

Sostituire tutte le ralle graffiate e quelle

con uno spessore di 0,1 mm inferiore a
quello delle ralle nuove.
Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Diametro interno del cuscinetto a rulli

conici del pignone consumato

1. Uso intenso
2. Gioco assiale del pignone eccessivo
3. Lubrificazione inadeguata
4. Lubrificante sporco

Sostituire il cuscinetto
Controllare il gioco assiale del pignone
Usare il lubrificante corretto, riempire fino
al giusto livello e sostituirlo agli intervalli
raccomandati.

Semiasse ritorto o rotto

Funzionamento intenso del veicolo,

sovraccarico

Sostituire il semiasse

Semiasse spezzato presso la flangia

ruota

1. Supporto della ruota allentato

2. Corpo trave piegato

Sostituire il semiasse
Controllare la distorsione del corpo trave.
Accertarsi che il sostegno della ruota non
sia consumato o mal regolato.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

E.1

PAG.77

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

E.1 Troubleshooting
This chapter is a descriptive and explanatory guide to common axle problems. This guide suggests the correct repair
procedures to be followed.
Problem

Cause

Action

Ring gear tooth broken on the outer side 1. Excessive gear load compared to the
one foreseen
2. Incorrect gear adjustment (excessive
backlash)
3. Pinion nut loosened

Replace bevel gear set

Follow carefully the recommended
operations for the adjustment of bevel
gear set backlash

Ring gear tooth broken on the inner side 1. Load bump

2. Incorrect gear adjustment (insufficient
backlash)
3. Pinion nut loosened

Replace bevel gear set

Follow carefully the recommended
operations for the adjustment of bevel
gear set backlash.

Pinion or ring gear teeth worn

Replace bevel gear set.

Follow carefully the recommended
operations for the adjustment of bevel
gear set backlash.
Use correct lubricants, fill up to the right
levels and replace according to the
recommended program.

1. Insufficient lubrication
2. Contaminated oil
3. Incorrect lubrication or depleted
additives
4. Worn out pinion bearings that cause
an incorrect pinion axle backlash and
wrong contact between pinion and ring.

Overheated ring and pinion teeth. See if 1. Prolong ed functioning at high

gear teeth have faded
temperatures
2. Incorrect lubrication
3. Low oil level
4. Contaminated oil

Replace bevel gear set.

Use proper lubrication, fill up to right level
and replace at recommended program.

Pinion teeth pitting

1. Excessive use
2. Insufficient lubrication

Replace bevel gear set.

Use correct lubrication, fill up to the right
level and substitute at recommended
intervals

Axle beam body bent

1. Vehicle over loaded

2. Vehicle's accident
3. Load bump

Replace axle beam body

Worn out or pitted bearings

1. Insufficient lubrication
2. Contaminated oil
3. Excessive use
4. Normal wear out
5. Pinion nut loosened

Replace bearings.
Use correct lubrication fill up, to the right
level and replace at recommended
intervals

Oil leakage form gaskets and seals

1. Prolonged functioning at high

temperature of the oil
2. Oil gasket assembled incorrectly
3. Seal lip damaged
4. Contaminated oil

Replace the gasket or seal and matching

surface if damaged.
Use correct lubrication and replace at
recommended intervals.

Excessive wearing out of input flange

spline

1. Exhaustive use
2. Pinion nut loosened
3. Pinion axle backlash

Replace the flange.

Check that the pinion spline is not
excessively worn out.
Replace bevel gear set if required.

Fatigue failure of pinion teeth

See if the fracture line is well defined
(wave lines, beach lines)

1. Exhaustive use
2. Continuous overload

Replace bevel gear set

Pinion and ring teeth breakage

1. Crash load of differential components

Check and/or replace other differential

components.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

E.1

PAG.78

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

Problem

Cause

Action

Side gear spline worn out.

Replace all scratched washers
(Excessive backlash)

Excessive use

Replace differential gear group.

Replace halfshaft if required

Thrust washer surface worn out or

scratched.

1. Insufficient lubrication
2. Incorrect lubrication
3. Contaminated oil

Use correct lubrication and fill up to right

level.
Replace at intervals recommended.
Replace all scratched washers and those
with 0,1mm thickness lower than the new
ones.

Inner diameter of tapered roller bearing

worn out.

1. Excessive use
2. Excessive pinion axial backlash
3. Insufficient lubrication
4. Contaminated oil

Replace bearing.
Check pinion axial backlash.
Use proper lubrication, fill up to right level
and replace at recommended intervals.

Bent or broken halfshaft

Vehicle intensively operated or

overloaded

Replace

Halfshaft broken at wheel side

1. Wheel support loosened

2. Beam body bent

Replace
Check that wheel support is not worn out
or wrongly adjusted.

LA10077

REVISION DATE:

00/00

P /N :

CA357248

E.1

PAG.79

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

E.2 Diagnosi per problemi all'assale

Problema
Rumore durante la guida

Causa

Azione consigliata

1. Gioco tra corona dentata e pignone

eccessivo
2. Pignone e corona dentata consumati
3. Cuscinetti del pignone consumati
4. Cuscinetti del pignone allentati
5. Gioco assiale del pignone eccessivo
6. Cuscinetti del differenziale consumati
7. Cuscinetti del differenziale allentati
8. Eccessiva scentratura della corona
dentata
9. Livello lubrificante basso
10. Lubrificante di grado povero od errato
11. Semiasse piegato

1. Regolare

1. I rumori provenienti dall'assale con il

veicolo in movimento di solito si sentono
durante landatura in folle anche se non
molto forti
2. Errato gioco tra pignone e corona (il
rumore che si sente decelerando
sparisce allaumentare della velocit).
3. Usura scanalatura pignone o flangia
entrata

1. Regolare o sostituire (vedere sopra)

Rumore intermittente

1. Corona dentata danneggiata

2. Bulloni della scatola del differenziale
allentati

1. Sostituire coppia conica

2. Serrare a coppia

Rumore costante

1. Danni sui denti della corona dentata o

del pignone
2. Cuscinetti usurati
3. Scanalature del pignone consumate
4. Semiasse piegato

1. Sostituire coppia conica

1. Satelliti planetari differenziale

consumati
2. Scatola differenziale e/o perni del
differenziale consumati
3. Ralle di rasamento del differenziale
consumate
4. Scanalature del semiasse consumate

1. Sostituire

Rumore durante landatura in folle

Rumore in curva

LA10077

REVISION DATE:

00/00

P /N :

CA357248

2. Sostituire
3. Sostituire
4. Regolare
5. Regolare
6. Sostituire
7. Regolare
8. Sostituire
9. Rabboccare
10. Sostituire
11. Sostituire

2. Regolare

3. Sostituire

2. Sostituire
3. Sostituire
4. Sostituire

2. Sostituire
3. Sostituire
4. Sostituire

E.2

PAG.80

RICERCA GUASTI
TROUBLESHOOTING

Mod. 28.46M

E.2 Axle problems and diagnosis

Problem
Noise while driving

Cause

Action

1. Excessive backlash between pinion

and ring gear
2. Worn out pinion and gear ring
3. Worn out pinion bearings
4. Pinion bearings loosened
5. Excessive axial pinion backlash
6. Worn out differential bearings
7. Differential bearings loosened
8. Ring gear out of roundness
9. Low lubricant level
10. Poor or wrong lubricant
11. Bent halfshaft

1. Adjust
2. Replace
3. Replace
4. Adjust
5. Adjust
6. Replace
7. Adjust
8. Replace
9. Oil level
10. Replace
11. Replace

Noise while driving in neutral

1. Noise coming from axle are usually

1. Replace or adjust (see above)
heard when vehicle moves in neutral
gear but are not loud.
2. Incorrect backlash between pinion and 2. Replace
ring (sound heard while decelerating
disappears while increasing the speed)
3. Pinion or input flange worn out
3. Adjust

Intermittent noise

1. Ring gear damaged

2. Differential box bolts loosened

1. Replace bevel gear set

2. Tighten to torque

Constant noise

1. Ring gear teeth or pinion damaged

2. Worn out bearings
3.Pinion spline worn out
4. Bent halfshaft

1. Replace bevel gear set

2. Replace
3. Replace
4. Replace

Noise while seering

1. Worn out differential gears

2. Worn out differential box or spider
3. Differential thrust washers worn out
4. Half shaft spline worn out

1. Replace
2. Replace
3. Replace
4. Replace

LA10077

REVISION DATE:

00/00

P /N :

CA357248

E.2

PAG.81

Mod. 28.46M

ATTREZZATURE SPECIALI

SPECIAL TOOLS

REVISION DATE:

00/00

P /N :

CA357248

ATTREZZATURE SPECIALI
SPECIAL TOOLS

Mod. 28.46M

F.1

Attrezzature speciali

F.1 Special tools

Battitoi e tamponi per il montaggio di tenute, cuscinetti

e bronzine devono essere utilizzati con il manico
intercambiabile CA119033; se ne raccomanda luso
abbinato ad unimpugnatura di sicurezza per la
protezione delle mani (da commercio).

The special drifts/pad used to assembly the seals,

bearings and bushes should always be used with the
interchangeble handle CA119033; its use is
recommended togheter with a suitable safety handle in
order to protect the hands.

CA119030

Chiave
Wrench

CA119033

Manico
Handle

CA119060

Chiave
Wrench

CA715022

Chiave
Wrench

CA715033

Battitoio
Driver

CA715056

Chiave
Wrench

CA715118

Battitoio
Driver

CA715146

Attrezz. mis. gioco

Backlash meas. tool

CA715181

Battitoio
Driver

CA715433

Battitoio
Driver

CA715531

Battitoio
Driver

CA715578

Falsa scatola differenziale

False differential box

LA10077

REVISION DATE:

00/00

P /N :

CA357248

F.1

PAG.83

ATTREZZATURE SPECIALI
SPECIAL TOOLS

Mod. 28.46M

CA715583

Battitoio
Driver

CA715631

Chiave
Wrench

CA715632

Battitoio
Driver

CA715633

Battitoio
Driver

CA715634

Battitoio
Driver

CA715635

Battitoio
Driver

CA715636

Battitoio
Driver

CA715637

Battitoio
Driver

CA715638

Falso pignone
False pinion

CA715639

Kit inserimento cuscinetti

Bearing insertion kit

LA10077

REVISION DATE:

00/00

P /N :

CA357248

F.1

PAG.84

Cyclopac Service Procedures

Proper air cleaner servicing results in maximum
engine protection against the ravages of dust.
Proper servicing can also save time and money
by maximizing filter life and dust cleaning
efficiency.

Two of the most common problems:

A) Over Servicing. New filter elements increase
in dust cleaning efficiency as dust builds up on the

Measure
Restriction
Measure the restriction
of the air cleaner with a
Donaldson restriction
indicator, such as The
Informer, a service
gauge, or water manometer at the restriction
tap provided in the air
cleaner, the transfer
pipe, or the blower intake.
One of two conditions will exist
(1) If the reading indicates the maximum
restriction (per engine manufacturers
recommendations), change out the filter.
(2) If the reading shows below the maximum, the
filter still has life left and should not be touched.

Empty the Dust Cup

Donaldson

Dust should not be allowed to build up closer than

one inch from the baffle. On models equipped
with a Donaldson Vacuator valve, dust cup
service is cut to a minimum; all that is necessary
is a quick check to see that the Vacuator valve
is not inverted, damaged, or plugged.

media. Dont be fooled by filter appearance....

the filter should look dirty. By using proper filter
measurement tools you will use the full life of the
filter at maximum efficiency.
B) Improper Servicing. Your engine is vulnerable
to abrasive dust contaminants during servicing.
The most common cause of engine damage is
careless servicing procedures. By following the
steps shown, you can avoid unnecessary risk to
the engine.

Filter Servicing
When restriction indicates that filter servicing is
required, loosen the wingnut and remove the
primary filter. Before installing new filter, inspect
the filter and gasket for shipping or storage
damage. (See service
tips on reverse side of
this document.) Carefully
install new element and
wingnut.
Always use authentic
replacement Donaldson
filters, which have been
engineered to fit the air
cleaner and engine intake
system exactly.

Cover the Inlet

Dont leave the air inlet
exposed! If the new filter wont be installed
immediately, cover the opening to prevent stray
contaminant from entering the induction system.

Safety Element Service

For Maximum engine
protection and air
cleaner service life,
replace the safety
filter every third
primary filter change
or cleaning, or as
indicated by the
Donaldson Safety
Signal service
indicator. Note that
the safety element is not intended to be cleaned.

Reinstall the Dust Cup

Be sure the dust cup is sealed 360 around the air
cleaner body. Reset the restriction indicator to
green.

Check Connections
Ensure that all connections between the air
cleaner and the engine are tight and leak-free.

Air Filter Service Tips

7 Important Steps to Follow

The Important Dont

Dont remove filter for inspection.

(1) Remove the old element

gently to prevent knocking
dust off of it.

Never rap a filter to

clean it. Rapping only
damages the filter.

2) Always clean
the inside of the
housing carefully

3) Always clean the gasket

sealing surfaces of the
housing

4) Check for uneven dirt

patterns in your old filter
that indicate gasket leakage

5) Press your fresh gasket

to see that it springs back

Never judge the

filters life by looking at it.
Measure how restricted its
airflow is.

Never leave an
air cleaner open
longer than necessary.

Dont ignore a worn or

damaged gasket in the
housing....replace it!

Dont use a damaged or

bunched filter.
6) Make sure the gasket seats
evenly

7) Ensure an
airtight fit on all
connections
and ducts
T

Never use a
warped cover
on a housing.

Never substitute an
incorrect filter model
number.

Brochure No. F114004 (4/96) Replaces 1400-23

For more Information, Contact:

Donaldson
P.O. Box 1299
Minneapolis,
MN 5544-1399 USA
I
Tel: 800-374-1374
FAX: (612) 887-3716

Interleuvenlaan, 1
B-3001 Leuven, Belgium
Tel. (32)-(16)-383811
Telefax: (32)-(16)-400077
Telex: 23205 Beldo B

Printed in the U.S.A.

Copyright 1996
An Equal Opportunity Employer
Donaldson Company Inc. reserves the right to change or discontinue any model or specification at any time and without notice

Open Center
HYDRAULIC
POWER BRAKE
VALVE

MICO Incorporated
1911 Lee Boulevard (Zip Code 56003-2507)
P.O. Box 8118/North Mankato, MN U.S.A. 56002-8118
Phone: (507) 625-6426 Facsimile: (507) 625-3212

Form No. 81-460-047

Revised 10/95

MICO West Division

701 East Francis Street (Zip Code 91761-5514)
P.O. Box 9058/Ontario, CA U.S.A. 91762-9058
Phone: (909) 947-4077 Facsimile: (909) 947-6054

Printed in U.S.A.

TABLE OF CONTENTS
System Schematic...........................................................................................................................Page 2
Representative Performance Data......................................................................................................Page 2
Description and Operation of Power Brake Valve......................................................................Pages 3, 4 & 5
External Dimensional Views...............................................................................................................Page 5
Installation of Power Brake Valve........................................................................................................Page 5
Cross Sectional Views of Three Power Brake Valve Designs.................................................................Page 6
Specification Chart...........................................................................................................................Page 7
Primary Cup Design..................................................................................................................Pages 8 & 9
Teflon Seal Design.................................................................................................................Pages 10 & 11
Sliding Piston Design.............................................................................................................Pages 12 & 13
Service Diagnosis...........................................................................................................................Page 14
Bleeding...............................................................................................................................Pages 14 & 15

SYSTEM SCHEMATIC (TYPICAL)

POWER
STEERING
CYLINDER

BRAKE

FLOWTHRU

RETURN
LINE

MICO
BRAKE
VALVE

RESERVOIR

PRESSURE

FIGURE 1

PERFORMANCE DATA (Typical)

Flow capacity.................................................................................See Specification Chart (page 7)
System pressure..........................................................................................................0 - 2000 psi
Brake line pressure.........................................................................See Specification Chart (page 7)
Master cylinder, capacity......................................................................................................3.1 in.3
Push rod travel with power...........................................................................................0.2 (approx.)
Push rod force with power.................................................... .340 lbs. at 1500 psi brake line pressure
225 lbs. at 250 psi brake line pressure (Model 06-460-652 only)
Push rod travel without power...................................................................................1.844 (approx.)
Push rod force without power..............................................................................1500 lbs. at 725 psi
518 lbs. at 250 psi (Model 06-460-652 only)

NOTE: Brake system rubber parts (Buna-N) must be compatible with mineral based hydraulic oil.

(2)

DESCRIPTION AND OPERATION OF THE MICO OPEN

CENTER HYDRAULIC POWER BRAKE VALVE
The MICO Open Center Brake
Valve will provide hydraulic power
braking when installed in an open
center hydraulic circuit. It can be
used in conjunction with other
hydraulic devices such as power
steering, also installed in the same
circuit. Using a single pump to
provide flow and pressure, the brake
valve should be installed in the
system circuitry, in series, between
the pump relief valve and the other
hydraulic devices. The entire pump
flow is directed thru the brake valve
and is available to actuate the
downstream devices. The brake
valve requires a very small volume
of oil for its operation; therefore, it
does not interfere with the rest of the
circuit, nor does usual actuation of
the downstream hydraulic devices
affect operation of the brake valve .

Full system pressure is always

available for operating the rest of the
system.
The MICO Brake Valve provides
a single-fluid system using the
systems hydraulic oil to operate the
brakes. Synthetic rubber wheelcylinder cups must be used to
prevent swelling.
This valve reduces the braking
effor t to any required degree
depending on pedal ratio. Brake
pedal force is directly proportional to
brake line pressure, thus giving a
sense of feel in the operation of the
brakes. Manual braking is always
available whenever the hydraulic
power system is not functioning.
This is accomplished by a
mechanical follow through within the

brake valve. A longer pedal stroke,

usually with increased pedal effort,
will be expected when braking in this
condition.
The manner in which the hydraulic
power brake valve funtions will be
discussed in the following
paragraphs.
Oil from the pump flows through
the brake valve and on to the
downstream hydraulic unit as
indicated (Figure 3). Sections of the
valve which are communicated to the
return port and the tank when the
valve is not operating are shown
(Figure 2). The compensating port
(Figure 2) provides for thermal
expansion of the oil in the brake lines
and the master cylinder.
The residual valve (Fig. 2), if used,
maintains pressure of 12-20 PSI in
the brake lines when the pedal

Schematic of Brake Valve in Neutral

FIGURE 2
Return Port to Tank

RETURN LINE
PRESSURE

Manual Brake Actuating Sleeve

Compensating Port

BRAKE LINE
PRESSURE
FLOW THRU
PRESSURE

To Brake Pedal

Pressure Regulating Spring

Pressure Regulating Spool Orifice
Residual Valve
Sleeve Guide

Check Valve

Brake Valve Actuated -- Power Steering in Neutral

FIGURE 3

RETURN LINE
PRESSURE

Land B

BRAKE LINE
PRESSURE

Inlet Port From Pump

Land C

Land A

FLOW THRU
PRESSURE

Master Cylinder Piston

CONTROLLED
PRESSURE

To Brake Pedal

Return Line Pressure

Orifice

Flow Thru Port

Reaction Chamber

Master Cylinder

(3)

Hydraulic System Pressure Equal to Brake Line Pressure

RETURN LINE
PRESSURE

Inlet Port From Pump

Land B

BRAKE LINE
PRESSURE

FIGURE 4

Land C
Land A

CONTROLLED
PRESSURE

To Brake Pedal

Return Line Pressure

Orifice

Reaction Chamber
Flow Thru Port

Schematic of Brake Valve in Manual Operation

RETURN LINE
PRESSURE

FIGURE 5

Inlet Port From Pump

BRAKE LINE
PRESSURE

Orifice
Manual Brake Actuating Sleeve

To Brake Pedal

Pressure Regulating Sleeve

Flow Thru Port

is released. In drum brake systems,

this low pressure aids in preventing
air from entering the brakes when
the vehicle is at rest. The residual
valve is removed from models
designed for disc brake systems
because of the drag which would
develop in this type of brake, even
at these relatively low pressures.
When force is applied to the
brake pedal, this force acts through
the PRESSURE REGULATING
SPRING to shift the PRESSURE
REGULATING SPOOL restricting
the flow of oil at LAND C to build
up pressure when there is no
requirement for pressure to the
power steering or other hydraulic
device (Figure 3). As the pressure
builds up, a small amount of oil flows
through the ORIFICE and down
through the passage inside the
spool to the REACTION CHAMBER

(4)

(Figure 3). At the same time, oil

flows along a groove in the outside
diameter of the MANUAL BRAKE
ACTUATING SLEEVE into the
chamber ahead of the MANUAL
BRAKE ACTUATING SLEEVE
(Figure 2). Flow to the area ahead
of
the
MANUAL
BRAKE
ACTUATING SLEEVE moves the
MASTER CYLINDER PISTON,
building up pressure in the MASTER
CYLINDER which, in turn, builds
pressure in the brake lines. Pressure
in the REACTION CHAMBER
moves the SPOOL back a small
amount against the PRESSURE
REGULATING SPRING, and when
the hydraulic pressure balances
against
the
PRESSURE
REGULATING SPRING the
pressure is controlled to the
MASTER CYLINDER.
The
ORIFICE controls the rate of flow to

Check Valve

the REACTION CHAMBER; hence,

the rate of pressure increases and
stability of the pressure regulating
spool is controlled. Therefore,
system efficiency is maintained
since the power brake valve does
not momentarily take all of the fluid
from the pump. When the pedal effort
is released, the spring in the
REACTION CHAMBER returns the
pressure regulating spool to neutral.
This closes LAND B to pressure
and opens LAND A which allows
the oil ahead of the spool in the
REACTION CHAMBER to flow to the
return port as well as the oil ahead
of
the
MANUAL
BRAKE
ACTUATING SLEEVE. The spring
in the MASTER CYLINDER returns
the MASTER CYLINDER PISTON.
In case the downstream power
hydraulic system requires a pressure
that is equal to or greater than

one-half the brake line pressure, the

PRESSURE REGULATING SPOOL
shifts a minute amount and the
pressure is regulated across LAND
A and LAND B (Figure 4).
If the pressure required by the
brake valve is lower than that
required by the power steering, the
power steering will not normally
interfere with the operation of the
brake (Figure 4).
NOTE: Brake line pressure can
exceed preset specifications in the unusual condition of a simultaneous
brake application and sudden elevation of the steering pressure above the
value.
In the standard MICO Open
Center Valve, the pressure in the
REACTION CHAMBER and ahead
of the MASTER CYLINDER PISTON

is equal to one-half of the brake line

pressure. To accomplish this, the
area of the MASTER CYLINDER
PISTON is twice the area of the
MASTER CYLINDER. Therefore,
any pressure that is applied to the
MASTER CYLINDER PISTON will
be multiplied by two to determine the
master cylinder pressure. The
pressure regulating spring can be
factory set to normally limit brake
line pressure regardless of system
pressure.
This valve will act as a manual
brake master cylinder, in the event
of failure in the hydraulic circuit
supplying power to it. The
PRESSURE
REGULATING
SLEEVE contacts the MANUAL
BRAKE ACTUATING SLEEVE
which, in turn, pushes directly on the
master cylinder piston, thereby
building pressure in the MASTER
CYLINDER (Figure 5). This requires
millimeters
inches

64.00
2.52
32.00
1.26

19.05
.75

a longer stroke in the pedal. This

amount of pressure that can be
generated in the brake lines in
manual operation is proportional to
the pedal ratio and the effort which
the operator is able to exert on the
pedal. In most cases, the operator
is not able to build as much pressure
in the brake line as can be done in
power operations. The ports from
the pump are restricted when the
valve is actuated manually; however,
as soon as the engine is started,
hydraulic pressure will push the
MANUAL BRAKE ACTUATING
SLEEVE back against the retaining
ring which contains it and the valve
again functions with power. This is
rather an abrupt action when the
engine is started, causing the brake
pedal to return to its power mode
position, and it is suggested that the
brakes not be applied manually when
starting the engine.

RETURN PORT

50.8
2.07

36.32
1.43
79.37
3.125

BRAKE
PORT
1 - 20 UNF - 28 THD.
2 13
DEEP
16

3 DIA.THRU
8 (3) HOLES

NOTE: Dimensions will vary

slightly between units
and are to be used for
reference purposes only.

38.10
1.50

FLOW
THRU
PORT

61.91
2.43

86.86
3.42
43.43
1.71

136.12
5.35

FIGURE 6

22.22
.875

PRESSURE PORT
369.87
14.56

INSTALLATION INSTRUCTIONS
1. Mount MICO Open Center Power
Brake Valve on vehicle and
complete push rod and pedal hookup. NOTE: It is important that the
system reservoir be mounted above
the brake valve, or that the return
line have a vertical section of one
foot directly above the valve.
2. The pedal assembly must have its
own return spring. DO NOT rely on

the internal spring in the valve for

this function.
3. Pedal should be adjusted to allow
1/32 clearance between pressure
regulating rod and actuator.
4. Bleed system (see bleeding
instruction on page 14).
5. Be sure all hydraulic fittings are tight
and visually check system for leaks
with power applied.

(5)

THREE OPEN CENTER HYDRAULIC POWER BRAKE VALVE DESIGNS

PRIMARY CUP DESIGN
The Primary Cup Design uses a
residual valve. This valve will maintain a
pressure of 12 - 20 PSI in the brake lines
when the pedal is released. When used in
drum brake systems this low pressure aids
in preventing air from entering the brakes
when the vehicle is at rest.

RING SEAL DESIGN

The Ring Seal Design is used mainly
in disc brake systems. The residual valve
is removed from models designed for disc
brake systems because of the pressure
they maintain in the brake lines when the
pedal is released. Even these relatively
low pressures (12 - 20 PSI) would develop
drag in this type of brake.

Residual Valve

FIGURE 7

Primary Cup

Ring Seal & O-Ring

FIGURE 8

SLIDING PISTON DESIGN

The Sliding Piston Design was created
with a specific function in mind. A
specially designed piston slides inside the
primary piston when the brake pedal is
actuated. If primary piston strokes too far,
the brake pedal will be pulled down with a
short abrupt stroke. This indicates to the
operator that maintenance is required.

Check Valve

Sliding Piston

(6)

FIGURE 9

SPECIFICATIONS CHART
Brake
Port

Pressure
Port

Flow Thru
Port

Return
Port

Brake
Line Pressure
(with power)

Flow
Capacity

* 06-460-520
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-658

SAE No. 10

1/2-14 NPTF

1850 psi 50 psi

3-24 gpm

06-460-522
9/16-18 UNF
SAE No. 10
1/2-20 UNF
* 06-460-550
SAE No. 10
Complete unit replaced by 06-460-656
* 06-460-560
1/2-20 UNF
SAE No. 8
Complete unit replaced by 06-460-656
9/16-18 UNF
* 06-460-570
SAE No. 8
Complete unit replaced by 06-460-662
* 06-460-580
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-656
* 06-460-588
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-664

SAE No. 10
SAE No. 10

SAE No. 10
1/2-14 NPTF

1850 psi 50 psi

1500 psi 50 psi

3-24 gpm
3-24 gpm

SAE No. 8

SAE No. 10

1550 psi 50 psi

3-24 gpm

SAE No. 8

SAE No. 10

1550 psi 50 psi

3-24 gpm

SAE No. 10

SAE No. 10

1500 psi 50 psi

3-24 gpm

SAE No. 10

SAE No. 10

1550 psi 50 psi

3-24 gpm

* 06-460-610
9/16-18 UNF
SAE No. 10
Complete unit replaced by 06-460-666
* 06-460-620
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-656
1/2-20 UNF
06-460-642
SAE No. 10
* 06-460-650
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-656
* 06-460-654
9/16-18 UNF
SAE No. 8
Complete unit replaced by 06-460-676
* 06-460-656
SAE No. 10
1/2-20 UNF
1/2-20 UNF
SAE No. 10
* 06-460-658
1/2-20 UNF
* 06-460-660
SAE No. 10
* 06-460-662
9/16-18 UNF
SAE No. 10
* 06-460-664
SAE No. 10
1/2-20 UNF
SAE No. 10
* 06-460-666
9/16-18 UNF
06-460-668
1/2-20 UNF
SAE No. 10
* 06-460-670
SAE No. 10
1/2-20 UNF
06-460-672
SAE No. 10
1/2-20 UNF
* 06-460-674
SAE No. 10
1/2-20 UNF
9/16-18 UNF
SAE No. 10
06-460-676
SAE No. 10
1/2-20 UNF
06-460-678
* 06-460-680
1/2-20 UNF
SAE No. 8
Complete unit replaced by 06-460-670
06-460-682
SAE No. 8
1/2-20 UNF
Complete unit replaced by 06-460-672
1/2-20 UNF
06-460-684
SAE No. 10
* 06-460-686
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-460-674
06-461-520
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-461-658
06-461-550
1/2-20 UNF
SAE No. 10
Complete unit replaced by 06-461-656
06-461-610
9/16-18 UNF
SAE No. 10
Complete unit replaced by 06-461-666
06-461-656
SAE No. 10
1/2-20 UNF
1/2-20 UNF
06-461-658
SAE No. 10
06-461-660
SAE No. 10
1/2-20 UNF
06-461-666
9/16-18 UNF
SAE No. 10
06-461-674
SAE No. 10
1/2-20 UNF

SAE No. 10

1/2-14 NPTF

950 psi 50 psi

3-24 gpm

SAE No. 10

SAE No. 10

1500 psi 50 psi

3-24 gpm

SAE No. 10
SAE No. 10

SAE No. 10
1/2-14 NPTF

1550 psi 50 psi

1500 psi 50 psi

3-24 gpm
3-24 gpm

SAE No. 8

SAE No. 10

1500 psi 50 psi

3-12 gpm

SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 8

SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10

1500 psi 50 psi

1850 psi 50 psi
1150 psi 50 psi
1550 psi 50 psi
1500 psi 50 psi
950 psi 50 psi
1000 psi 50 psi
1550 psi 50 psi
750 psi 50 psi
1500 psi 50 psi
1500 psi 50 psi
1700 psi 50 psi
1550 psi 50 psi

3-24 gpm
3-24 gpm
3-24 gpm
3-24 gpm
3-12 gpm
3-24 gpm
3-12 gpm
3-8 gpm
3-24 gpm
3-12 gpm
3-12 gpm
3-24 gpm
3-8 gpm

SAE No. 8

SAE No. 10

750 psi 50 psi

3-24 gpm

SAE No. 10
SAE No. 10

SAE No. 10
1/2-14 NPTF

1100 psi 50 psi

1500 psi 50 psi

3-12 gpm
3-12 gpm

SAE No. 10

1/2-14 NPTF

1850 psi 50 psi

3-24 gpm

SAE No. 10

1/2-14 NPTF

1500 psi 50 psi

3-24 gpm

SAE No. 10

1/2-14 NPTF

950 psi 50 psi

3-24 gpm

SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10

SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10
SAE No. 10

1500 psi 50 psi

1850 psi 50 psi
1150 psi 50 psi
950 psi 50 psi
1500 psi 50 psi

3-24
3-24
3-24
3-24
3-12

Part
Number

gpm
gpm
gpm
gpm
gpm

For use with drum brakes (has residual check valve)

NOTE: The valves should be used within the flow capacities indicated above for optimum performance. Valves are functional
at lower flows but response is reduced. At the higher flow operation higher pressure drops are seen.

(7)

OPEN CENTER HYDRAULIC BRAKE VALVE

PRIMARY CUP DESIGN
(Refer to Figure 10)
Disassembly
1. Remove boot (item 1) and
pressure regulating spring
assembly (item 2).
CAUTION: Pressure regulating
spring assembly has
been set at the factory and should
never be disassembled, re-adjusted
or interchanged with
another valve.
2. Separate end cap (item 21) from
housing (item 11).
CAUTION: Care must be taken
as end cap is under
tension of spring
(item 19).
Remove gasket (item 14).
3. Remove primary cup (item 17),
retainer (item 18), spring (item 19)
and residual valve (item 20) from
end cap (item 21).
4. Remove cap screw (item 13)
from under side of housing (item
11). Remove o-ring (item 12)
from cap screw.
5. Remove retaining ring (item 8)
from housing (item 11).
6. Remove sleeve (item 10) by
pulling on push rod (item 4).
Remove cup (item 9) from
sleeve.
7. Remove piston (item 16) from
housing (item 11). Remove piston
ring (item 15) from piston.
8. Remove retaining ring (item 3)
carefully with a small flat tool. Do
not scratch bore of sleeve (item
10).
9. Remove push rod (item 4), spool
(item 6) and spring (item 7) from
sleeve (item 10). Remove cup
(item 5) from spool (item 6).
Inspection
Clean and inspect all component
parts for scratches, cracks or wear.
Replace any par ts that are
excessively worn or damaged.
CAUTION: If spool (item 6), sleeve

(8)

on end of spring (item 19).

(item 10) or bore of
housing (item 11) 10. Assemble end cap (item 21) with
its components to housing (item
are in any way dam11) making sure lip on primary
aged, scratched or
cup (item 17) has properly
broken, the entire
engaged bore of housing.
assembly must be
replaced. These 11. Install lock washer (items 22) and
bolts (items 23). Torque 16 to 18
parts are select-fitted
ft. lbs.
and are not interchangeable or re- 12. Install pressure regulating spring
assembly (item 2) on push rod
placeable with ser(item 4). Install new boot (item 1).
vice items.
Assembly
1. Install new cup (item 9) on sleeve
(item 10) and new cup (item 5) on
spool (item 6).

SEE BLEEDING SECTION FOR

COMPLETE BLEEDING
INSTRUCTIONS

CAUTION: Lips on cups (items

5 & 9) should be
away from ends of
spool (item 6) and
sleeve (item 10).
2. Place spring (item 7) in sleeve
(item 10).
3. Install spool (item 6) in sleeve
(item 10). Note direction of spool.
4. Install push rod (item 4) in sleeve
(item 10) and secure it with new
retaining ring (item 3).
5. Install new o-ring (item 12) on cap
screw (item 13) and install in
housing (item 11).
6. Carefully install sleeve (item 10)
into housing (item 11).
CAUTION: Make sure that
groove on sleeve
will engage cap
screw (item 13).
Install retaining ring (item 8).
7. Install new piston ring (item 15)
on piston (item 16) and install in
housing (item 11).
8. Place new residual valve (item
20), spring (item 19) and retainer
(item 18) in end cap (item 21).
CAUTION: Residual valve must
be checked for
proper seating in
end cap.
9. Place new gasket (item 14) on
mounting face of end cap (item
21) and new primary cup (item 17)

PARTS LIST

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

DESCRIPTION

BOOT
PRESSURE REGULATING
SPRING ASSEMBLY
RETAINING RING
PUSH ROD
CUP
SPOOL
SPRING
RETAINING RING
CUP
SLEEVE
HOUSING
O-RING
CAP SCREW
GASKET
PISTON RING
PISTON
PRIMARY CUP
RETAINER
SPRING
RESIDUAL VALVE
END CAP
LOCKWASHERS
BOLTS

Items included in Repair

Kit 06-459-002

FIGURE 10

Model
Number

Repair
Kit

06-460-520
06-460-522
06-460-550
06-460-560
06-460-570
06-460-580
06-460-588
06-460-610
06-460-620
06-460-650
06-460-680
06-460-686

06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002
06-459-002

(9)

OPEN CENTER HYDRAULIC BRAKE VALVE

RING SEAL DESIGN
(Refer to Figure 11)
Disassembly
1. Remove boot (item 1) and
pressure regulating spring
assembly (item 2).
CAUTION: Pressure regulating
spring assembly has
been set at the factory and should
never be disassembled.
2. Separate end cap (item 21) from
housing (item 11).
CAUTION: Care must be taken
as end cap is under
tension of spring
(item 20).
Remove gasket (item 14).
3. Remove piston & poppet
assembly (item 17) and spring
(item 20) from end cap (item 22).
CAUTION: If you have model
06-460-566, you will
also have to remove
residual valve (item
21).
4. Remove cap screw (item 13) from
under side of housing (item 11).
Remove o-ring (item 12) from cap
screw.
5. Remove retaining ring (item 8)
from housing (item 11).
6. Remove sleeve (item 10) by pulling
on push rod (item 4). Remove cup
(item 9) from sleeve.
7. Remove piston (item 16) from
housing (item 11). Remove piston
ring (item 15) from piston.
8. Remove retaining ring (item 3)
carefully with a small flat tool. Do
not scratch bore of sleeve (item
10).
9. Remove push rod (item 4), spool
(item 6) and spring (item 7) from
sleeve (item 10). Remove cup
(item 5) from spool (item 6).
Inspection
Clean and inspect all component
parts for scratches, cracks or wear.
Replace any par ts that are
excessively worn or damaged.

(10)

CAUTION: If spool (item 6), sleeve

(item 10) or bore of
housing (item 11) are in
any way damaged,
scratched or broken,
the entire assembly
must be replaced.
These parts are selectfitted and are not
interchangeable or
replaceable
with
service items.
Assembly
1. Install new cup (item 9) on sleeve
(item 10) and new cup (item 5) on
spool (item 6).
CAUTION: Lips on cups (items
5 & 9) should be
away from ends of
spool (item 6) and
sleeve (item 10).
2. Place spring (item 7) in sleeve
(item 10).
3. Install spool (item 6) in sleeve
(item 10). Note direction of spool.
4. Install push rod (item 4) in sleeve
(item 10) and secure it with
retaining ring (item 3).
5. Install new o-ring (item 12) on cap
screw (item 13) and install in
housing (item 11).
6. Carefully install sleeve (item 10)
into housing (item 11).
CAUTION: Make sure that
groove on sleeve
will engage cap
screw (item 13)
Install retaining ring (item 8).
7. Install piston ring (item 15) on
piston (item 16) and install in
housing (item 11).
8. Install new o-ring (item 18) and
new ring seal (item 19) on new
piston & poppet assembly (item
17).
9. Install spring (item 20) and piston
& poppet assembly (item 17) in
end cap (item 22).
NOTE: If you have model 06-460566, you will have to install
new residual valve (item
21). You must also check

residual valve for proper

seating in end cap.
CAUTION: Extreme care must be
taken so as not to
scratch teflon seal
(item
19)
when
installing piston &
poppet assembly (item
17) in end cap (item 22).
10. Place new gasket (item 14) on
mounting face of end cap (item
22) and assemble, with its
components, to housing (item 11).
11. Install lock washers (item 23) and
bolts (item 24). Torque 16 to 18
ft. lbs.
12. Install pressure regulating spring
assembly (item 2) on push rod
(item 4). Install new boot (item 1).
SEE BLEEDING SECTION FOR
COMPLETE BLEEDING
INSTRUCTIONS
PARTS LIST
ITEM

DESCRIPTION

1 * BOOT
2
PRESSURE REGULATING
SPRING ASSEMBLY
3
RETAINING RING
4
PUSH ROD
5 * CUP
6
SPOOL
7
SPRING
8
RETAINING RING
9 * CUP
10
SLEEVE
11
HOUSING
12 * O-RING
13
CAP SCREW
14 * GASKET
15 * PISTON RING
16
PISTON
17 * PISTON & POPPET
ASSEMBLY
18 * O-RING
19 * RING SEAL
20
SPRING
21 * RESIDUAL VALVE
END CAP
22
LOCKWASHERS
23
BOLTS
24

Items included in Repair

Kit 06-459-010
Items included in Repair
Kit 06-459-020

FIGURE 11

NOTE: Residual Valve (item 21) is only found in

Model 06-460-566.

Model
Number

Repair
Kit

06-460-654
06-460-656
06-460-658
06-460-660
06-460-662
06-460-664
06-460-666
06-460-668
06-460-670
06-460-672
06-460-674
06-460-676
06-460-678
06-460-682

06-459-010
06-459-020
06-459-020
06-459-020
06-459-020
06-459-020
06-459-020
06-459-010
06-459-020
06-459-010
06-459-020
06-459-010
06-459-020
06-459-010

(11)

OPEN CENTER HYDRAULIC BRAKE VALVE

SLIDING PISTON DESIGN
(Refer to Figure 12)
Disassembly
1. Remove boot (item 1) and
pressure regulating spring
assembly (item 2).
CAUTION: Pressure regulating
spring assembly has
been set at the factory and should
never be disassembled.
2. Separate end cap (item 20) from
housing (item 3).
CAUTION: Care must be taken
as end cap is under
tension of spring
(item 18).
3.

4.

5.

6.

7.

Remove gasket (item 6).

Remove piston & poppet
assembly (item 15), spring (item
18) and residual valve (item 19)
from end cap (item 20).
Remove cap screw (item 5) from
under side of housing (item 3).
Remove o-ring (item 4) from cap
screw.
Remove sleeve & piston
assembly (item 14) from housing
(item 3). Remove cup (item 12)
and piston ring (item 13) from
sleeve & piston assembly (item
14).
Remove retaining ring (item 7)
carefully with a small flat tool. Do
not scratch bore of sleeve & piston
assembly (item 14).
Remove push rod (item 8), spool
(item 10) and spring (item 11) from
sleeve & piston assembly (item
14). Remove cup (item 9) from
spool (item 10).

Inspection
Clean and inspect all component
parts for scratches, cracks or wear.
Replace any par ts that are
excessively worn or damaged.
CAUTION:

(12)

If spool (item 10),

sleeve (item 14) or
bore of housing (item
3) are in any way
damaged, scratched

or broken, the entire

assembly must be
replaced. These parts
are select-fitted and are
not interchangeable or
replaceable
with
service items.
Assembly
1. Install new cup (item 12) and new
piston ring (item 13) on sleeve &
piston assembly (item 14).
CAUTION: Lips on cup (item
12) should be away
from end of sleeve
(item 14).
2. Install new cup (item 9) on spool
(item 10).
CAUTION: Lips on cup (item 9)
should be away from
end of spool (item
10).
3. Insert spool (item 10) and push
rod (item 8) into sleeve & piston
assembly (item 14). Secure with
retaining ring (item 7).
4. Carefully install sleeve & piston
assembly (item 14) into housing
(item 3).
CAUTION: Make sure that
groove on sleeve
will engage screw
(item 5).
5. Install new o-ring (item 4) on cap
screw (item 5) and install in
housing (item 3).
6. Install new o-ring (item 16) and
new ring seal (item 17) on new
piston & poppet assembly (item
15).
7. Place residual valve (item 19),
spring (item 18) and piston &
poppet assembly (item 15) in end
cap (item 20).
NOTE: Residual valve must be
checked for proper
seating in end cap.

CAUTION: Extreme care must be

taken so as not to
scratch ring seal (item
17) when installing
piston & poppet
assembly (item 15) in
end cap (item 20).
8. Place new gasket (item 6) on
mounting face of end cap (item
20) and assembly, with its
components, to housing (item 3).
9. Install lock washers (items 21)
and bolts (items 22). Torque 16
to 18 ft. lbs.
10.Install pressure regulating spring
assembly (item 2) on push rod
(item 8). Install new boot (item 1).
SEE BLEEDING SECTION FOR
COMPLETE BLEEDING
INSTRUCTIONS
PARTS LIST

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

DESCRIPTION

BOOT
PRESSURE REGULATING
SPRING ASSEMBLY
HOUSING
O-RING
CAP SCREW
GASKET
RETAINING RING
PUSH ROD
CUP
SPOOL
SPRING
CUP
PISTON RING
SLEEVE & PISTON
ASSEMBLY
PISTON & POPPET
ASSEMBLY
O-RING
RING SEAL
SPRING
RESIDUAL VALVE
END CAP
LOCKWASHERS
BOLTS

Items included in Repair

Kit 06-459-020

FIGURE 12

Model
Number
06-460-642
06-460-684

Repair
Kit
06-459-020
06-459-020

(13)

GENERAL SERVICE DIAGNOSIS

With Engine Off -PEDAL GOES TO FLOOR
1. Brake not adjusted
1. Check adjustment
2. Air in system
2. Bleed brakes
3. Inoperative brakes
3. Check brakes
4. Blown hydraulic line
4. Check brake line
5. Worn out primary cup
5. Check by making sure brakes
are properly adjusted, in good
operating condition, and
system well bled. If pedal
continues to go to the floor,
service brake valve.
SPONGY PEDAL
1. Air in system
1. Bleed brakes
PEDAL IS FIRM BUT STOPS TOO
NEAR FLOOR
1. Brakes out of adjustment
1. Adjust brakes

BLEEDING
The MICO Open Center Power Brake
Valve and remaining brake system
are sometimes difficult to bleed. The
difficulty arises when the hydraulic
oil used does not flow easily through
lines and small holes by means of
gravity. Generally, to effectively
remove air, oil must be forced into
the brake valve master cylinder
cavity and the rest of the system.

2. Inoperative brakes
2. Check for wear

3. Brakes not adjusted

3. Check adjustment

3. Displacement problem
3. Wheel cylinders too large for
valve to handle properly.
Consider alternate braking
valve.

4. Air in system
4. Bleed system

PEDAL IS FIRM BUT BRAKING IS

INADEQUATE TO STOP VEHICLE
IN EVENT OF ENGINE FAILURE
1. Pedal ratio too small
1. Increase pedal ratio
2. Brakes inoperative
2. Check brakes for wear or oily
brakes

NO POWER STEERING OR OTHER

DOWNSTREAM
HYDRAULIC
ACTION AT ANY TIME
1. Hydraulic lines crossed
1. Recheck circuit
2. No hydraulic action at any time
2. Check and fill reservoir. Check
relief valve setting on pump.
Check for proper rotation at
pump, vee belt, sheared keys,
etc.

With Engine Running -PEDAL GOES DOWN PART WAY

THEN BOUNCES BACK
1. Insufficient flow from pump
1. Check and fill reservoir
2. Small volume from pump at idle
2. Crack throttle and recheck

CAUTION: Make sure the

machine is in a safe
and controlled state
before attempting
any
servicing
including bleeding
the brake system.
Manual and pressure bleeding are
two methods of bleeding a brake
system. MICO recommends using

NO OR SLOW POWER STEERING

WITH BRAKES APPLIED
1. Recheck relief valve on pump for
proper setting
2. Check and fill reservoir
3. Check and tighten pump belt if
necessary

one of these two methods of

bleeding the Open Center Power
Brake Valve and the rest of the brake
system.
CAUTION: Be sure brake valve
is installed properly
and brakes adjusted
correctly before
beginning bleeding
procedures.

MANUAL BLEEDING
PROCEDURES
1. Start engine and allow enough
time to pass for the system to
become filled and thoroughly
flushed with oil.
2. With engine still running, one
person can stroke the brake pedal
while another person opens and
closes the brake bleeder screws.
3. Only on the down stroke of the
brake pedal, open bleeder screw

(14)

on the brake closest to brake

valve first. When all flow stops
from bleeder, close it and allow
pedal to return to rest.
4. Wait at least 30 seconds and
repeat the process until all air has
been expelled from that brake.
Then go on to the next closest
brake bleeder and repeat process
until all brakes have been bled.

5. Stop engine and depress brake

pedal. Pedal should be hard, not
spongy, and fairly high. If pedal
is too spongy and/or travels too
far, repeat bleeding process.
6. It is a characteristic of the brake
valve to kick the pedal back when
actuated if system is not bled with
engine running.

PRESSURE BLEEDING
PROCEDURE
1. Refer to Figure 13. Install a small
BLEEDER BY-PASS LINE as
shown. A 1/4 size line or hose is
sufficient.
2. Start engine and allow enough
time to pass for the system to
become filled and thoroughly
flushed with oil.
3. It is necessary to develop between
50-200 PSI at the inlet to brake
valve. A method to throttle the oil
will be needed if the system does
not already have a secondary
hydraulic device downstream from
the brake valve.
THIS
PRESSURE SHOULD BE HELD
THROUGHOUT THE BLEEDING
PROCESS AND SHOULD NOT
EXCEED 250 PSI.

4. DO NOT STEP ON THE BRAKE

PEDAL
DURING
THIS
BLEEDING PROCESS.
5. Oil will now be forced directly into
the brake line by the pump and fill
the brake valve master cylinder
cavity. This may take a minute or
two.
6. Continue to hold the bleed
pressure while bleeding each brake
starting with the line and brake
closest to the brake valve.
7. Allow a sufficient amount of fluid
to pass at brake bleeder screw to
insure all air is removed from each
bleeder point.
8. Continue this method until all
brakes and lines are bled.
9. When all brakes are bled and

fittings tight, release the 50-200

PSI pressure and SHUT OFF
ENGINE.
10. Remove the bleeder by-pass line
and plug the connections. Be sure
not to lose fluid or ingest air at the
brake line connection when
removing bleeder by-pass line.
11. With engine off, step on brake
pedal. It should be fairly high and
hard. If a spongy pedal is felt, the
system still contains air. If pedal
strokes downward too far, check
and readjust brakes and repeat
bleeding process.
12. When the pedal is satisfactory,
restart engine and actuate brake
pedal several times. Now check
for leaks.

FIGURE 13

BLEEDER
BY-PASS LINE
(Remove after Bleeding)

RETURN
LINE

BRAKES

FLOW-THRU

DOWNSTREAM SECONDARY
HYDRAULIC DEVICE SUCH
AS POWER STEERING

PRESSURE

BLEEDING SCHEMATIC

(15)

MICO has made every attempt to present accurate information in catalogs, brochures and
other printed material. MICO can accept no responsibility for errors from unitentional oversights
that may exist. Due to a continuous program of product improvement, both materials and
specifications are subject to change without notice or obligation.