JLG 1732 Supplemental Repair Manual
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JLG 1732 Supplemental Repair Manual

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Drive Axle
Supplemental Repair Manual
Models
943, 1043, 1055,
1255, G9-43A,
G10-43A, 1644,
1732, 7013H,
8010H,
10042 & 10054
JLG - 31200239
Component Manufacturer
ASM-0029E
Revised
March 5, 2019 - Rev I
An Oshkosh Corporation Company

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  • Page 1 Drive Axle Supplemental Repair Manual Models 943, 1043, 1055, 1255, G9-43A, G10-43A, 1644, 1732, 7013H, 8010H, 10042 & 10054 JLG - 31200239 Component Manufacturer ASM-0029E Revised March 5, 2019 - Rev I An Oshkosh Corporation Company...
  • Page 2 DISCLAIMER: Information provided within is supplied directly from the component manufacturer. The information has not been altered in any way and is the sole property of the component manufacturer. Due to continuous improvements, the component manufacturer reserves the right to make changes without prior notification.

  • Page 3: Effectivity Page

    EFFECTIVITY PAGE DATE REVISION DESCRIPTION November 6, 2007 Original Issue Of Manual May 15, 2012 Revision October 16, 2013 Revision February 26, 2014 Revision May 6, 2015 Revision November 17, 2016 Revision July 27, 2018 Revision October 10, 2018 Revision March 5, 2019 Revision...
  • Page 5 Axle 223 ASM-0029E May 2018...
  • Page 6 CONTENTS DISCLAIMER The official language chosen by the Product manufacturer is English. No liability is assumed as a result of translations in other languages not in compliance with the original meaning. In case of conflicting language versions of this document, the English original prevails.

  • Page 7: Table Of Contents

    CONTENTS INTRODUCTION ..........................5 VERSION TRACKING ........................... 6 MANUAL APPLICABILITY AND SUPPORTED MODELS ................6 SPECIFICATIONS ..........................7 DEFINITION OF VIEWPOINTS ........................7 DATA PLATE ..............................7 CONVERSION TABLES ..........................8 UNITS OF PRESSURE ..........................8 UNIT OF WEIGHT ............................ 8 UNITS OF TORQUE ..........................
  • Page 8 U-JOINT ............................. 53 EXPLODED VIEW ............................53 DISASSEMBLY ............................. 54 ASSEMBLY ..............................56 SPECIAL TOOLS ............................58 T1 ................................58 T2 ................................58 BRAKE WEAR CHECK PROCEDURE ....................59 OLD VERSION ............................59 NEW VERSION ............................60 SPECIAL TOOLS ............................61 T1 ................................

  • Page 9: Introduction

    INTRODUCTION The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient re- pair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a com- plete overhaul of the unit.

  • Page 10: Version Tracking

    VERSION TRACKING VERSION TRACKING FILE NAME REVISION DATE CHANGES DESCRIPTION MO223S10 10/02/2003 Document issued ASM_0029_ENG_13092013 13/09/2013 Updated layout Added: - DISCLAIMER p. 2 - VERSION TRACKING p. 6 - MANUAL APPLICABILITY AND SUPPORTED MODELS p. 6 ASM-0029E_Rev.02 CE 223 23/01/2018 Changes: - “DANA HOLDING CORPORATION”...

  • Page 11: Specifications

    SPECIFICATIONS DEFINITION OF VIEWPOINTS DATA PLATE MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY Type and model unit - modification index Serial number Lubricant ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 12: Conversion Tables

    CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE 14,4 14,4 0,00001 0,00001 UNIT OF WEIGHT 0,001 0,102 0,225 1daN 0,01 1,02 2,25 1000 9,81 0,981 0,00981 2,205 UNITS OF TORQUE N·m daN·m kN·m kg·m lb·in 1N·m 0,001 0,102 8,854 1daN·m 0,01 1,02 88,54 1kN·m...

  • Page 13: Torque Specifications

    TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270 M6 x 1 mm 9,5 - 10,5 N·m 10,5 - 11,5 N·m 14,3 - 15,7 N·m 15,2 - 16,8 N·m 16,2 - 17,8 N·m 18,1 - 20 N·m...

  • Page 14: Wheel Nut Tightening Torques

    WHEEL NUT TIGHTENING TORQUES WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material. WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY ST 37 **ST 52 WHEEL NUTS WITH...

  • Page 15: Maintenance

    MAINTENANCE MAINTENANCE POINTS Oil filling plug Oil draining plug Check level plug Check brake disc wear Minimum thickness between counter discs is 5.2 mm. NOTE: For details see BRAKE WEAR CHECK PROCEDURE p. 59. ONLY FOR HEAVY DUTY Oil filling plug Grease zerk ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 16: Oil Draining Mandatory Procedure

    OIL DRAINING MANDATORY PROCEDURE OIL DRAINING MANDATORY PROCEDURE WARNING • Do not attempt any maintenance if the axle is hot (40-50°C / 104-122°F). Hot oil and components can cause personal in- jury. Avoid skin contact. Wear protective gloves and glasses. •...

  • Page 17: End-Stop Plier Setting

    END-STOP PLIER SETTING END-STOP PLIER SETTING FOR EXTERNAL RETAINING SNAP RING FOR INTERNAL RETAINING SNAP RING Measure the bore diameter of circlip (or snapring) "d1"; Measure the shaft diameter of circlip (or snapring) "d1"; Pre-set the caliber at value "Dmin" ("Dmin"= "d1" x 0,99); Pre-set the caliber at value "Dmax"...

  • Page 18: Maintenance Intervals

    MAINTENANCE INTERVALS MAINTENANCE INTERVALS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 19: Lubricant & Sealant Specifications

    LUBRICANT & SEALANT SPECIFICATIONS LUBRICANT & SEALANT SPECIFICATIONS 1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor. 2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar products marketed by different brand names with different trade marks.
  • Page 20 LUBRICANT & SEALANT SPECIFICATIONS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 21: Safety Precautions

    SAFETY PRECAUTIONS During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts mentioned should rest on supporting benches. When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm. When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po- sitioned and that the machine is locked lengthways.
  • Page 22 LUBRICANT & SEALANT SPECIFICATIONS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 23: Trunnion

    TRUNNION EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 24: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 3: Remove the snap ring (3). FIGURE 1: Remove the grease zerk (1). WARNING Removal of the snap rings can cause personal injuries. You must wear appropriate safety equipment. To avoid injury to eyes, wear eye protection equipment. FIGURE 2: Remove the seal ring (2).

  • Page 25: Assembly

    ASSEMBLY ASSEMBLY FIGURE 8: If removed, install the grease zerk (1). Torque wrench setting: 10 - 15 N·m. FIGURE 5: Install the bushing (4) in the swinging support. FIGURE 6: Install the snap ring (3). WARNING Personal injury can result when installing snap ring. The ap- propriate safety equipment must be worn.
  • Page 26 ASSEMBLY Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 27: Planetary Reduction Gear

    PLANETARY REDUCTION GEAR EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 28: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 4: ONLY FOR HEAVY DUTY Remove the complete planetary cover (2). NOTE: Heavy duty version is equipped with 4 planetary wheel ge- ars.
  • Page 29 DISASSEMBLY FIGURE 6: Using a puller, remove the planetary gears (10). FIGURE 9: Remove the complete ring gear flange (5) by using a puller and applying counter pressure to the studs. NOTE: Write down direction of installation of planetary gears. FIGURE 10: Remove the ring gear (13) snap ring (12).
  • Page 30 DISASSEMBLY FIGURE 12: Partially extract the wheel hub (7) by using a pla- FIGURE 15: Remove seal ring (15) from wheel hub (7). stic hammer. NOTE: NOTE: Mark the seal ring position. Hammer alternately on several equidistant points. FIGURE 16: Remove inner bearing (16). FIGURE 13: Remove the external bearing (8).
  • Page 31 DISASSEMBLY FIGURE 18: Take out the pins and remove the steering knuc- kle (3). For pin removal details, see COMPLETE STEERING KNUC- KLE p. 37. 7 17 FIGURE 19: Using a puller, remove seal ring (17) from stee- ring knuckle (3). NOTE: Write down seal ring orientation.

  • Page 32: Assembly

    ASSEMBLY ASSEMBLY Tecnolube 101 Loctite 270 FIGURE 24: Only if studs have been removed. Apply a coat of Loctite 270 to the fast end of studs (19) and apply Tecno- lube 101 to ground nut end; tighten studs (19) as far as they will go.
  • Page 33 ASSEMBLY FIGURE 27: Position tool T5 (See drawing T5 p. 36) and press FIGURE 30: Install the outer bearing (8). the seal ring (15) into its seat. NOTE: Push the bearing as far as it will go by tapping with a pla- stic hammer all around the rim.
  • Page 34 ASSEMBLY FIGURE 32: Install the complete ring gear flange (5). FIGURE 34: NORMAL NUTS MODELS: Install the new nuts (4) and tighten them in short time limited, using the criss-cross method applying initial tightening tor- NOTE: que of 100 N·m. To engage the flange (5), use a plastic hammer and ham- Pay attention to clean the thread of the original stud.
  • Page 35 ASSEMBLY FIGURE 35: FLANGED NUTS MODELS: FIGURE 37: Lock gears (10) into position by installing the Install the new nuts (4) and tighten them, using the criss-cross snap rings (9). method applying initial tightening torque of 100 N·m. Ensure the snap ring (9) is in its seat. Pay attention to clean the thread of the original stud.
  • Page 36 ASSEMBLY FIGURE 39: Fit the planetary cover (2) on the wheel hub (7). CAUTION Check state and position of o-ring (11). FIGURE 40: Lock the planetary cover (2) with screws (1). Tightening torque for screws: 40 - 50 N·m. Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 37: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS 2364 P/N: x45° 3348 P/N: 0. 8 3 x15° 1. 5 3 x15° -- 0. 2 ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 38 SPECIAL TOOLS P/N: 2365 3x15 ° 3x15 ° 3. 5 -- 0, 2 D1240330 Dana Incorporated ASM-0029E - 223 Axle Service Manual...
  • Page 39 SPECIAL TOOLS P/N: 3265 Ø184 Ø4 0 Ø3 5 12. 5 20° -- 0. 1 Ø5 0 -- 0. 3 Ø178 27. 5 20° Ø4 5 0. 8 0. 8 Ø50 H7 Ø60 H7-p 6 Ø165 Ø184 ± 0.03 Ø200 ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 40 SPECIAL TOOLS P/N: 2366 Ø180 Ø4 0 0. 8 Ø140 + 0. 1 Ø154 -- 0. 2 Ø178 Ø189 Ø205 2378 P/N: x15 ° x45 ° 10 15 Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 41: Complete Steering Knuckle

    COMPLETE STEERING KNUCKLE EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 42: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 3: Using two levers, remove the top knuckle post (4) complete with front seal (9) and shims (3). Pay attention not to damage the surfaces. FIGURE 1: Loosen and remove the capscrews (15, 8) from the knuckle post (19, 4).

  • Page 43: Assembly

    ASSEMBLY ASSEMBLY upper articulation pin FIGURE 7: Fit a new seal (3) onto the top knuckle post (4). Lu- bricate and install the unit in the steering knuckle. Position the screws (8) and tighten to 140 N·m. FIGURE 5: Lubricate the terminal of the u-joint and install the Check the correct assembly side of the seal (3).
  • Page 44 ASSEMBLY FIGURE 10: Tighten the new capscrews (15) of the top and bottom knuckle posts in sequence using the criss-cross me- thod. Torque wrench setting: 140 N·m CAUTION Use only new screws pre-treated with Driloc locking adhe- sive. Threads must be cleaned from oil. Degrease only non pre-treated threads.

  • Page 45: Steering Cylinder

    STEERING CYLINDER EXPLODED VIEW 12 A 12 A ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 46: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 3: Using a puller, disconnect the tapered pins of the joints (3) from the steering knuckles (5). FIGURE 1: If required, remove the steering piston stroke cen- tering sensor (1).
  • Page 47 DISASSEMBLY FIGURE 6: Loosen and remove the steering cylinder (8) FIGURE 9: Lightly tap the cylinder head (2) with a plastic screws (7). hammer to push it inside the cylinder (3). NOTE: Insert the cylinder head so it is flush with the cylinder. FIGURE 7: Extract the steering cylinder (8) using a plastic hammer.
  • Page 48 DISASSEMBLY FIGURE 12: Take the cylinder unit (3) apart by extracting the head (2) first, followed by the piston (5). CAUTION Write down direction of installation of piston whose seal ring "A" is oriented towards cylinder head (2). FIGURE 13: Remove all seals, anti-extrusion rings, and scra- per rings from head (2), cylinder (3) and piston (5).

  • Page 49: Assembly

    ASSEMBLY ASSEMBLY FIGURE 17: Apply tool T1 (See drawing T1 p. 51) to the pi- ston rod on non-head side (2) and center rod into cylinder (3) so as to fit it into piston (5). FIGURE 14: Grease and install the piston rod seal ring (6) and scraper ring (7) into cylinder (3).
  • Page 50 ASSEMBLY FIGURE 20: Grease the seals of the head (2), slip the head FIGURE 23: Fit the snap ring (1) of head (2). onto the piston and, using a plastic hammer, introduce head If necessary, force it into the seat with a punch and hammer. into cylinder (3).
  • Page 51 ASSEMBLY FIGURE 26: Block cylinder (8) with screws (7) coated with FIGURE 29: If required, install the steering piston stroke cen- Loctite 242 and tightened to a torque of 180 - 200 N·m. tering sensor (1) for checking piston centering and tighten screws (13).
  • Page 52 ASSEMBLY I max=0,80 A NERO BLACK CONNETTORE CONNECTOR BLUE BATTERIA BATTERY MARRONE BROWN FIGURE 32: Sensor wiring diagram for STANDARD version. FIGURE 35: Check distance "C" of piston on either of the two sides and write down distance dimension to check subse- I max=0,80 A quent adjustments.
  • Page 53 ASSEMBLY FIGURE 41: Once toe-in has been adjusted, lock nuts (11). FIGURE 38: Adjust the toe-in with a difference between "A" Tightening torque for nuts: 328 - 363 N·m. and "B" of maximum 2,5 mm. A ± B = 2,5 mm R = 400 mm Pos.
  • Page 54 ASSEMBLY FIGURE 44: Perform one full steering operation until the adju- sted screw (15) leans against the arm stop. FIGURE 45: While holding the adjustment screw in position against the arm stop, adjust the screw opposite (16), on non- cylinder side, until it leans against the arm stop. CAUTION The screws (15, 16) must lean against the respective arm stops all at the same time.

  • Page 55: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS 2368 P/N: -- 0.05 Ø5 0 -- 0.10 x1.2 5 Ø6.5 Ø28. 3 -- 0.05 + 0.05 Ø48. 1 P/N: 2367 x45° ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 56 SPECIAL TOOLS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 57: U-Joint

    U-JOINT EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 58: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 3: Remove the snap ring (4) of the bushing kit (5). CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in END-STOP PLIER SETTING p.
  • Page 59 DISASSEMBLY FIGURE 5: Remove the bearing (7) snap ring (6). Remove the o-ring (8) and, using a puller for inner parts, re- move the bearing (7) and seal ring (9). CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in END-STOP PLIER SETTING p.

  • Page 60: Assembly

    ASSEMBLY ASSEMBLY FIGURE 8: Install the complete bushing (5) onto the twin u- joint and set bushing into position with a plastic hammer. FIGURE 6: Using tools T1 (See drawing T1 p. 58) and T2 (See drawing T2 p. 58), introduce the seal ring (9) and bearing (7) into the bushing (5).
  • Page 61 ASSEMBLY FIGURE 10: Introduce the twin U-joint (3) into the arm and lock into position with stud (2) coated with Loctite 242. Tighten stud to a maximum torque of 15 N·m. FIGURE 11: Apply Loctite 242 to the stud (2) and tighten nut (1).

  • Page 62: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS 3342 P/N: x45° x15° -- 0. 2 14 10 P/N: 2301 1. 5 x45° 0. 8 x45° Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 63: Brake Wear Check Procedure

    BRAKE WEAR CHECK PROCEDURE OLD VERSION CAUTION Perform all operations on both arms. 35 - 50 N·m FIGURE 4: Install the oil drain plug. Torque wrench setting for screws: 35 - 50 N·m. Fill with oil. FIGURE 1: Remove the oil drain plug and discharge oil. FIGURE 2: Apply the parking brake (or have someone hold the service brake) and with either brake applied, check the di- stance between discs using tool T1 (See drawing T1 p.

  • Page 64: New Version

    SPECIAL TOOLS NEW VERSION CAUTION Perform all operations on both arms. 35 - 50 N·m FIGURE 4: Install the inspection plug. Torque wrench setting for screws: 35 - 50 N·m. FIGURE 1: Remove the inspection plug. FIGURE 2: Apply the parking brake (or have someone hold the service brake) and with either brake applied, check the di- stance between discs using tool T1 (See drawing T1 p.

  • Page 65: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 66 SPECIAL TOOLS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 67: Service Brake And Negative Parking Brake

    SERVICE BRAKE AND NEGATIVE PARKING BRAKE EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 68: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p.
  • Page 69 DISASSEMBLY 0 bar FIGURE 6: Remove the adjusting screws (13) from the FIGURE 4: Gradually release the pressure in the braking cir- counterwasher (23). cuit, bringing it to zero through the external pump. DANGER Do not remove any part of the hydraulic circuit without ha- ving completely released the hydraulic pressure.
  • Page 70 DISASSEMBLY FIGURE 12: Remove the Belleville washers (1). FIGURE 9: Loosen the studs in an alternate method and re- move them. NOTE: Check the sense of direction of washers (1). FIGURE 10: Remove the cylinder (24). FIGURE 13: The o-rings (2) must be replaced each time the unit is disassembled.
  • Page 71 DISASSEMBLY FIGURE 15: Mark the assembly position. FIGURE 18: Remove the flange (17) complete with the discs (20, 19, 18). Down Down FIGURE 16: Slowly introduce low-pressure compressed air through the connection member for the service brake (P1), in order to extract the piston (3). CAUTION Hold the piston (3) back, as it may be suddenly ejected and damaged.

  • Page 72: Assembly

    ASSEMBLY ASSEMBLY FIGURE 22: Using a plastic hammer, install the piston (3) into the cylinder (24). FIGURE 20: Fit antitwist rings (2, 25) onto the piston (3). NOTE: Lightly hammer all around the edge in an alternate se- WARNING quence. Antitwist ring replaces o-ring + backup ring solution.
  • Page 73 ASSEMBLY FIGURE 24: Using a plastic hammer, install the piston (11) FIGURE 27: Check integrity and position of the cylinder's o- into the cylinder (24). ring (2). NOTE: Lightly hammer all around the edge in an alternate se- quence. DOWN DOWN FIGURE 28: Engage the cylinder (24).
  • Page 74 ASSEMBLY 30-35 N·m FIGURE 30: Tightening the studs to a torque of 30 - 35 N·m. FIGURE 32: Insert the stroke automatic regulation springs (22); place them in line with the piston (23). 21-35 Bar FIGURE 33: Insert the intermediate disk (23). FIGURE 31: Connect an external pump to the negative brake and introduce pressure to 21 -35 bar.
  • Page 75 ASSEMBLY 10-15 N·m 5 - 7 N·m Drilock Drilock FIGURE 35: Tighten with torque wrench setting of 10 - 15 FIGURE 37: Fit the pin screws. N·m Torque wrench setting: 5-7 N·m. CAUTION CAUTION Use only new screws pre-treated with Driloc locking adhe- Use only new screws pre-treated with Driloc locking adhe- sive.
  • Page 76 ASSEMBLY First Disc First Disc Arm fi x quote = 74 mm Arm fi x quote = 74 mm FIGURE 40: Arm fix quote = 74 mm FIGURE 43: Install the friction disc (18) on the flange (17) from arm side. Y=brake gap Y=brake gap S 28...
  • Page 77 ASSEMBLY 4° Disc 4° Disc FIGURE 46: Insert on the flange the discs (16, 15, 14). FIGURE 49: Check integrity and position of the cylinder's o- ring. FIGURE 50: Check integrity and position of the arm's o-ring; FIGURE 47: Check the alignment of last disc (14) and flange install the complete arm.
  • Page 78 ASSEMBLY 0 bar FIGURE 52: Gradually release the pressure in the braking cir- cuit, bringing it to zero through the external pump. DANGER Do not remove any part of the hydraulic circuit without ha- ving completely released the hydraulic pressure. The removal of pressurized parts or loss caused from relea- sing these components can cause serious injuries and even death.

  • Page 79: Manual Emergency Release

    MANUAL EMERGENCY RELEASE MANUAL EMERGENCY RELEASE ADJUST Tecno Lube 101 FIGURE 57: Remove screws complete with nuts and seals. FIGURE 54: Loosen nuts (30) of screws (31) provided for the Replace seals, apply silicone-based Tecno Lube /101 grease mechanical and manual release of the braking units, then to the screws and install all parts into the arm.
  • Page 80 ADJUST Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 81: Differential Unit

    DIFFERENTIAL UNIT EXPLODED VIEW NOTE: Items 29 & 30 not present on all models ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 82: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION 2 26 Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 4: Only if removing or adjusting, use special tool T1 (See drawing T1 p. 88) to mark the position of the ring nuts (2, 26).
  • Page 83 DISASSEMBLY FIGURE 7: Remove the cover and studs. FIGURE 10: Remove the cap (29). 33 38 FIGURE 8: Extract the whole differential unit. FIGURE 11: If the bearings need replacing, extract the exter- nal thrust blocks of the bearings (3, 25) from middle cover (33, 38).
  • Page 84 DISASSEMBLY FIGURE 13: If the bearing need replacing, extract the bearing FIGURE 16: Remove the screws (24) joining the differential (25) from the differential carrier (23). unit half box. FIGURE 14: Remove the ring gear (6) capscrews (4). FIGURE 17: Using a plastic hammer, take the half box (23, 5) to pieces.
  • Page 85 DISASSEMBLY FIGURE 19: Remove shoulder (22) and first planetary gear FIGURE 22: Remove the 2nd planetary gear (8) and shoulder (21). ring (7). 14 20 FIGURE 20: Remove shafts (18), complete with planetary ge- FIGURE 23: The differential unit. ars (15, 19) and spherical shoulder washers (14, 20). Sh = Shafts (18)(17) SW = spherical shoulder washers (9)(13)(14)(20) P = planetary gears (8)(21)

  • Page 86: Assembly

    ASSEMBLY ASSEMBLY INSPECTION SPECIAL TOOL INSPECTION SPECIAL TOOL BEVEL GEAR BEVEL GEAR HOLE GAP [MM] GAP [MM] HOLE GAP [MM] GAP [MM] RATIO RATIO PAIR P/N PAIR P/N min. max. min. max. min. max. min. max. 176.04.504.04 14/32 0,20 0,28 0,26 0,37 113.04.500.01...
  • Page 87 ASSEMBLY FIGURE 24: Install the shoulder ring (7) and planetary gear (8) FIGURE 27: Install the planetary gear (21) and shoulder ring into the halfbox (5). (22). 10 12 FIGURE 25: Install the planetary gears (10, 12) and spherical FIGURE 28: Install the locking half-box (5) onto the half-box shoulder washers (9, 13) onto the shafts (17).
  • Page 88 ASSEMBLY 80 N·m 150 N·m FIGURE 30: Fit the complete differential unit in a vice and FIGURE 33: Lock the ring gear (6) by tightening the screws (4) tighten the screws (24) holding the two half boxes together to to a torque of 150 N·m using the criss-cross method. a torque of 80 N·m.
  • Page 89 ASSEMBLY FIGURE 36: Only if bearings are replaced, insert the thrust FIGURE 39: Position the differential unit in the central hou- blocks of the bearings into the intermediate covers. sing using a bar and fit the middle cover. FIGURE 37: Thoroughly check the condition of the o-ring (36, FIGURE 40: Tighten the two safety screws "C"...
  • Page 90 ASSEMBLY 1/4 turn FIGURE 42: Only if ring nuts have been removed, tighten the FIGURE 45: Introduce a gauge "A" with long tracer through ring nut (2) on ring gear side until clearances between pinion the hole provided for the cap. Position the tracer on the side of and ring gear are zeroed.
  • Page 91 ASSEMBLY FIGURE 48: If torque and/or pinion-ring gear clearance is not FIGURE 51: Fit the top plug after applying repositionable within tolerance values and the ring nuts have not been remo- jointing compound for seals to the rims. Install the snap ring. ved, mark the position of the ring nuts (2, 26) and remove the safety plates (1, 27).

  • Page 92: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS 2379 P/N: ¯ 166 -- 0.1 ¯ 40.5 -- 0.2 ¯ 15H7-n6 ¯ 14 ¯ 25 ¯ 10 ¯ 35 ¯ 37H7-n6 ¯ 47 ¯ 143 Dana Incorporated ASM-0029E - 223 Axle Service Manual...
  • Page 93 SPECIAL TOOLS ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 94 SPECIAL TOOLS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 95: Bevel Pinion

    BEVEL PINION EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 96: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 3: Position tool T1 (See drawing T1 p. 100), so as to avoid pinion rotation. Loosen and remove the nut (1) and o-ring (11). FIGURE 1: Remove both axle arms.
  • Page 97 DISASSEMBLY FIGURE 5: Remove the sealing ring (9). FIGURE 8: Using a puller and a press, remove the inner bea- ring (5) from the pinion (6). FIGURE 6: Apply blocks T2 (See drawing T2 p. 101) and, using a puller, extract the pinion (5) complete with the internal FIGURE 9: Remove the thrust block of the external bearing bearing (6), the spacer (8), and calibrated spacer (4, 7).
  • Page 98 DISASSEMBLY FIGURE 11: Remove the thrust block of the internal bearing (6) as well as the shim washers (4). FIGURE 12: Remove the snap ring (15). FIGURE 13: Remove the cap (14). Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 99: Assembly

    ASSEMBLY ASSEMBLY I = 135 I = 135 - 0,1 = Y - 0,1 = Y 42 mm 42 mm FIGURE 16: Check nominal dimension "I" as marked on the pinion. Add up to or subtract from "I" the variation indicated as "Y"...
  • Page 100 ASSEMBLY FIGURE 18: Using special tool T3 (See drawing T3 p. 101) FIGURE 21: Introduce the tracer of a depth gauge "DDG" into partially insert the thrust block of the bearings (3, 6) and shims either side hole of tool T4 (See drawing T4 p. 102). Reset the (4).
  • Page 101 ASSEMBLY FIGURE 24: Deviation "H" must be added to a set value of FIGURE 27: Refer and keep to the positions marked during 0.12--0.13 mm (X) to obtain calibrated spacer "S1" (7) for in- disassembly. sertion between inner bearing (6) and spacer (8). Dimension "S1"...
  • Page 102 ASSEMBLY 120 - 180 N·cm FIGURE 30: Install the flange (10) onto the pinion (5) without FIGURE 32: Apply onto the pinion (5) the bar-hold and using the sealing ring. a torque meter, check the torque of the pinion (5). Torque: 120 - 180 N·cm Loctite 242 800 - 1000 N·m...
  • Page 103 ASSEMBLY FIGURE 34: Apply Arexons rubber cement to the outer surfa- FIGURE 37: Tighten the nut until the match marks line up. ce of the new seal ring (9) and fit ring in the central housing (12) using driver T5 (See drawing T5 p. 103). FIGURE 35: Fit the safety flange (2).

  • Page 104: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS 2308 P/N: ¯ 185 ¯ 105 -- 0 ¯ 34.5 + 0.2 ¯ 50 ¯ 32 ¯ 45 Dana Incorporated ASM-0029E - 223 Axle Service Manual...
  • Page 105 SPECIAL TOOLS P/N: 2381 2377 P/N: R 10 21.5 19.5 3 x 15 Cylinder Thrust block Thrust block Differential box ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 106 SPECIAL TOOLS P/N: 2374 ¯ 60 M16 x 1.5 ¯ 20 -0.2 ¯ 50 -0.4 -0.2 ¯ 40 -0.4 ¯ 20 M16 x 1.5 -0.02 ¯ 50 -0.04 ¯ 70 Dana Incorporated ASM-0029E - 223 Axle Service Manual...
  • Page 107 SPECIAL TOOLS P/N: 2375 ¯ 50 1 x 45 3 x 15 ¯ 39.5 + 0.1 ¯ 61.5 ¯ 85 ¯ 98 ¯ 125 ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 108 SPECIAL TOOLS Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 109: Limited Slip Differential Unit

    LIMITED SLIP DIFFERENTIAL UNIT EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 110: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 12. FIGURE 3: Make positional match marks on the half boxes of the differential gear (2); loosen and pull out joining screws (4). FIGURE 1: Remove the whole differential unit (2) from the main body (1).
  • Page 111 DISASSEMBLY CAUTION If the clutch pack does not need replacing, avoid swapping discs position. FIGURE 5: Remove the crown wheel (8) and planetary gears set (9). FIGURE 6: Remove the 2nd planetary gear (10). FIGURE 7: Remove the 2nd clutch pack (11) . CAUTION Check and write down the amount of differential discs.

  • Page 112: Assembly

    ASSEMBLY ASSEMBLY "MOLY" FRICTION DISCS "PAPER" FRICTION DISCS 8 10 8 10 FIGURE 8: Check the disc pack thickness "V" applying 3000 FIGURE 9: Check the disc pack thickness "V" applying 3000 N ± 5%. N ± 5%. "V" measurement must be 17,4 ± 0,08 mm. "V"...
  • Page 113 ASSEMBLY FIGURE 11: Install planetary gear (10). FIGURE 12: Fit the planetary gear set (9). Mount second planetary gear (8). NOTE: Make sure that spherical thrust washers (15) are present. FIGURE 13: Fit increased shim (12), clutch pack (7) onto the crown wheel (8).
  • Page 114 ASSEMBLY Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 115: Swinging Support

    SWINGING SUPPORT EXPLODED VIEW Bushing cut position ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 116: Disassembly

    DISASSEMBLY DISASSEMBLY Bushing cut position Bushing cut position FIGURE 1: Remove the swinging support (4). FIGURE 2: Remove the swinging support (4) on the side op- posite the drive. FIGURE 3: Position the swinging support (4) under a press and remove the complete bushing (3). Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 117: Assembly

    ASSEMBLY ASSEMBLY FIGURE 6: Install the swinging support (4). reference direction FIGURE 4: If the bushing (3) is worn and needs replacing, wri- NOTE: te down the assembly side of the connection notch "A". Check that it is properly oriented. Bushing cut position Bushing cut position reference direction...
  • Page 118 ASSEMBLY Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 119: Service Brake

    SERVICE BRAKE EXPLODED VIEW ASM-0029E - 223 Axle Service Manual Dana Incorporated...

  • Page 120: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. CAUTION Before draining oil, release the internal pressure, for details Down Side Down Side see OIL DRAINING MANDATORY PROCEDURE p.
  • Page 121 DISASSEMBLY reversal springs reversal springs FIGURE 6: Remove the flange (4) complete with the discs. FIGURE 9: Remove the adjusting screws (5) FIGURE 7: Remove braking discs (2, 3), noting down direc- tion of assembly. NOTE: If disks are not being replaced, avoid changing their posi- tion.
  • Page 122 DISASSEMBLY FIGURE 10: Slowly introduce low-pressure compressed air through the connection member for the service brake (P1), in order to extract the piston (9). CAUTION Hold the piston (9) back, as it may be suddenly ejected and damaged. Dana Incorporated ASM-0029E - 223 Axle Service Manual...

  • Page 123: Assembly

    ASSEMBLY ASSEMBLY Drilock 10 - 15 N·m FIGURE 14: Fit the reversal springs screws (7) on the piston (9). Tighten with torque wrench setting of 10 - 15 N·m FIGURE 11: Insert the stroke automatic regulation springs (6); place them in line with the piston (9). CAUTION Use only new screws pre-treated with Driloc locking adhe- sive.
  • Page 124 ASSEMBLY fi rst disc FIGURE 16: Insert the brake discs in the correct sequence. FIGURE 19: Insert the intermediate disk (1). NOTE: The first brake disc (2) to be inserted must be of metal material. second disc FIGURE 20: Check condition and position of the cylinder's o- ring.
  • Page 125 ASSEMBLY ASM-0029E - 223 Axle Service Manual Dana Incorporated...
  • Page 126 Copyright 2018 Dana Incorporated For product inquiries or support, All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445 be reproduced in whole or in part by any means, For other service publications, electronic or otherwise, without prior written approval. visit www.SpicerParts.com/literature.asp THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,...
  • Page 128 31200239 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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