Service Manual
Contents
1. Ban SPICER Off Highway Products service Manual Drive Axle 190 amp 290 ASM 0093 March 1998 PRINTED IN ITALY Copyright By DANA SPICER CLARK HURTH Vietata la riproduzione anche parziale di testo ed illustrazioni Realizzazione a cura dell Ufficio Pubblicita e dell Ufficio Post Vendita della DANA SPICER CLARK HURTH Impaginazione TEMAS s r l Gallarate Va Stampa Marzo 1998 N L 7338 Data subject to change without notice We decline all responsability for the use of non original components or accessories which have not been tested and submitted for approval Dati soggetti a modifiche senza impegno di preavviso Si declina ogni responsabilit per l utilizzo di componenti non originali o accessori non collaudatied apporvati Anderungen ohne vorherige Ank ndingung vorbehalten Es wird jede Verantwortung f r die Verwendung von Nichtoriginalteilen oder nicht abgenommenem und genehmigtem Zubeh r abgelehnt Los datos pueden ser modificados sin aviso previo Se declina toda responsabilidad en el caso de uso de componentes no originales o bien de accesorios no ensayados y aprobados Le constructeur se r serve le droit d apporter des modifications sa production sans pour cela tre tenu d en donner pr avis Nous declinons toute responsabilit pour l utilisation de pieces non originales ou d accessoires non test s et homologues MOD 190 HOW TO REMOVE AND INSTALL THE COMPLETE ARMS HOW TO DISASSEMBLE THE2. CONVERGENCY ADJUSTMENT DANA SPICER CLARK HURTH Mq A y y OJ E S nnd NA o SA N N ui F1240321 Heat the nuts 48 at approximately 100 C and unscrew them up to Remove the pins 6 connecting the cylinder 49 and the steering the limit stop bar 3 Remove the screws 1 and the plates 2 Also remove the shim rings 6 NOTE Note down the position of the shim rings D1240025 O Turn the eye connections 50 one at a time in order to adjust CAUTION If the eye connections 50 or the steering cylinder 49 convergency are replaced check that convergency is correct when the stem of CAUTION Turn eyes evenly to maintain the centring of the stroke the piston shows the juts indicated in the drawing F1240323 F1240321 4 D Tie the tension rods to the steering cylinder again and insert the Apply Loctite 270 to the thread of the eye connections 50 and lock pins 5 and the shim rings 6 the nuts 48 Lock the pins with the screws 1 treated with Loctite 270 and the Torque wrench setting for nuts 350 360 plates 2 Torque wrench setting for screws 52 58 Nm 31 SPECIAL TOOLS SPICER CLARK HURTH 0184 T33 12 5 32 O Yo nu gl a bx15 ND sp 131 45 176 0165 80 ob 0184 200 0 D1240024 660 38 3265 0154 i035 154 5101 0189 660 38 3281 D1240025 VN SPECIAL TOOLS D1240023 660 38 3059 D1240026 660 38 3348
3. A F1240328 wg a t F1240329 Remove the elastic check ring 25 of bearing and flange 26 Position the complete u joint 18 under a press and remove the bearing 27 and the flange 26 at the same time 20 HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES DISASSEMBLY Sum SPICER CLARK HURTH F1240330 Extract the sealing ring 28 from the flange 26 NOTE Note down the assembly side D I 1 KON f y um GN 14 ff CAE l T f f F T WO d D 1 Wi m m x 2 F1240296 Extract the bearing 32 21 F1240295 Remove the centring ring 30 and the sealing ring 31 from the articulation unit by using an extractor for inner parts NOTE Note down the assembly side of sealing ring 31 and centring ring 30 lt gt HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES ASSEMBLY F1240298 F1240297 Lubricate the seat and install the bearing 32 using fixture T36 Lubricate the outer surfaces of sealing ring 31 and centring ring 30 Slot them into position using fixture T37 1 F1 E ER Install the top bush 22 and the bottom spherical seat 23 using Apply Loctite 641 to the outer surface of seals 21 and using an extractor fixture T38 slot them into position NOTA Accurately check assembly side F1240331 F1240301 If the spherical cap 24 has been removed fit the new cap onto the With the aid of ext
4. 34 SPECIAL TOOLS Sam SPICER CLARK HURTH D1240022 660 38 1945 D1240021 660 38 3441
5. crown carrier unit 23 by centring the bushes 24 Install the hub 15 and the external bearing 16 F1240276 Insert the bushes 24 using a plastic mallet Insert the screws 22 and tighten by using the cross tightening CAUTION The bushes 24 should be inserted gradually and in a method cross over manner until the flange 23 is secured onto the axle Torque wrench setting 220 230 Nm hub F1240275 12 HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR Sam SPICER CLARK HURTH F1240252 Use the fixture T35 to insert first the sealing ring 21 then the Lubricate the sealing ring 21 with oil and insert the axle all the guide ring 20 way 19 NOTE Accurately check the assembly side NOTE After completing the final positioning of the axle it is possible to discharge the pressure from the braking circuit F1240278 F1240258 Install the shim washer of the axle 14 inside the spider cover 11 Install the planet wheel gears 14 and the relative check rings 12 in the cover 11 NOTE Check assembly side of the planet wheel gears F1240251 F1240279 Fit the spider cover 11 onto the hub 15 Lock the spider cover 11 by tightening the screws 10 CAUTION Check condition and position of the O ring 27 Torque wrench setting 86 89 Nm 13 Se SPICER CLARK HURTH 290 HOW TO REMOVE AND INSTALL THE COMPLETE ARMS Sum SPICER CLARK HURTH F1240281 11 387 pm F1240282 Re
6. position with grease CAUTION Be sure that the end of the threaded stem is perfectly flat perfettamente piano j n N O l 7 W a i du IA u m s ke I IA F1240257 Remove the screw 22 that has been left on for safety and remove Sling the entire hub 5 and extract the whole unit from the axle by the crown flange 23 using a plastic mallet NOTE Insert a screw 22 to prevent the bearing 16 from falling HOW TO DISASSEMBLE UNITS F1240258 F1240259 Remove the elastic rings 12 and extract the planet wheel gears Remove the shim washer of the axle by using an extractor 14 13 including bearings from the spider cover 11 NOTE Note down assembly side HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR F1240260 F1240261 Remove the bushes 24 if necessary by using a plastic mallet and Remove the elastic ring 25 and extract the flange 23 a pushing device if the case may be NOTE Partially extract the bushes 24 anyhow F1240263 F1240262 Remove the sealing ring 18 Remove the bearing 16 NOTE Note down the assembly side F1240264 Remove the external thrust blocks 17 from the bearings by NOTE Clean out the seat of the sealing ring by removing any inserting a pin extractor E in the specific slots placed on the hub sealant residues with sealing effect Ermetico NOTE Alternate hammering to prevent crawling and deformation of t
7. 40312 Unloose and remove the screws 36 from the crown flange 37 To extract the crown flange 37 insert two flat washers C e 10 NOTE Leave a screw 36 on the top for safety s sake and fix two screws B M12x1 5x40 in the appropriate holes Keep washers into position by applying grease CAUTION Be sure that the end of the threaded stem is perfectly flat 25 lt gt HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR F1240313 Alternately turn the two screws B one fourth turn until the bushes Remove the screw 36 which has been left on for safety and 38 of the crown flange 37 are released remove the crown flange 37 F1240315 F1240336 Sling the entire hub 39 and using a plastic mallet extract the Screw down an eyebolt in the articulation box 4 and connect it to a whole unit from the axle piece of hoisting equipment NOTE Insert a screw 36 to prevent the bearing from falling 40 Remove the articulation pins 15 and 16 and extract the articulation box 4 from the u joint 18 NOTE See HOW TO REPLACE U JOINT SEALS for details about the removal of articulation pins and u joints HOW TO DISASSEMBLE UNITS F1240258 F1240260 Remove the elastic rings 41 and extract the planet wheel gears If necessary remove the bushes 38 using a plastic mallet and a 42 including the bearings from the spider cover 35 pushing device as the case may be NOTE Note down
8. EPYCYCLIC REDUCTION GEAR HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR MOD 290 HOW TO REMOVE AND INSTALL THE COMPLETE ARMS SLACK ADJUSTMENT FOR BRAKING DISCS Rn SPICER CLARK HURTH HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES DISASSEMBLY HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES ASSEMBLY HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR CONVERGENCY ADJUSTMENT SPECIAL TOOLS The efficiency and continued operation of me chanical units depend on constant correct maintenance and also on efficient repair work should there be a break down or malfunction The instruc tions contained in this manual have been based on a complete overhaul of the unit However it is up to the mechanic to decide whether or not it is necessary to assemble only individual components when partial repair work is needed The manual provides a quick and sure guide which with the use of photographs and diagrams illustrating the various phases of the operations allows accurate work to be performed All the information needed for correct disassembly checks and assembly of each individual component is set out below In order to remove the differential unit from the vehicle the manuals provided by the vehicle manufacturer should be consulted In describing the following operations it is presumed that the unit has already been removed from the vehicle IMPORTANT In order to facilita
9. REDUCTION GEAR Sam SPICER CLARK HURTH F1240272 F1240271 If the bushes 38 have been removed position the bushes in the Insert the flange 37 in the crown 46 and fix into position with the crown flange 37 elastic ring 43 Insert bushes so as to obtain a jut of 4mm which can be used for centring TD F1240316 F1240317 Insert the articulation box 4 in the u joint 18 and fit the Lubricate the sealing ring 44 the hub of the articulation box articulation pins 15 and 16 Install the hub 39 and the on bearing 40 See HOW TO REPLACE U JOINT SEALS for details F1240318 Position the crown unit 37 centring the bushes 38 Insert the bushes 38 using a plastic mallet CAUTION The bushes 38 should be inserted gradually and in a cross over manner until the flange 37 is secured onto the hub of the articulation box 4 29 lt gt HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR F1240319 F1240258 Insert the screws 36 and tighten using the cross tightening Insert the planet wheel gears 42 in the cover 35 as well as the method relative check rings 41 Torque wrench setting 220 230 Nm NOTE Check the assembly side of planet wheel gears 42 F1240311 Install the spider cover 35 onto the hub 39 Lock the spider cover 35 with screws 34 CAUTION Check condition and position of the O ring 47 Torque wrench setting 86 89 Nm F1240320 30
10. a max torque of Lock the nut 7 while keeping the screws 6 into position 10 Nm Torque wrench setting for nut MAX 15 Nm Before continuing check that all screws have the same jut lt gt HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR F1240249 F1240250 Remove the securing screws 10 from the spider cover 11 Disjoin the spider cover 11 from the hub 15 by alternately inserting a screwdriver A in the specific slots F1240252 F1240251 Sling the whole spider cover 11 and remove it completely CAUTION If the axle 19 needs removing introduce pressure into the braking circuit in order to lock the braking disks Extract the axle 19 F1240253 o F1240254 With the aid of an extractor B remove first the guide ring 20 Unloose and remove the screws 22 of the crown flange 23 then the sealing ring 21 NOTE Leave a screw 22 in one of the top positions for safety s NOTE Note down assembly side for the guide ring 20 and the sake sealing ring 21 HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR Sam SPICER CLARK HURTH D 9e 10 I a 1 r ge J C M12x1 5x40 D1240022 F1240255 To extract the crown flange insert two flat washers D e 10 and Alternately turn the two screws C one fourth turn until the bushes screw down two C screws M12x1 5x40 in the specific holes 24 are released from the crown flange 23 Keep washers into
11. ame for all versions SPECIFIC EQUIPMENT AND SPARE PARTS The drawings of all specific tools required for maintenance and repair work can be found at the end of this manual spare parts may be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorised Distributors of SPICER CLARK HURTH Se SPICER CLARK HURTH 190 HOW TO REMOVE AND INSTALL THE COMPLETE ARMS Sum SPICER CLARK HURTH v A er M y gt d d D ER i 7 E 1 31 a 1 Vtc I t r AVEK fb ke a A E NN y i a NS r dda BER P j lh GAR 3 OM x D mr AP f d i o Op A D F1240247 F1240246 ua Sling the arm 1 and put the rod under slight tension After inspection and replacement of the braking disks re install the Unloose and remove screws 2 nuts 3 and the relative washers arms and check flatness Lock the arms with the screws 2 the 4 and 5 nuts 3 and the relative washers by using the cross tightening Remove the arm including the braking disks method Torque wrench setting for screws 285 310 Nm Torque wrench setting for nuts 185 205 Nm SLACK ADJUSTMENT FOR BRAKS i U D1240021 F 1240248 Turn the adjusting screws 6 anti clockwise until the disk push Turn the screws 6 one turn clockwise so as to obtain a slack of device 9 is made to rest on the braking disks 8 1 mm between the disks CAUTION Turn the screws in an even way up to
12. etails F1240285 F1240286 Disconnect the steering bar 3 from the articulation box 4 See Sling the entire articulation unit and put the rod under slight tension Remove the screws 14 and the bottom articulation pin 15 NOTE to ease removal it may be necessary to insert two levers in the openings of the flange of the articulation pin F1240287 Remove the check screws 14 of the top articulation pin 16 Remove the top articulation pin 16 by inserting two levers in the openings of the flange of the articulation pin Also remove the shims 17 NOTE Pay attention not to damage surfaces and shims 17 F1240289 Extract the entire articulation unit 4 from the u joint 18 Introduce pressure into the braking circuit to lock the braking disks 10 Unloose the nut 19 and unscrew the check dowel 20 of the u joint 18 19 HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES DISASSEMBLY F1240291 F1240292 2 Clean out the seats by removing any sealant residue With the aid of a lever extract the u joint 18 Remove top and bottom seals 21 NOTE 1 Note down the assembly side F1240293 Extract the top bush 22 and the lower spherical seat 23 using an If the spherical cap 24 needs replacing remove the cap from the extractor for inner parts lower articulation pin 15 F1240294 py Wii V J 7 dh lt A W 6 5 8 e SC ME A Jw A ac D
13. he thrust blocks 10 HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR Sam SPICER CLARK HURTH Position the lower part of fixture T33 and the external bearing Lubricate the housings of the bearings and position the hub 15 on thrust block 17 under the press the fixture T33 position the internal bearing thrust block 17 NOTE Check the orientation of the thrust block 14 he ce E 3 A F1240267 026 1240268 Position the top part of fixture T33 and push the thrust blocks 17 Install the bearing 16 in the thrust block 17 all the way into the wheel carrier hub 15 jf 5 200 0403 K 2 E m r 7 4 U e za H Qe d i Cmm A a SE z p 1240269 md Coat the outer surface of the sealing ring 18 with sealant Position fixture T34 and press the sealing ring 18 into position Ermetico Position the sealing ring 18 inside the hub 15 NOTE Check the orientation of the ring 18 11 HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR F1240271 F1240272 Introduce the bushes 24 in the crown flange 23 if they have Insert the flange 23 in the crown 26 and lock into position by previously been removed using the elastic ring 25 Push in the bushes so as to obtain a jut of 4mm which can be used for centring 9 ei h L x 9 40 Y j PNA E vf Ri s y F1240273 Lubricate the sealing ring 18 and the axle hub Position the
14. move the screw 1 and the plate 2 Disconnect the steering bar 3 from the articulation box 4 by removing the pin 5 and the shims 6 NOTE Note down the position of the shim rings 6 F1240327 Sling the arm 7 and put the rod under slight tension After inspecting or replacing the braking disks 10 re install the Unloose and remove the screws 8 the nuts 9 and the relative arms 7 and check flatness washers Lock the arms by using the cross tightening method Remove the entire arm including the braking disks 10 Torque wrench setting for screws 283 312 Nm Torque wrench setting for nuts 200 221 Nm F1240282 F1240281 Connect the steering bar 3 by inserting the shim rings 6 and the Lock the pin 5 with the plate 2 and the screw 1 treated with coupling pin 5 Loctite 270 Torque wrench setting for the screw 52 58 Nm 17 SLACK ADJUSTMENT FOR BRAKING DISCS D1240023 F1240248 Turn the adjusting screws 11 anti clockwise until the disk push Turn the screws 11 one turn so as to obtain a slack of device 12 is made to rest on the braking disks 10 1 mm between the disks CAUTION Turn the screws evenly up to a maximum torque of 2 Nm Lock the nut 13 while keeping the screws 11 into position Torque wrench setting for the nut MAX 15 Nm HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES DISASSEMBLY LS SPICER CLARK HURTH HOW TO REMOVE THE ARMS for d
15. ractor insert the sealing ring 28 of the shaft in bottom articulation pin 15 the flange 26 Use a press for assembly NOTE accurately check the assembly side Also replace the outer O ring 29 22 HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES ASSEMBLY DANA SPICER CLARK HURTH F1240332 Insert the flange 26 into the u joint 18 Heat up the bearing 27 at about 100 C then insert it in the u joint and secure it F1240290 y Insert the u joint until the flange 26 is secured Tighten the dowel 20 using a torque wrench setting of 15 Nm MAX Lock into position by tightening the nut 19 Torque wrench setting 86 89 Nm NOTE After fixing the u joint discharge the pressure from the braking circuit F1240302 Install the top articulation pin 16 without the shims and temporarily keep it into position with the screws 14 23 F1240328 Fit the elastic check ring 25 of the bearing 27 F1240333 Grease the inside of both sealing ring 31 and bearing 32 Insert the articulation unit 4 in the u joint 18 F1240303 Lubricate the bottom articulation pin 15 with Molikote and lock it into its final position with the screws Torque wrench setting 220 240 Nm 14 lt gt HOW TO REPLACE U JOINT SEALS ARTICULATION PINS AND BUSHES ASSEMBLY F1240304 Provisionally tighten the screws 14 of the top pin 16 in an e
16. te work and protect both working surfaces and operators it is advisable to use proper equipment such as trestles or supporting benches plastic or copper hammers appropriate levers extractors and specific spanners or wrenches Before going on to disassemble the parts and drain the oil it is best to thoroughly clean the unit removing any encrusted or accumulated grease INTRODUCTORY REMARKS All the disassembled me chanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage wear cracking or seizing have occurred INTRODUCTION In particular thoroughly check the condition of all moving parts bearings gears crown wheel and pinion shafts and sealing parts O rings oil shields which are subject to major stress and wear In any case it is advisable to replace the seals every time a component is overhauled or repaired During assembly the sealing rings must be lubricated on the sealing edge In the case of the crown wheel and pinion replacement of one component requires the replacement of the other one During assembly the prescribed pre loading backlash and torque of parts must be maintained CLASSIFICATION This manual classifies units according to part numbers For a correct interpretation classification is indicated as follows DD up to the part number gt gt from the part number on When no classification is given disassembly and assembly operations are the s
17. the assembly side NOTE Partially extract the bushes 38 anyhow 26 HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR Sam SPICER CLARK HURTH F1240262 F1240261 Remove the sealing ring 44 NOTE Note down the assembly side Remove the elastic ring 43 and the flange 36 F1240264 F1240263 Remove the internal bearing 40 Remove the external thrust blocks 45 of the bearings by inserting a pin extractor D in the specific slots placed on the hub 39 NOTE Alternate hammering to avoid crawling and deformation of the thrust blocks 27 lt gt HOW TO ASSEMBLE THE EPYCYCLIC REDUCTION GEAR 1240265 Position the lower part of fixture T33 and the thrust block 45 of the Lubricate the seats of the bearings and position the hub 39 on the external bearing under the press fixture T33 position the thrust block 45 of the internal bearing NOTE Check the orientation of the thrust block zz 2 Position the top part of fixture T33 and press down the thrust Install the bearing 40 in the internal thrust block 45 blocks 45 into the hub 39 all the way F1240268 mp um F1 4 Coat the outer surface of the sealing ring 44 with sealant Position fixture T34 and press the sealing ring 44 into position Ermetico Position the sealing ring 44 inside the hub 39 NOTE Check the orientation of the ring 44 FA 240269 28 HOW TO ASSEMBLE THE EPYCYCLIC
18. ven To check the torque of the articulation unit apply a wrench to one way using the cross tightening method and simultaneously of the screws 14 and connect it to a spring dynamometer E checking the torque of the articulation unit Tighten the screws 14 until the articulation reaches a torque of 40 60 Nm F1240305 12 18kg gd Y EI AN AN m i D1240024 A F1240308 The force X which should be applied to the dynamometer with an By means of a feeler gauge F measure the slack between the arm measuring about 33 cm from the rotation centre is 12 18 kg articulation pin 16 and the articulation box 4 F1240307 s _F1240308 After defining shim requirements remove the top articulation pin Tighten the screws 14 by cross tightening and lock the pin 16 16 lubricate it with Molikote and re install it by inserting the shims Torque wrench setting 220 240 Nm 33 24 HOW TO DISASSEMBLE THE EPYCYCLIC REDUCTION GEAR Sam SPICER CLARK HURTH F1240285 d F1240309 Disconnect the steering bar 3 from the articulation box 4 See Remove the fastening screws 34 from the spider cover 35 HOW TO REMOVE THE ARMS for details F1240310 F1240311 Detach the spider cover 35 from the articulation box 4 inserting a Sling the entire spider cover 35 and remove it completely screwdriver A alternately in the specific slots B M12x1 5x40 D1240026 F12
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