facing page carraro 711-19 axle workshop manual.ppp
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1. SERVICE MANUAL CARRARO 711 19 AXLE TYPE 125672 WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE LANCS BL4 OLS Tel 44 0 1204 854650 Fax 44 0 1204 854663 service winget co uk parts winget co uk www winget co uk SERVICE MANUAL CARRARO 711 19 AXLE TYPE 125672 WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE LANCS BL4 OLS Tel 44 0 1204 854650 Fax 44 0 1204 854663 service winget co uk parts winget co uk www winget co uk INTRODUCTION Winget Limited gratefully acknowledge the assistance given by Carraro in the preparation of this manual however neither Winget Limited nor Carraro can be held responsible for any errors or omissions The procedures described within this manual should enable experienced service personnel to strip repair and re build Carraro Axles fitted to Winget Site Dumpers in a safe and competent manner The procedures are not intended to be used by personnel who are unfamiliar with Winget products nor mechanically inexperienced It is assumed that personnel are aware of the Health amp Safety Regulations which should be applied but the following should act as a reminder Whenever possible any repairs or service should be carried out in a clean environment If work must be carried out on site or in the field steps should be taken to ensure that dirt or foreign materials cannot enter the assembly Ensure all works tools are in2. 125552 121618 022411 092270 021565 126022 119354 022429 020754 119906 120853 020510 115812 THREAD M6 x 20 M12 x 33 M6 x 12 M10x 75 M10 x 1 25 M22 x 1 5 M22 x 1 5 M14x 2 M14x 1 5 M14 x 1 5 M6 x 30 M14 x 65 M18x 1 5 M12 x 30 as per pre load 10 169 10 78 20 50 40 40 266 70 156 10 220 to 250 70 80 300 REPAIR MANUAL 711 19 AXLE D1 LUBRICATION Oil filling use oil with specification MIL L 2105C and API GLS on Final Reduction Gears E g with ambient air temperature above 40 C use ESSO GEAR OIL GX85W140 with ambient air temperature between 10 C and 40 C use ESSO GEAR OIL GX80W90 with ambient air temperature below 10 C use ESSO GEAR OIL GX80W Use oil with specification MF M 1135 and FORD ESEN M2C 86A and API GL4 on Differential Eg ESSO TORQUE FLUID 62 OUANTITY Quantity for Differential 8 litres Quantity for Reduction Unit 1 l tres CHECKING Initial Change at 150 hours unless advised otherwise in Operators Manual Subseguent Changes every 1000 hours unless advised more of freguent changes in Operators Manual Inspection of Oil Levels every 150 Hours unless advised otherwise in Operators Manual PRESSURE FITINGS with ambient temperature above OC use a good nr 2 lithium gun grease with molybdenum bisulphide with ambient temperature above below OC use a good nr 1 lithium gun grease with molybdenum bisulphide Applications eve
3. F4 WHEEL HUB WHEEL HUB Unscrew bolts 1 to remove hub from housing To remove the crown gear assembly use four bolts 1 as puller on the threaded holes of the wheel carrier 2 Inspect the cassette seal 3 on the hub and replace if necessary Use a suitable driver to ensure the cassette seal is correctly seated to prevent oil leakage The special arrangement Set Right of taper bearings do not require specific setting of pre load or clearance In any case before reassembling new spare parts it is better to checking the following dimensions A 17 95 18 00 B 64 257 64 325 C 21 43 D 23 070 23 172 Replace the incorrect items Fig 3 SPECIAL TOOLS Driver for cassette seal 3 Ref 119086 REPAIR MANUAL 711 19 AXLE F4 WHEEL HUB 2 E 3 WHEEL HUB On the wheel shaft 11 there is a removable oil seal journal 12 Inspect this journal for damage If necessary carefully cut off the journal thoroughly clean the wheel hub surface and press o a new part Ensure that the same is correctly seated to prevent oil leakage The special arrangement Set Right of taper bearings do not require specific setting of pre load or clearance because the relevant surfaces are machined to fine tolerances In any case before reassembling new spare parts it is better to check the following dimensions A 17 95 18 00 B 64 257 64 325 C 21 43 D 23 070 23
4. can be reduced Spares for Carraro Axles fitted to Winget Equipment can only be obtained from Winget Limited or one of our authorised distributors and not from Carraro directly Always quote your machine s serial number and model together with the axle serial number and model when ordering spare parts Carraro Axles are designed to operate under arduous conditions and providing they are regularly and correctly maintained they will provide long trouble free service The contents of this manual although correct at the time of publication may be subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused Winget Limited operate a policy of continuous product development Therefore some illustrations or text within this publication may differ from your machine REPAIR MANUAL 711 19 AXLE INDEX OF SECTIONS SECTION DESCRIPTION A SPECIFICATION amp FEATURES B SECTION VIEW AND SILHOUETTE C TORQUE SETTINGS D LUBRICATION SPECIAL TOOLS F DISASSEMBLING REASSEMBLING AND SETTING OPERATIONS REPAIR MANUAL 711 19 AXLE A1 DESCRIPTION Rigid Axle monoblock in spheriodial cast iron centre differential with self locking device Planetary reduction in final drives SPECIFICATION amp FEATURES BEVEL DRIVE DIFFERENTIAL Ra
5. to avoid twisting during shaft assembly SHIMS For each adjustment select the correct shim s by individual measurement Do not trust pack measurement or the thickness indicated on the shim BEARINGS For a correct assembly it is suggested Warming from 80 to 90 C before installation in their respective seats ROLL PIN When installing split cut roll pin ensure the cut is oriented towards the direction of the force acting on the roll pin Spiral type roll pins do not require any precaution SEALING COMPOUND On area to be sealed use SILASTIC or LOCTITE 510 ensuring both sides to be sealed are clean dry and totally free from grease and oil REPAIR MANUAL 711 19 AXLE F3 EPICYCLIC REDUCTION GEARS Fig 1 EPICYCLIC REDUCTION GEARS Turn the hub so that the filler drain plug 3 is at the lowest position and drain the hub oil Remove the 2 centering studs 14 and the 2 screws 4 securing the planetary carrier assembly to the hub assembly Inspect the needle bearings 12 and the thrust washer 7 for wear and replace if necessary Inspect the pinion shaft 6 for wear and replace if worn or damaged Reassembling if necessary hold the needle bearings in place with grease Refill the hub with the correct oil see specification or refer to relevant operators manual The filler drain plug bore position must be at the top Check the level with the plug at the horizontal line REPAIR MANUAL 711 19 AXLE
6. 172 Replace the incorrect items REPAIR MANUAL 711 19 AXLE F5 WHEEL SHAFT AND BRAKES Fig 4 WHEEL SHAFT AND BRAKES Inspect the splines on the half shaft 7 for wear and replace if necessary Inspect the brake disc 12 for wear and replace if necessary Inspect the brake piston 23 and reaction plates 11 for wear pitting or grooves and replace if necessary Inspect the guadrings 14 and 25 for damage and replace if necessary Replace the oil seal 26 REPAIR MANUAL 711 19 AXLE F6 0 DIFFERENTIAL SUPPORT AND BEVEL GEAR PINION SET Fig 8 DIFFERENTIAL SUPPORT AND BEVEL GEAR PINION SET To remove the differential unscrew the bolts 25 for on bench overhauling Inspect the pinion bearings 4 and the differential side bearings for wear or damage at the same time inspect the lip seal 1 and preferably replace it Inspect the bevel pinion splines and replace the ring nut 2 and collapsible spacer 5 The setting operations to complete for this group are as follows SETTING THE BEVEL DISTANCE SETTING THE PRE LOAD OF THE PINION BEARINGS SETTING THE PINION CROWN WHEEL BACKLASH SETTING THE DIFFERENTIAL BEARING PRE LOAD Described on the following pages SPECIAL TOOLS Driver for Pinion Seal 1 Ref 119047 Wrench for differential ring nut 9 and 16 Ref 119030 REPAIR MANUAL 711 19 AXLE F6 1 SETTING THE BEVEL DISTANCE Install the pinion bearings in the differential s
7. ISASSEMBLING SETTING AND REASSEMBLING INDEX OF PAGES FOREWORD EPICYCLIC REDUCTION WHEEL HUB WHEEL SHAFT AND BRAKES DIFFERENTIAL SUPPORT AND BEVEL GEAR PINION SET SETTING THE BEVEL DISTANCE PINION BEARING PRE LOAD CROWN WHEEL PINION BACKLASH DIFFERENTIAL BEARING PRE LOAD DIFFERENTIAL AXLE HOUSING FOREWORD DISASSEMBLY REASSEMBLY 6 l 6 2 6 3 6 4 The overhauling of the Final Drives and Wheel Hubs can be completed without removing the axle from the machine Should it be necessary to remove the Axle Assembly adeguate supporting of the machine must be ensured to work with safety REPAIR MANUAL 711 19 AXLE F2 OIL SEAL FOR ROTATING SHAFT For an installation of oil seal adhere to the following recommendation Before installation soak the seal for half hour in the same oil that will be used in the housing to be sealed Clean the shaft and ensure the seal area of the same is not damaged pitted or grooved Place the sealing lips towards the oil side Lubricate the lip seal oil is better than grease and fill with grease the space between oil lip and dust lip of dual lip seals Install the oil seal using a suitable seal driver Avoid hammering directly on the seal To avoid damage to the seal lip caused by the shaft adequately protect the same during shaft assembly procedure O RING Ensure adequate lubrication of the seals before inserting them in their seats
8. VES Ratio Thrust Washer Thickness Planetary Gear Wheel Bearing Pre load 269 7 to 269 8 229 7 to 229 8 270 000 to 270 081 230 000 to 230 072 8 150 to 8 186 7 978 to 8 000 9 90 to 10 10 0 80 to 1 00 1 6 1 45 to 1 55 System Set Right REPAIR MANUAL 711 19 AXLE B1 SECTION VIEW INDI TI a x SC 6 L NE F A n yon gt BI WEN o Hd g N o i a N co 17 REPAIR MANUAL B2 711 19 AXLE SILHOUETTE VIEW PEER A v l eman AUD tat M LANA N JE ou AAN REPAIR MANUAL 711 19 AXLE C1 TIGHTENING TORQUE refer to page B1 for identification Note all mating surfaces are to be sealed with SILASTIC 732 or equivalent DESCRIPTION BEVEL GEAR DIFFERENTIAL AXLE HOUSING Input Shaft Ring Nut Bolt Input Shaft Cover Bolt Differential Support to Axle Housing Bolt Crown Wheel Bearing Ring Gear Lock Plate Bolt Crown Wheel to Differential Carrier use Loctite 270 6 Breather Support 7 Nuts Input Shaft Flange 8 Oil Drain Plug 9 1 U C t mm Oil Level Plug 0 Bolts Crown Wheel Bearing Cap to Differential Support BRAKES AND FINAL DRIVES 11 Studs Wheel Shaft to Axle Beam 12 Nuts Wheel Shaft to Axle Beam 13 Bolts Self Adjust Device 14 Bolts Wheel Carrier to Wheel Shaft 15 Studs Planetary Carrier to Wheel Hub 16 Screw Planetary Carrier to Wheel Hub 17 Nuts Wheel Rim CODE 115054 020749 125827 020744
9. good condition and only use the correct tool for the job in hand Always wear safety spectacles when using soft or hard faced hammers chisels drifts or when using air tools Wear safety spectacles when cleaning components or when grinding Do not misuse airlines and be aware of the damage compressed air can cause if misused Always make sure lifting equipment is in good condition and the Safe Working Load exceeds the weight of the component to be lifted Always use suitable supports i e axle stands or baulks of timber in conjunction with hydraulic jacks etc Never rely on hydraulic jacks alone to support a machine Be aware of hot surface temperatures and take care when draining hot oils Always dispose of waste oils in accordance with local and national regulations Whenever possible always disconnect the battery or battery isolator when working on the machine to prevent electrical shorts and unauthorised starting Refer to the operator s handbook for a guide to the correct sequence for assembling components and sub assemblies Oils fuels silicone sealer etc can cause skin diseases if allowed to contaminate the skin Always apply barrier creams wear suitable protective clothing or when contamination is unavoidable clean the area with soap and water as soon as possible Do not use thinners or other solvents to clean skin Health amp Safety is a matter of common sense If common sense is applied correctly the risk of accidents
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11. orrect The total amount of the pre load to find differential pinion bearings on the diameter 34 87 of the pinion queue must be T P 2 9 TO P 4 3 where P is the final value found for the pinion REPAIR MANUAL 711 19 AXLE F7 4 SUN GEAR DIFFERENTIAL Inspect the thrust washer 5 and 3 for wear and replace if necessary Inspect the other differential components and the shafts 1 particularly Use LOCTITE 270 to secure the bolts 9 which fasten the crown wheel to the differential housing 8 REPAIR MANUAL 711 19 AXLE F8 AXLE HOUSING 12 Inspect the breather pipe 2 to ensure the valve is working correctly and replace if necessary Inspect the splines on the halfshaft 12 and replace if necessary Draining oil from the plug 8 on the differential end plate Filling with oil and checking the level use the plug 1 located in the front face of the axle housing Use SILASTIC 732 or equivalent to seal between the differential end plate and axle housing
12. r ring nut in a clockwise direction at the same time lightly hitting the bearing caps with a soft faced hammer to align the bearings Continue until all the clearance in the bearings has been removed this will be indicated when the ring nut becomes difficult to move Put the dial gauge in position so that the probe is in contact with and at 90 to a tooth on the spiral gear Check the amount of backlash between the spiral gear and bevel pinion Repeat on two or more teeth at equal distance around the spiral gear Make a note of the clearance if the amount of clearance is different put the probe of the dial gauge on the tooth that has the smallest clearance Move the spiral gear toward or away from the pinion by moving each ring nut an equal amount continue until the dial gauge shows a clearance of 0 18 to 0 24mm REPAIR MANUAL 711 19 AXLE F6 4 SETTING OF THE PRE LOAD FOR THE DIFFERENTIAL BEARINGS Adjust the pre load of the differential side bearings using the following method With the crown wheel in mesh with the pinion and the backlash correctly set rotate the pinion using a string and pull scale and record the effort required to rotate the pinion and crown wheel differential unit Tighten each differential side bearing adjuster ring nut by equal to preserve the backlash adjustment Install the adjuster ring lock tabs Fully tighten the cap nuts to the specified torque Recheck to make sure that the backlash is c
13. ry 50 hours REPAIR MANUAL 711 19 AXLE El SPECIAL TOOLS DESCRIPTION PART No Wrench for Input Shaft Ring Nut Ref 115054 119044 Driver for Input Shaft Oil Seal Ref 116722 119047 Driver for Drive Shaft Oil Seal Ref 025351 119047 Driver for Drive Shaft Bush Ref 109972 119043 Wrench for Differential Side Ring Nut Ref 117400 119030 Kit for Bevel Distance Measurement Ref 119049 Interchangeable Handle 119033 Driver for Cassette Oil Seal Ref 047705 119085 Driver for Cassette Oil Seal Ref 047705 119086 MIIA 3 4 75 32 TO BE USED TO FIT THE OIL SEAL BETWEEN COVER AND PINION SHAFT OFF MECC CARRARO S p A CAMPODARSEGO Padova TO BE USED WITH car119033 INTERCHANGEABLE HANDLE Macchina penominazion DRIVER FOR car109972 BUSH Classifica mater Sost il Mat SAE 1040 C40 Posizione Archivio ER Tratt termico Peso Finito N DISEGNO i 19043 CARRARO OFF MECC CARRARO S p A CAMPODARSEGO Padova olu osad ooa REL 9 8 0047201 VHAH9 Had 3AVIHO __ AYLI dd O 3SHVGOdWVO 67 OW1O VIA WAS OBVUUVI Ottdidt2 car 22121 ZA ALL M 12x110 BOLT UNI 5737 car 20948 swewe Bevel gear set OFF MECC CARRARO S p A KIT FOR BEVEL DISTANCE MEA CAMPODARSEGO Padova Denominazione c FULL E Ti Data 1 1 12 86 Tratt termico Peso Finito 14t 9049 00 U81 BEL ESOGLL ems oes Imana om
14. th of string or twine evenly and without overwrapping around the exposed input splines and using a pull scale measure the force required to rotate the pinion shaft in the bearings When the specified pull is achieved by tightening the retaining nut and collapsing the spacer pre loading the bearings lock the retaining nut Use silastic 732 or equivalent between the differential end plate and lip seal cover NOTE the approximate torque at the ring nut to begin deformation of the collapsible spacer is 17 18 daN l ji a i SPECIAL TOOLS Wrench for pinion ring nut Ref 119044 REPAIR MANUAL 711 19 AXLE F6 3 SETTING THE BACKLASH The correct amount of backlash is 0 18 to 0 24mm The adjustment is made by turning the side ring nuts The ring nuts push against the bearings and move the bevel gear toward or away from the bevel pinion When this adjustment is made the ring nuts can be difficult to move and it may be necessary to release the bearing cap nuts a small amount to relieve the pressure on the ring nuts Do not slacken the nuts more than is absolutely necessary To set the backlash carry out the following procedure Turn the right nut on the spiral gear side of the differential in a clockwise direction at the same time hit the bearing caps lightly with a soft faced hammer to align the bearings continue turning until the spiral gear is in contact with the pinion Turn the othe
15. tio T 10 32 Backlash mm 0 18 to 0 24 Shim Thickness for Bevel Pinion position mm 2 5 to 3 4 01 by 01 Bevel Pinion Bearing Pre load measured on diameter D 34 87 daN P 9 2 to 13 7 Crown Wheel Bearing Pre load measured on diameter D 133 daN 2 4 to 3 6 Bevel Gear Set total Bearing Pre load measured on the Pinion queue daN T P 2 9 to P 4 3 Sun Gear Planet Backlash mm 0 13 to 0 27 Thickness Sun Gear Thrust Washers mm 1 45 to 1 55 Thickness of Self Locking Differential Fixed Plates mm 1 47 to 1 53 Thickness of Self Locking Differential Rotating Plates mm 1 57 to 1 3 Thickness of Self Locking Differential Spacer mm 2 77 to 2 83 Sun Gear Shaft Diameter mm 21 967 to 21 980 Sun Gear Shaft Bore on Sun Gear mm 22 065 to 22 098 Assembly Clearance Shaft Bore mm 0 085 to 0 131 HALF SHAFT Short Shaft Outer Diameter mm 34 904 to 34 92 Short Shaft Bush Diameter Fitted mm 35 025 to 35 104 Clearance between Short Shaft and Bush mm 0 105 to 0 200 Long Shaft Outer Diameter mm 29 947 to 29 980 Long Shaft Bush Diameter Fitted mm 30 050 to 30 115 Clearance between Long Shaft and Bush mm 0 070 to 0 168 Interference Fit between Bushes and Seat mm 0 065 to 0 130 short shaft side REPAIR MANUAL 711 19 AXLE A2 WHEEL SHAFT AND BRAKES Brake Piston Outer Diameters Wheel Shaft Inner Diameters Brake Piston Area Centering Pin Seat Diameters on Brake Piston Centering Pin Diameter Brake Disc Thickness Maximum Wear of Brake Disc FINAL DRI
16. upport casing and lightly clamp the bearings using tool 5 Tighten the clamp part so that the bearing cones can just be turned by hand Do not overtighten Install the differential support casing side bearings cap and tighten by the relative retaining nuts Using an internal micrometer measure the side bearing bore D Locate the circular bar 6 across the bearing bores in the support casing and using a depth gauge 7 measure the dimension Y Determine the required thickness of shim using the following calculation B Y 25 shaft diameter D 2 The actual shim thickness will be the difference between calculation B and the dimension etched on the head of the pinion Select the calculated shim thickness from the range available and install on the pinion shaft Press the inner bearing onto the pinion shaft ensuring that it is fully seated N Position of gear protrusion dimension Position of spiral gear pinion mating number SPECIAL TOOLS Kit for bevel distance measurement Ref 119049 REPAIR MANUAL 711 19 AXLE F6 2 PRE LOAD OF PINION BEARINGS Assemble the pinion bearing and spacer assembly into the support casing together with the outer bearing and retaining nut do not fully tighten the retaining nut but tighten only until it touches the collapsible spacer The pinion bearing requires a pre load of 9 2 13 7 daN measured on the pinion queue without the cover and seal Wrap a leng
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