Manual de Servicio Mandos Finales Th255 - Axle D & A - Global - English

Disassembly/Assembly Manual
Axle
Model
TH255
S/N TBS00100 & After
31200451
Original
August 29, 2008
EFFECTIVITY PAGE
August 29, 2008 - A - Original Issue Of Manual
31200451 a
EFFECTIVITY PAGE
-b 31200451
SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Definition Of Viewpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Maintenance Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section 3
Reduction Gear - Disassembly/Assembly/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Reduction Gear - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Reduction Gear - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Section 4
Brake - Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Service Brake/Negative Brake/100% Locked - Disassembly . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Service Brake/Negative Brake/100% Locked - Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3 Negative Brake (4 Cup Springs) - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.4 Negative Brake (4 Cup Springs) - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.5 Service Brake/mechanical Parking Brake - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.6 Service Brake/mechanical Parking Brake - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.7 Service Brake/Diff. Hyd. Lock 100% - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.8 Service Brake/Diff. Hyd. Lock 100% - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Section 5
Planetary Reduction/Steering Case - Disassembly/Assembly . . . . . . . . . . . . . . . . . . 5-1
5.1 Planetary Reduction - 1.6 and Steering Case - Disassembly . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Planetary Reduction - 1.6 and Steering Case - Assembly. . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3 Planetary Reduction Gear - 1:4, 23 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.4 Planetary Reduction Gear - 1:4, 23 - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Section 6
Differential - Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6.1 Normal Pre-Loaded Differential - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6.2 Normal Pre-loaded Differential - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
6.3 Preloaded Limited Slip Differential - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
6.4 Preloaded Limited Slip Differential - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
6.5 Differential Unit - with block to spheres 100% - Disassembly . . . . . . . . . . . . . . . . . . . . 5-21
6.6 Differential Unit- With Block To Spheres 100% - Assembly . . . . . . . . . . . . . . . . . . . . . . 5-27
31200451 i
Section Subject Page
6.7 Normal Differential - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

6.8 Normal Differential - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
6.9 Limited Slip Differential (45%) - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
6.10 Limited Slip Differential (45%) - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Section 7
Bevel Pinion - Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
7.1 Bevel Pinion - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
7.2 Bevel Pinion - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
7.3 Normal Flange Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
7.4 Revolution Counter Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Section 8
Differential Ring and Pinion Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
8.1 Step For Pre-loaded Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
8.2 Version Pinion Cover And Single Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
8.3 Version Pinion Integral And Double Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Section 9
Steering Cylinder - Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
9.1 Steering Cylinder - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
9.2 Steering Cylinder - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
9.3 Steering Cylinder - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Section 10
Swinging Support - Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
10.1 Swinging Support - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
10.2 Swinging Support - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Section 11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ii 31200451
Section 1
Safety Practices
1.1 INTRODUCTION 1.2 DISCLAIMER

This service manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and The manufacturer reserves the right to make changes
equipment reliability. and improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & MAINTENANCE
provide directions for meeting every possible contingency MANUAL
during operation, maintenance, or testing. When additional
information is desired consult the local Caterpillar dealer. The mechanic must not operate the machine until the
Operation & Maintenance Manual has been read &
Many factors contribute to unsafe conditions: carelessness,
understood, training has been accomplished and
fatigue, overload, inattentiveness, unfamiliarity, even
operation of the machine has been completed under the
drugs and alcohol, among others. For optimal safety,
supervision of an experienced and qualified operator.
encourage everyone to think, and to act, safely.
An Operation & Maintenance Manual is supplied with
Appropriate service methods and proper repair
each machine and must be kept in the manual holder
procedures are essential for the safety of the individual
located in the cab. In the event that the Operation &
doing the work, for the safety of the operator, and for the
Maintenance Manual is missing, consult your local
safe, reliable operation of the machine. All references to
Caterpillar dealer before proceeding.
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction.
Supplementary information is available from the
manufacturer in the form of Service Bulletins, Service 1.4 DO NOT OPERATE TAGS
Campaigns, Service Training Schools, the service
website, other literature, and through updates to the Place Do Not Operate Tags on the ignition key switch and
manual itself. the steering wheel before attempting to perform any
service or maintenance. Remove key and disconnect
battery leads.
31200451 1-1
Safety Practices
1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
DANGER the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards

WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
WARNING indicates a potentially hazardous situation is properly attached.
which, if not avoided, could result in death or serious NEVER stand or otherwise become positioned under a
injury. suspended load or under raised equipment. The load or
equipment could fall or tip.
CAUTION DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
CAUTION indicates a potentially hazardous situation HAND TOOLS: Always use the proper tool for the job;
which, if not avoided, may result in minor or moderate keep tools clean and in good working order, and use
injury. special service tools only as recommended.
1-2 31200451
Safety Practices
1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
HOUSEKEEPING: Keep the work area and operator’s
injury. To prevent personal injury, NEVER remove the
cab clean, and remove all hazards (debris, oil, tools, etc.).
radiator cap while the cooling system is hot. Wear safety
FIRST AID: Immediately clean, dress and report all injuries glasses. Turn the radiator cap to the first stop and allow
(cuts, abrasions, burns, etc.), no matter how minor the pressure to escape before removing the cap completely.
injury may seem. Know the location of a First Aid Kit, and Failure to follow the safety practices could result in death
know how to use it. or serious injury.
CLEANLINESS: Wear eye protection, and clean all FLUID FLAMABILTITY: DO NOT service the fuel or
components with a high-pressure or steam cleaner hydraulic systems near an open flame, sparks or smoking
before attempting service. materials.
When removing hydraulic components, plug hose ends NEVER drain or store fluids in an open container. Engine
and connections to prevent excess leakage and fuel and hydraulic fluid are flammable and can cause a
contamination. Place a suitable catch basin beneath the fire and/or explosion.
machine to capture fluid run-off.
DO NOT mix gasoline or alcohol with diesel fuel. The
Check and obey all Federal, State and/or Local mixture can cause an explosion.
regulations regarding waste storage, disposal and
PRESSURE TESTING: When conducting any test, only
recycling.
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
1.6.4 Operational Hazards manner, and make changes or repairs as indicated by the
ENGINE: Stop the engine before performing any service test procedure to achieve the desired result.
unless specifically instructed otherwise. LEAVING MACHINE: Lower the forks or attachment to
VENTILATION: Avoid prolonged engine operation in the ground before leaving the machine.
enclosed areas without adequate ventilation. TIRES: Always keep tires inflated to the proper pressure
SOFT SURFACES AND SLOPES: NEVER work on a to help prevent tipover. DO NOT over-inflate tires.
machine that is parked on a soft surface or slope. The NEVER use mismatched tire types, sizes or ply ratings.
machine must be on a hard level surface, with the wheels Always use matched sets according to machine
blocked before performing any service. specifications.
FLUID TEMPERATURE: NEVER work on a machine MAJOR COMPONENTS: Never alter, remove, or
when the engine, cooling or hydraulic systems are hot. substitute any items such as counterweights, tires,
Hot components and fluids can cause severe burns. batteries or other items that may reduce or affect the
Allow systems to cool before proceeding. overall weight or stability of the machine.
FLUID PRESSURE: Before loosening any hydraulic or BATTERY: DO NOT charge a frozen battery.Charging a
diesel fuel component, hose or tube, turn the engine frozen battery may cause it to explode. Allow the battery
OFF. Wear heavy, protective gloves and eye protection. to thaw before jump-starting or connecting a battery
NEVER check for leaks using any part of your body; use charger.
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under
1.7 SAFETY DECALS
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause Check that all safety decals are present and readable on
infection, gangrene and other serious personal injury. the machine. Refer to the Operation & Maintenance
Relieve all pressure before disconnecting any Manual supplied with machine for information.
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
31200451 1-3
Safety Practices
This Page Intentionally Left Blank
1-4 31200451
Section 2
General Information and Specifications
2.1 INTRODUCTION CLASSIFICATION

This manual classifies units according to part numbers.
The efficiency and continued operation of mechanical For a correct interpretation, classification is indicated as
units depend on constant, correct maintenance and also follows:
on efficient repair work, should there be a break-down or
malfunction. The instructions contained in this manual
= up to the part number.
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, = from the part number on.
when partial repair work is needed. The manual provides
a quick and sure guide which, with the use of When no classification is given, disassembly and
photographs and diagrams illustrating the various phases assembly operations are the same for all versions.
of the operations, allows accurate work to be performed.
All the information needed for correct disassembly,
SPECIFIC EQUIPMENT AND SPARE PARTS
checks and assembly of each individual component is set
out below. In order to remove the differential unit from the The drawings of all specific tools required for
vehicle, the manuals provided by the vehicle maintenance and repair work can be found at the end of
manufacturer should be consulted. In describing the this manual ; spare parts may be ordered from your
following operations it is presumed that the unit has Caterpillar dealer.
already been removed from the vehicle.
IMPORTANT: In order to facilitate 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,
pullers 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 mechanical units should be
thoroughly cleaned with appropriate products and
restored or replaced if damage, wear, cracking or seizing
have occurred.
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.
31200451 2-1
2.2 DEFINITION OF VIEWPOINTS
2.3 DATA PLATE
2.4 MAINTENANCE POINTS
2-2 31200451
Table 2-1. MAINTENANCE INTERVALS
OPERATION INTERVAL LUBRICANT
Differential Every 250 Hours

Check Levels SAE85W90 (API GL4 - MIL L-2105)
Planetary Reduction Every 250 Hours With additives for oil-bath brakes
SAE85W90 (API GL5 - MIL 2105-B)

Differential Every 800 Hours *
With additives for oil-bath brakes, for
units presenting hypoid crown wheel
Oil Change Planetary Reduction Every 1000 Hours *
and pinion and /or self-locking differen-
tial gear
Self-Locking Differential Gear Every 700 Hours *
* Initially after 100 working hours

When it starts sounding noisy
OPERATION MEMBER CONDITIONS INTERVAL LUBRICANT
Normal Work Monthly

CAT Molybdenum
Greasing Articulation
Paste
Awkward Work Weekly
Table 2-2. ADJUSTMENT AND CHECKS
UNIT OPERATION INTERVAL SERVICE BRAKE CIRCUIT
Negative Brake Adjustment Every 1000 Hours *

Only for mineral oil use e.g. ATF Dexron
Service Brake Adjustment Every 500 Hours II. Make sure that master cylinder seals
are suitable for mineral oil.
Wheel Nuts Tightening Every 200 Hours
* Initially after 100 working hours
31200451 2-3
Table 2-3. SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS

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.
TYPE APPLICATION
Anaerobic product apt to prevent the loosening of screws, nuts and
CAT Threadlock 242 plugs. Used for medium-strength locking. Before using it, completely
remove any lubricant by using the specific activator.
The oleocompatible alternative to 242. Does not require the activation of
CAT Threadlock 243
lubricated surfaces.
Anaerobic product for very-high strength locking of screws and nuts.
Before using it, completely remove any lubricant by using the specific
Loctite 270
activator. To remove parts, it may be necessary to heat them at 80°C
approx.
Anaerobic product suitable for high-strength locking and sealing of large
threaded parts, bolts and stud bolts, for pipe sealing and for protecting
Loctite 275
parts against tampering; suitable for sealing coupling surfaces with a
max. diametrical clearance of 0.25 mm.
Anaerobic product for the hermetic sealing of flanged units and screw
CAT Gasket Maker holes communicating with fluids. Can seal clearances between flanges
up to 0.2 mm.
Quick anaerobic sealant for sealing threaded portions of conical or cylin-
drical unions up to M80. Before using it, remove any lubricant with the
CAT Threadlock 577
specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal
CAT High Strength/High Tempera-
joints (hub on shaft). Can glue together parts with clearance ranging
ture Retaining Compound 638
between 0.1 and 0.25 mm.
Anaerobic adhesive for fast and medium-strength gluing of cylindrical
CAT High Strength/High Tempera-
metal joints (hub on shaft). Can glue together parts with radial clearance
ture Retaining Compound 648
below 0.1 mm.
(AREXONS) Solvent-based sealing compound for elastic seals, drying through evapo-
Repositionable jointing compound ration. Used for sealing the outer diameter of sealing rings for rotating
for seals shafts with outer metal reinforcement.
Semi-fluid adhesive material used for sealing and filling and to protect
CAT RTV Silicone Adhesive Sealant components from environmental and physical elements. Polymerises
with non-corrosive dampness.
Highly adhesive synthetic grease, with silicone compounds added.
CAT Multi Purpose Grease Applied to adjustment screws with hole communicating with oil-type flu-
ids. Used when frequent adjusting is required.
Lubricating compound containing molybdenum disulphide, used to lubri-
CAT Molybdenum Paste cate articulation pins and to prevent sticking and oxidation of parts that
are not lubricated on a regular basis.
Applied to bearings, sliding parts and used to lubricate seals or parts
CAT White Assembly Grease
during assembly
2-4 31200451
Table 2-4. WHEEL NUTS TIGHTENING TORQUES RECOMMENDED
RECOMMENDED WHEEL
WHEEL NUTS TORQUE
WHEEL NUTS
STUD NUT FIXING'S SOLUTION
CHARACTERISTIC MATERIAL QUALITY
THREAD
ST 37 **ST 52
330 N/m 460 N/m
M18 X 1,5
(243 ft. lb.) (339 ft. lb.)
WHEEL NUTS WITH
490 N/m 630 N/m
INTEGRATED M20 X 1,5
(361 ft. lb.) (464 ft. lb.)
SPHERICAL COLLAR
630 N/m 740 N/m
M22 X 1.5
(464 ft. lb.) (545 ft. lb.)
270 N/m 360 N/m
M18 X 1,5
(199 ft. lb.) (265 ft. lb.)
FLAT COLLAR WHEEL NUTS
360 N/m 450 N/m
WITH SEPARATE SPHERICAL M20 X 1,5
(265 ft. lb.) (332 ft. lb.)
LOCK WASHER
460 N/m 550 N/m
M22 X 1.5
(339 ft. lb.) (406 ft. lb.)
260 N/m 360 N/m
M18 X 1,5
(192 ft. lb.) (265 ft. lb.)
WHEEL NUTS WITH
350 N/m 500 N/m
INTEGRATED SEAT CAPTIVE M20 X 1,5
(258 ft. lb.) (369 ft. lb.)
WASHER
450 N/m 650 N/m
M22 X 1.5
(332 ft. lb.) (479 ft. lb.)
31200451 2-5
2-6 31200451
Section 3
Reduction Gear - Disassembly/Assembly/Adjustment
3.1 REDUCTION GEAR - DISASSEMBLY
3.1.1 GENERAL DRAWING
31200451 3-1
3.1.2 Disassembly: Integral 603 Type Input

Gear
4. Lift off the cover (21).
1. Remove screws (14) (20) of the drive side flange

cover.
5. To remove the drive side shaft (1), remove the snap

ring (2).
2. Take off the drive side flange cover (21).

IMPORTANT: Remove carefully do not damage.
6. Using two levers, remove the drive side shaft (1)
3. Place two levers into the appropriate slots. NOTE:

Look out not to damage the surfaces.
3-2 31200451
7. Using two levers, remove the flange sealing ring (6). 10. Remove the snap ring (4).
11. With a puller, remove the bearing (7) from the flange
8. Remove the snap ring (4). shaft (18).
IMPORTANT: Remove carefully do not damage. IMPORTANT: Remove carefully do not damage.
9. With a puller, remove the bearing (3) from the input 12. Remove the secondary gear wheel (8) using two
shaft (1). levers.
31200451 3-3
13. Remove the snap ring (9). 16. Pull out the cup of the sealing ring (11) by using drift.
14. Remove the flange (18) by means of a plastic

hammer.
15. Remove the internal bearing (10).
3-4 31200451
3.2 REDUCTION GEAR - ASSEMBLY
3.2.1 GENERAL DRAWING
31200451 3-5
3.2.2 Assembly: Integral 603 Type Input

Gear
3. Fit the flange (18) and fasten it.

4. For keying the flange (18), use a plastic hammer if
1. Insert the sealing ring (6) with (T12) tool. necessary.
Note: Bring the sealing ring just to the end stop, apply IMPORTANT: Install carefully do not damage, also note
grease to the sealing lips direction of installation.
IMPORTANT: Install carefully do not damage, also note

direction of installation.
5. Lubricate, then insert the bearing (10).
2. Insert the sealing ring (11) with (T12) tool.

Note: Bring the sealing ring just to the end stop, apply
grease to the sealing lips
6. Using a normal tool insert the bearing (10) and snap

ring (9).
3-6 31200451
7. Install the secondary gear wheel (8) with a plastic 10. Fix the bearing with the snap ring (4).
hammer.
11. Install the drive side shaft (1) with a plastic hammer.
8. Lubricate the bearing, then using a normal tool
insert the bearing (7).
12. Install drive side flange cover, apply CAT Gasket

Maker to the mating surfaces and the short screws.
9. Lubricate the bearing, then insert the snap ring (2)
and using a normal tool insert the bearing (3).
31200451 3-7
13. Tighten side flange cover screws (hex and allen)

with a torque wrench setting of 80-90 Nm (66 - 74 ft.
lb.).
3-8 31200451
Section 4
Brake - Assembly/Disassembly
4.1 SERVICE BRAKE/NEGATIVE BRAKE/

100% LOCKED - DISASSEMBLY
4.1.1 General Drawing
31200451 4-1
4.1.2 Axle/Axle Housing - Removal
3. Insert block screws to end stroke and release

pressure.
1. Connect an external pump to the union piece “ P1 “
of the negative brake and introduce a pressure of 15
± 30 bar (15 bar = 217 PSI) to eliminate the pressure
of the Belleville washers.
2. Loosen the unlocking screws (30) and remove both

stop washers (32).
4. Remove the screws of the planetary gearbox cover

on the brake side.
5. Remove the planetary gearbox cover.
4-2 31200451
4.1.3 Brake Piston Assembly - Removal
6. Remove the axle half shaft.

IMPORTANT: Remove carefully do not damage. 9. In order to keep the disc springs of the negative
brake preloaded, install provisional screws with
washers to the end stop.
7. Sling the arm to be removed and connect it to a

hoist, remove screws.
10. Remove the negative brake locking screws (30).
11. Always replace the O-ring (31).
8. Carefully, take off the arm and lay it down vertically.
12. Loosen the previously installed provisional screws in

the same sequence and same measure.
31200451 4-3
4.1.4 Brake Piston Module - Disassembly
14. Pull out brake piston assembly module.

13. Insert the screws of the puller (M12) into the
tapholes of the negative brake housing and remove
the pistons of the brake.
15. Inspect the locking screw (33) of the brake piston

module.
16. Remove intermediate disc (2).

Note: Mark the assembly position.
4-4 31200451
17. Applying pressure to the first hole, remove the 20. Turn the brake module upside down and with a pin
service brake piston (7). driver remove the locking pin of the slotted nut.
18. Applying pressure to the second hole, remove the 21. Mark the position of the slotted nut.
hydraulic block piston (12).
22. Unscrew the slotted nut (29).
19. Applying pressure to the third hole, remove the three

bolts (24).
31200451 4-5
23. Remove the disc springs (28). 25. Check the position of the anti-extrusion
(8)(10)(14)(5) and o-rings (9)(10)(13)(6).
IMPORTANT: Replace o-rings.
24. Applying pressure, remove the piston (27) of the

negative brake.
IMPORTANT: Remove carefully do not damage. Inspect 26. Check the position of the O-rings (25)(26).
after removal, replace o-rings. IMPORTANT: Replace o-rings.
4-6 31200451
IMPORTANT: Replace o-rings. 29. Using a puller, preload the spring (42).
27. Remove the snap ring (4) from the intermediate disc 30. Remove the snap ring (44).
(2).
Note: Spring preloaded.
28. Remove coupling (40) and washers (45). 31. Remove the fixing ball (41).
Note: Build a stack of washers and record the height
measurement.
31200451 4-7
32. Remove the spring (42) an d washer (43). 34. Remove the brake discs one after the other(39)(38).
Note: If they are not to be replaced, do not mix up the
sequence and note direction of installation.
33. Remove the snap ring of the brake stack
4-8 31200451
4.2 SERVICE BRAKE/NEGATIVE BRAKE/

100% LOCKED - ASSEMBLY
31200451 4-9
4-10 31200451
4.2.3 Brake Piston Module - Assembly
1. Insert spring (43) and washer (42) onto the hydraulic

block coupling.
4. Shift the cut of the snap ring (15) according to the

2. Preload the spring (42) by using a puller acting on ball (41).
the washer (43).
3. Insert the snap ring (44) and the fixing ball (41).
5. Install the o-rings and anti-extrusion rings on all

pistons.
IMPORTANT: The o-rings always have to be assembled
from the pressure facing side.
31200451 4-11
6. Install new o-rings (23) and insert the bolts (24). 9. Install the intermediate disc (2) note the previously
marked position and direction of installation.
7. Install the hydraulic block piston (12).

IMPORTANT: Install carefully do not damage. 10. Turn upside down and insert the negative brake
piston (27).
IMPORTANT: Install carefully do not damage.
8. Install the service brake piston (7) hammering

alternately with a plastic hammer.
IMPORTANT: Install carefully do not damage. 11. Install the slotted nut (29), screw down clockwise 5
full turns.
4-12 31200451
12. Find out the thickness of the brake discs “D”. 14. Determine the level “A” between the external plane
E.g. D=44.7 mm and the brake plate by the adjustment of the slotted
13. Add to D the value G = brake clearance (e.g. 1.4 nut.
mm). Note: To define the level A, adjust the slotted nut always
D + G = 44,7 + 1,4 = 46,1 to the smaller value by driving to the closer notch.
A = 141 - (D+G) = 141 - 46,1 = 94,9 mm
X = constant value 141 mm
IMPORTANT: To determine the level A the slotted nut

has to be operated without spring mounted.
31200451 4-13
15. Before removing the slotted nut in order to insert the 18. Insert and place into position washers (45) and
springs, note the distance Z from the plane to the coupling (40) (position ball in notch) into the brake
tooth near the pin. module (22).
Note: Mark this slot in the nut.
19. With the positioned pack determine the distance L

16. Turn upside down and fit on the intermediate disc between coupling and brake disc surface.
(2). E.g. L=37.5 mm
IMPORTANT: Install carefully do not damage. Set aside for later installation.
17. Select a pack of washers (20)of 1.5 mm

S4=1.5 mm const.
4-14 31200451
4.2.4 Brake Piston Module - Installation
22. Zero the depth gage from the plane of the splined
coupling to the surface of the brake discs.
20. Insert the brake discs (38) in the right sequence.
Note: Press the brake disc pack before zeroing, execute
Note: The first brake disc to be inserted must be of
the measurement in some points and take an average.
friction material.
23. CHECK OF THE CLEARANCE “R” BETWEEN

21. Insert the brake discs (39) in the right sequence.
COUPLING AND THRUST BEARING.
Note: The last brake disc to be inserted must be of Find out the distance “M” between the brake discs
metal material. surface and thrust bearing.
E.g. M=36.4mm Brake discs clearance G = 1,4
R =(M+G)-L=(34,6+1,4)-37,5=0,3mm
31200451 4-15
4.2.5 Brake Piston Module - Correction of

S4 Shim Pack Thickness- If Required
Note: If not required continue to Section 4.2.6, “Brake
Piston Module - Installation - Continued”.
3. Insert the complete intermediate disc (2).
1. CORRECTION OF THE SHIMS S4 DEPENDING

ON THE CALCULATION OF THE VALUE “R”
Note: The value of “R” has always to result in 0.1 mm. in
case it is not so, the shims S4 (45) under the coupling
(40) have to be modified.
4. Turn upside down and unscrew the slotted nut (29).
2. Depending on the calculation assemble the exact

shims to arrive at R=0.1 mm.
a. Assemble all with safety ring.
where 1.5 const. Shims S4 z.B.: S4= 1,5+(0,3-
0,1)= 1,5+0,2= 1,7mm 0.3mm = R calculated
clearance
b. 0.1mm = R wanted clearance 5. Insert the disc springs in the right position (28).
4-16 31200451
6. Insert at the bottom the piston of the negative brake 9. Put the pin in locking position (21).
(27) and screw on the slotted nut (29).
10. Insert two screws of M12 to fix the break arm.

7. Screw down the slotted nut to the earlier determined
position.
IMPORTANT: Position the groove of the brake module

in line with the lock screw in the arm.
8. Check the earlier measured distance Z from the
plane to the tooth next to the pin.
31200451 4-17
IMPORTANT: Check locking screw (33) of the brake

piston module.
4-18 31200451
4.2.6 Brake Piston Module - Installation -

Continued
4. Tighten with a torque wrench setting of max. 45 Nm

(33 ft.lb.)
1. Insert the brake module facing the input holes to the
top.
5. Insert the negative brake unlocking screw (30) up to

the end stop.
2. Insert the piston to the end stop by alternating light
strokes and remove the screws.
6. Remove the two auxiliary screws.
3. Temporary insert screws M12x45.
31200451 4-19
4.2.7 Axle/Axle Housing - Installation
7. Replace and lubricate the o-ring and install the axle

housing to the main housing.
10. Insert the two “U”-shaped shims and tighten the

unlocking screws with a torque wrench setting of 95-
115 Nm (70-85 ft.lb.).
8. Apply CAT Threadlock to the axle housing screw Note: The position of the negative brake is unlocked.
threads and tighten the screws alternately to 128 Nm
(94 ft.lb.).
9. Introduce a pressure of max. 25 bar (362 PSI) and

loosen the unlocking screws.
4-20 31200451
31200451 4-21
4-22 31200451
31200451 4-23
4-24 31200451
4.3 NEGATIVE BRAKE (4 CUP SPRINGS)

- DISASSEMBLY
31200451 4-25
1. For details, see «BRAKE: SERVICE BRAKE, 3. Remove the disc springs (28).
NEGATIVE BRAKE, 100% LOCKED». Turn the
brake module upside down and with a pin driver
remove the locking pin of the slotted nut.
Note: Mark the position of the slotted nut.
4. Inspect for debris or damage.
2. Unscrew the slotted nut (26).
4-26 31200451
4.4 NEGATIVE BRAKE (4 CUP SPRINGS)

- ASSEMBLY
3. Find out the level of the brake discs “D”.

E.g. D=44.7 mm
4. Add to D the value G = brake clearance (e.g. 1,25
1. For details, see «BRAKE: SERVICE BRAKE, mm).
NEGATIVE BRAKE, 100% LOCKED». D + G = 44,9 + 1,25 = 46,2 mm
Replace the o-rings and anti-extrusion rings on all
pistons.
5. Before removing the slotted nut in order to insert the

springs, measure and note the distance Z from the
plane to the tooth near the pin.
2. Determine the level “A” between external plane and Note: Mark the tooth.
the brake plate by the adjustment of the slotted nut.
Note: To define the level A adjust the slotted nut always
to the smaller value by driving to the closer notch.
A = 131,5 - (D+G) = 131,5 - (44,95 + 1,25) = 85,3 mm
X = constant value 131,5 mm
31200451 4-27
6. Insert the disc springs in the right position and 9. Put the pin in locking (21) position.
direction.
7. Screw the slotted nut on, 8 turns.
8. Check the earlier measured distance Z from the

plane to the tooth next to the pin.
4-28 31200451
4.5 SERVICE BRAKE/MECHANICAL

PARKING BRAKE - DISASSEMBLY
1. Sling the arm to be removed and connect it to a 2. Take off the arm and lay it down vertically.
hoist, remove screws.
31200451 4-29
3. Remove the snap ring of the brake stack. 5. Remove intermediate disc (7).
4. Remove the brake discs (1)(2) one after the other. Note: Mark the assembly position.
Note: If they are not to be replaced, do not mix up the
brake stack sequence.
6. Remove the springs (21).
Note: Mark the assembly position.
4-30 31200451
7. Insert the screws of the puller (M12) into the 10. Remove the fixing screw of the lever brake.
tapholes of the negative brake (22) and remove the
pistons of the brake.
IMPORTANT: Remove carefully, do not damage.
11. Remove the brake lever locking screw (38) and conic
washer (37).
8. Pull out brake piston assembly module.
12. Mark position of brake lever before removing.
9. Remove the breather (47).
31200451 4-31
13. Remove the fixing screws (39) of the thrust bushing 16. Illustration of thrust bushing and o-rings.
(40).
17. Remove the attaching screws (23) of the opposite

14. Remove the thrust bushing (40) complete the o- side thrust bushing.
rings. IMPORTANT: Mark position of thrust bushing before
removing.
15. View of thrust bushing (40), external o-ring (41), and

internal o-ring (42). 18. With a plastic hammer, hammer on the internal lever
(27).
4-32 31200451
19. Remove the thrust bushing (24) complete with the o- 21. Note direction of ends during removal.
rings (25).
22. Place the lever (27) under a press and remove the
bearings (43).
20. Remove the internal lever complete with bearings.

IMPORTANT: Remove carefully, do not damage. 23. Place the lever under a press and remove the other
side bearing (26).
31200451 4-33
24. Applying pressure to the hole, remove the hydraulic 26. Remove coupling (3) and washers (6).
piston (9).
Note: Remove the stack of washers and measure
thickness, mark down for later reference.
27. Using a puller, preload the spring (16).
25. Remove the snap ring (14) from the intermediate

disc (7).
28. Remove the snap ring (15).
IMPORTANT: Springs are preloaded.
4-34 31200451
29. Remove the fixing ball (4).
30. Remove washer (5) and spring (16).
31200451 4-35
4-36 31200451
4.6 SERVICE BRAKE/MECHANICAL

PARKING BRAKE - ASSEMBLY
31200451 4-37
3. Shift the cut of the snap ring (15) according to the

1. Insert spring (16) and washer (5) onto the hydraulic ball (4).
block coupling (3).
2. Preload the spring by using a puller acting on the

washer. Insert the snap ring (15) and the fixing ball
(4).
4-38 31200451
4. Using a surface plate, positioning disc (7), the 7. To relieve the quota A that results between plain box
coupling (3) and brake discs. and bearing.
8. Calculation of shims S to be inserted.

5. Record the distance B between coupling and first S = (B+G) - (A+R)
brake disk. Example: 8,6mm G= o = 0,1mm
R = fix gap = 1, 4m m
6. Zero the depth gage from the plane of the splined 9. Insert and bring into position washers S (6) and
coupling to the surface of the brake discs. coupling into the brake module.
10. Install the intermediary disk (7) on coupling (3)
securing it with the snap ring (15).
31200451 4-39
12. Install last disk brake in material metallic. Note facing

direction.
11. Install the first friction disk. Note facing direction.
13. Install the snap ring securing brake discs.
4-40 31200451
14. Insert the service brake piston (9) hammering 17. Install the thrust bushing (24) complete with new o-
alternately with a plastic hammer. ring (25).
15. Heat the bearings to 100°C (212°F) to assist

installation onto the lever brake shaft.
16. Insert the lever brake (27).
31200451 4-41
18. Insert screws (23). 20. Replace and lubricate the o-ring (25) and insert the
thrust bushing (24) into the housing.
19. Tight the screws to 10 Nm (7 ft.lb.).

21. Insert screws (39). Tighten the screws to 10 Nm (7
ft.lb.).
4-42 31200451
22. Insert the springs (21) in the piston. 25. Replace and lubricate the o-ring and attach the arm
to the box.
23. Install the intermediate brake disk on the piston.

Install in correct direction.
26. Insert the screws and tighten them in an alternating

24. Install the piston pack pattern.
31200451 4-43
27. Install the brake lever (36) in the position previously 30. Applying a light pressure to bring in rest the lever
marked brake to the piston, without preload the inside rubber
band.
28. Lock the lever (36) with the screw (37) and washer
(38).
29. Torque wrench setting: 10 Nm (7 ft.lb.).
31. With the adjusting screw (33) draw near to the lever
(36) leaving a gap of 0,1 - 0,2 mm.
4-44 31200451
4.7 SERVICE BRAKE/DIFF. HYD. LOCK

100% - DISASSEMBLY
1. Remove the spacer (1). 2. Remove the countersunk screw and conic washer
attaching the brake lever to the shaft.
31200451 4-45
3. Mark the brake lever before disassembly, then 6. Remove the fitting screw of the thrust bushing.
remove it.
7. With a hammer of plastic material act on the inside

4. Remove the fitting screw of the thrust bushing. lever.
5. Remove the thrust bushing including the o-rings.
4-46 31200451
8. Remove the thrust bushing including the o-rings. 10. Applying pressure to the hole, remove the piston
differential block.
9. Remove the internal lever complete with bearings.

11. Piston differential block.
12. Remove the plug.
31200451 4-47
13. Using an extractor, remove the plug (4).

4-48 31200451
4.8 SERVICE BRAKE/DIFF. HYD. LOCK

100% - ASSEMBLY
3. Using a plastic hammer, ram the plug (18) into the

arm.
1. Remove o-ring (18) from the plug (4).

Note: The o-ring (18) must be replaced each time the
unit is disassembled.
4. Fit o-rings (3) and (20) onto the piston (21).

5. Lubricate the piston and the o-rings and install the
unit into the cylinder.
2. Fit o-rings (18) and onto the plug (4).

Lubricate the plug and the o-rings and install the unit
into the arm.
31200451 4-49
6. Using a plastic hammer, ram the piston into the arm.
7. Install the lever (10) complete with bearings (11)(12).
8. Insert the spacer (1).
4-50 31200451
Section 5
Planetary Reduction/Steering Case - Disassembly/Assembly
5.1 PLANETARY REDUCTION - 1.6 AND

STEERING CASE - DISASSEMBLY
31200451 5-1
1. Remove the securing screws (23) from the planetary 5. Remove the safety spring rings (28) of the planetary
carrier cover (25). gears (27).
2. Disconnect the steering bars from the steering case
(14).
6. Remove the planetary gears (27).

3. Pry the planetary carrier cover (25) from the steering IMPORTANT: Remove carefully do not damage.
case by alternatively forcing a screwdriver into the
appropriate slots.
Note: Note down direction of assembly of planetary

gears.
4. Remove the complete planetary carrier cover (25).
5-2 31200451
7. Remove the snap ring (30). 10. Remove the safety flange (33).
IMPORTANT: Mark before disassembly.
11. Using a puller, remove the complete crown flange

8. Loosen and remove the tightening nuts (32) from the (35) by acting on the stud bolts.
crown flange (35).
IMPORTANT: Note position and direction of installation.

9. Remove the shim washer (31).
31200451 5-3
12. Partially extract the hub (41) using a plastic hammer. 15. Remove the external thrust blocks of bearings, using
a pin driver.
Note: Alternately hammer on several equidistant points.
Note: Hammer in an alternate sequence to prevent
crawling and deformation of the thrust blocks.
13. Remove the external bearing (38).
16. Remove the sealing ring from the steering case (44).
IMPORTANT: Pay attention not to damage the seat of
bearing.
14. By hand remove the complete hub (41).
5-4 31200451
17. Record the measurement of the steering case - lock 20. Disconnect the tapered pins of the articulation from
screw. the steering case (14) by means of a puller.
18. Loosen the lock screw and screw it inward to allow 21. Loosen and remove the fitting screws (19) from the
access to the articulation pin nuts. bottom articulation pin (20).
Note: Screws cannot be re-used.
19. Remove the nuts that lock the articulation pins.
22. Remove the bottom articulation pin (18) complete

with front sealing ring (20).
31200451 5-5
23. Loosen and remove the fitting plate screws (13) from 26. Use a puller to remove the sealing ring from the
the top articulation pin (10). steering case (14).
Note: Note the orientation of sealing ring (5).
24. Using two levers, remove the top articulation pin (10)
complete with front seal (8).
IMPORTANT: Do not damage the surfaces. 27. Remove the bushing (6) from the steering case (14).
Note: Note the orientation of the bushing.
25. Remove the complete steering case (14).

5-6 31200451
28. Remove the u-joint (4). 31. If the ball cover (17) needs replacing, remove it from
the bottom articulation pin (20).
Note: To remove the u-joint, if necessary, use a plastic
hammer or a lever.
32. Remove seal ring (3) and the bushing (2) from the
arm (1).
29. Using a puller for inner parts, remove the top bush IMPORTANT: Remove carefully do not damage.
(7) and the bottom ball-bushing (17).
30. Remove the articulation pins (10)(20) and the front

sealing rings (8)(18).
Note: Note the side for assembly.
31200451 5-7
5-8 31200451
5.2 PLANETARY REDUCTION - 1.6 AND

STEERING CASE - ASSEMBLY
31200451 5-9
1. Lubricate the bushing (6) and the seat of the

steering case (14).
2. Install the bushing (6), using tool T13.
4. Using special tool T15 apply a repositionable jointing

compound for seals to the outer surface of the
sealing ring (44). Position the sealing ring (44) in the
steering case (14).
Note: Check that the ring (44) is correctly oriented.
3. Lubricate the outer surface of the sealing ring (5); fit

them into their seat using tool T14.
5. If the bottom articulation pin (17) has been extracted,
position the pin under a press and fit the ball cover
(20).
5-10 31200451
6. Fit the front sealing rings (18)(8) onto the articulation 9. Lubricate and fit the sealing ring (3) onto tool T14;
pins (4) and (6). install the rings into the arm.
Note: Carefully check that the rings are properly IMPORTANT: Pay particular attention to the direction of
oriented (18)(8). assembly of the rings.
7. Lubricate the top bush (7) or the bottom ball bush 10. Insert the u-joint (4).
(17) and fit them into the fulcrum holes of the arm.
11. Lubricate the terminal of the u-joint (4) and install the
8. Lubricate the bushing (2) and the seat of the steering case (14).
steering case (1). Install the bushing (2), using tool
T13. IMPORTANT: Pay close attention not to damage the
dust cover rings and the sealing rings.
31200451 5-11
12. Prepare a series of shims (9) of 0,4 up to 0,7 mm to 15. Fit the unit (20) in the steering case (14). Position
be assembled under the upper pin (10). the screws (19) and tighten securely.
Note: Apply CAT Gasket Maker to the surfaces before
installing.
13. Lubricate with CAT Molybdenum Paste and install

the unit in the steering case.
16. Tighten the new fitting screws (13) of top articulation
pins in sequence using the cross tightening method.
Torque wrench setting: 90 - 100 Nm (66-73 ft.lb.)
14. Lubricate the steering case.
17. Tighten the new fitting screws (19) of bottom

articulation pins in sequence using the cross
tightening method.
Torque wrench setting: 90 - 100 Nm (66-73 ft.lb.)
5-12 31200451
18. Check by means of a lever that there is no vertical 21. Adjust the lockscrew to the measurement previously
gap. In case there is any gap, determine the width noted during disassembly.
and reduce it by removing shims.
19. Check the torque of the pins, which has to be 22. Position the lower part of tool T1 and the thrust block
between 40 and 80 Nm (29 - 59 ft.lb.). If the of the external bearing (38).
preliminary measured value is too high, the shims
have to be increased.
23. Lubricate the seats of the bearings and position the

hub (41) on tool T1; position the thrust block of the
20. Look for the position of the notch regarding the internal bearing (43).
safety cotter pin hole when the nut is finally locked
max 300 Nm. (221 ft.lb.) Note: Check that the thrust block is correctly oriented.
31200451 5-13
24. Lubricate and install the external bearing (38). 27. Fit the complete crown flange (36).
Note: Move the bearing to the seat by hammering lightly Note: In order to fasten the flange (36), use a plastic
all around the edge. hammer and alternately hammer on several equidistant
points.
25. Lubricate and Install the wheel hub (41). 28. Install the security flange (33). Using CAT Multi-
IMPORTANT: Install carefully do not damage. Purpose Grease, grease the surface of the safety
flange (33) that touches the crown wheel.
26. Install the crown wheel (36).

29. Coat the nuts (23) with CAT Threadlock and install.
5-14 31200451
30. Tighten nuts (32) in two stages, using the criss-cross 33. Check the continuous rolling torque on the hub.
method. Torque 7 - 20 Nm (5 - 14 ft.lb.).
Initial torque wrench setting: 90 Nm (66 ft.lb.)
Final torque wrench setting: 100 Nm (73 ft.lb.)
IMPORTANT: Check the condition and position of the o-

ring (37).
31. Install the spacer (15).
34. Fit the planetary gear (27) onto the planetary gear
32. Install the snap ring (31). cover(25).
IMPORTANT: The jointed portion of the internal ring of
the bearings must face the bottom of the pin.
31200451 5-15
35. Lock into position the planetary gears (16) with the 37. Secure using the countersunk hex screws and
snap rings (15). torque to 40-50 Nm (29 - 36 ft.lb.).
36. Fit the planetary gear cover (18) onto the wheel hub
(4).
5-16 31200451
5.3 PLANETARY REDUCTION GEAR -

1:4, 23 - DISASSEMBLY
1. Remove snap ring (1). 2. Using a screw M6 remove all bolts (2).
31200451 5-17
3. Position the planet wheel gear (3) in center of the

spider cover and remove.
IMPORTANT: Note direction of installation.
5-18 31200451
5.4 PLANETARY REDUCTION GEAR -

1:4, 23 - ASSEMBLY
4. Check the concentricity of the planetary gear, the

seat and friction washers. Using a screw M6 install
the pin (2).
1. Install the spherical washer (6).
5. Carefully check that pin is completely inserted and

2. Install planetary gears complete with roller bearing
install the snap rings (1).
(3).
3. Install the other friction washers (5).

Note: Two friction washers for every planetary gear, one
above, one below.
31200451 5-19
5-20 31200451
Section 6
Differential - Disassembly/Assembly
6.1 NORMAL PRE-LOADED

DIFFERENTIAL - DISASSEMBLY
31200451 6-1
1. Remove the brake side arm and the brake discs 4. Pull out the differental.
pack. IMPORTANT: Remove carefully do not damage.
2. Sling the arm to be removed and connect it to a
hoist, remove screws of the crown wheel side arm.
5. Remove the snap ring (22) that secures the thrust

bearing.
3. Carefully, take off the arm and lay it down vertically.
6. Remove the snap ring (22) and thrust bearing (23).

IMPORTANT: Position the differential gear sideways
into the recess in order to be able to pull it out.
6-2 31200451
7. Remove the hydraulic block discs (20)(24) one after 8. Remove the snap ring (19) that secures the
the other. planetary gear.
IMPORTANT: Note direction of disks.
9. Remove the brake side planetary gear.
31200451 6-3
10. Remove the snap ring (33) out of it’s seat by moving 13. Remove fixing screws (32) of the crown wheel (31);
it sideways. exchange each time when removed.
11. Using a puller, extract the bearing (35) and the 14. Extract the crown wheel (4).
washer (34).
15. Remove the tapered roller bearing (2) of the crown

12. Remove completely bearing (35), washer (34) and wheel side, using two levers.
snap ring (33). IMPORTANT: Remove carefully do not damage.
6-4 31200451
16. Remove the three spider blocking pins (10)(13)(26) 19. Remove the two half bolts (9)(28), spherical washers
by using a pin driver. (8)(28) and satellite wheels (27)(7).
17. Move the two opposite mounted short bolts (9)(28) 20. Remove long bolt (14), spherical washers (12)(29)
to the outside of the box using the same pin driver. and satellite wheels (30)(11).
18. Drive out the long bolt (14) and pull out the spider 21. Remove the planetary gear (6).
(16) from the center.
31200451 6-5
6.2 NORMAL PRE-LOADED

DIFFERENTIAL - ASSEMBLY
22. Arrangement of the differential.
1. Differential module assembled.
2. Lubricate and insert washer and plantary wheel.
3. Insert the two half bolts (28)(9), spherical washers

(8)(28) and satellite wheels (7)(27).
6-6 31200451
4. Partially insert the long bolt (14), satellite wheels 6. Insert completely the half bolts (9)(28).
(11)(30) and spherical washers (29)(12).
7. Center the pin holes and insert the 3 pins

(10)(13)(26).
Note: Check the free rotation of the satellite wheels on
the bolts.
5. Insert spider (16) and completely insert the long bolt

(14).
31200451 6-7
8. Insert the planetary wheel together (17) with the 11. Insert thrust bearing (23) and snap ring (22).
centering sleeve (25).
Note: The centering sleeve must have the fixing ball
(18) assembled.
12. Insert crown wheel (31).
9. Insert snap ring (22) of the planetary wheel.
13. Insert the screws (32). Tighten screws with a torque

wrench setting of 78-86 Nm (57-63 ft.lb.).
Note: Always use new screws to fix the crown wheel. In
10. Insert and replace, if necessary, the discs (20)(24) of case the screws are not thread locking pretreated, use
the differential lock. Loctite 270.
IMPORTANT: First and last disc have to be of steel.
6-8 31200451
14. Assemble the bearing (2). 16. Assemble shim (34) and bearing (35).
Note: Heat the bearing to 100°C (212°F) before Note: Heat the bearing as well as the shim to 100°C
assembling. (212°F) before assembling.
15. Assemble the snap ring (33) in it´s seat.
31200451 6-9
6-10 31200451
6.3 PRELOADED LIMITED SLIP

DIFFERENTIAL - DISASSEMBLY
31200451 6-11
1. Remove the brake side arm and the brake discs 3. Pull out the differential.
pack. Sling the arm to be removed and connect it to IMPORTANT: Remove carefully, do not damage.
a hoist, remove screws of the crown wheel side arm.
4. Remove the snap ring (23) that secures the thrust

2. Place the arm on a bench. bearing.
IMPORTANT: Position the differential gear sideways 5. Remove the snap ring (23) and thrust bearing (24).
into the recess in order to be able to pull it out.
6-12 31200451
6. Remove the hydraulic block discs (21)(25) one after

the other.
7. Remove the snap ring (20) that secures the

planetary gear.
31200451 6-13
8. Remove the brake side planetary gear (18). 11. Completely remove the bearing (35), washer (34)
and snap ring (33).
9. Remove the snap ring (33) out of it’s seat by moving

it sideways.
IMPORTANT: Remove carefully, do not damage. 12. Remove the fitting screws (3) from the crown.
Replace the screws (3) during reassembly.
10. Using a puller, extract the bearing (35) and the

washer (34). 13. Extract the crown wheel (34).
6-14 31200451
14. Remove the tapered roller bearing (1) of the crown 17. Drive out the long bolt (17) and pull out the spider
wheel side, using two levers. (33) from the center.
18. Remove the planetary gear (9).

15. Remove the three spider blocking pins (13)(16)(27)
by using a pin driver.
19. Remove the limited slip discs friction (6)(7)(8).

IMPORTANT: Do not change the position of the disks
16. Move the two opposite mounted short bolts (12)(30) forming the friction.
to the outside of the box using the same pin driver.
31200451 6-15
20. Remove the half shaft bushing (5).
6-16 31200451
6.4 PRELOADED LIMITED SLIP

DIFFERENTIAL - ASSEMBLY
31200451 6-17
1. Install the half shaft bushing (5). 4. Install the planetary gears (10)(28) and spherical
shoulder washers (11)(29) onto the shafts (12)(30).
2. Insert in the body of the differential unit, any required

shims and the friction discs (6)(7)(8). 5. Insert the spider (33) and partially insert the long
IMPORTANT: Pay attention to direction of installation. bolt (17).
IMPORTANT: Pay attention to direction of installation.
3. Install the planetary gear (9).

IMPORTANT: Pay attention to direction of installation. 6. Insert the satellite wheels (32)(14), spherical
washers (15)(31) and completely insert the long bolt
(17).
6-18 31200451
7. Completely insert the half bolts (30)(12). 10. Insert the snap ring (20) of the planetary wheel (18).
8. Center the pin holes and insert the 3 pins

(13)(16)(27). 11. Replace, if necessary, and insert the discs of the
differential lock.
Note: Check the free rotation of the satellite wheels on
the bolts. IMPORTANT: The first and last disc must be made of
steel.
IMPORTANT: Insert carefully, do not damage.
9. Insert the planetary wheel (18) together with the 12. Insert the thrust (24) bearing and snap ring (23).
centering sleeve (26).
IMPORTANT: The centering sleeve must have the fixing
ball (19) assembled.
31200451 6-19
13. Insert the crown wheel (34). 16. Assemble the snap ring (33) in it´s seat.
14. Insert the screws (3). Tighten screws with a torque

wrench setting of 78-86 Nm (57 - 63 ft.lb). 17. Assemble shim (34) and bearing (35).
Note: Always use new screws to fix the crown wheel. In Note: Heat the bearing as well as the shim to 100°C
case the screws are not thread locking pretreated, use (212°F) before assembling.
Loctite 270.
15. Assemble the bearing (1).

Note: Heat the bearing to 100°C (212°F) before
assembling.
6-20 31200451
6.5 DIFFERENTIAL UNIT - WITH BLOCK

TO SPHERES 100% - DISASSEMBLY
31200451 6-21
1. Sling the arm being removed and connect it to a 4. Extract the bearing (24) from the differential carrier.
hoist. Loosen and remove screws and nuts. IMPORTANT: Remove carefully, do not damage.
2. Remove the arm together with brakes and axle 5. Remove the 4 fixing screws from the coupling on the
shafts; set the arm down vertically. cover.
IMPORTANT: Remove carefully, do not damage. Note: Mark the position of the coupling.
3. Extract the whole differential unit.

IMPORTANT: Hold down the spring to keep the
IMPORTANT: Remove carefully, do not damage. coupling from jumping off, then remove the remaining
two screws.
6-22 31200451
6. Pull off the coupling (17) and the spring (16). 9. Remove the shim washer (15) and the planetary
gear (14).
7. Note the position of the slot where the coupling (17)

is attached to the fixing ball (4). (6mm).
10. Remove the blocking balls (3).

8. Remove the cover (18) from the blocking side of the
differential unit.
31200451 6-23
11. Remove the fixing ball (4) from the differential box by 14. Separate the crown wheel (33) from the differential
using a magnetic tool. box (2).
12. Partially extract the bearing (1), Using a puller,

remove the bearing (1) from the crown wheel side 15. Replace the fixing screws every time.
(33).
16. Use a pin-driver of the correct size to remove the

pins.
13. Remove the crown wheel fixing screws (34).
6-24 31200451
17. Remove the fixing pins (10)(29) from the differential 20. Remove the two halves of the cross bolts (9)(28)
cross bolts. using a drift.
IMPORTANT: Remove carefully, do not damage. IMPORTANT: Remove carefully, do not damage.
18. With a pin-driver, push the two bolts (9)(28) to the 21. Remove the cross bolts (32).
outside.
22. Remove the gear wheels and the spherical washers.
19. Remove the bolts using a drift (12).

31200451 6-25
23. Remove the central gear wheel (8) with washer. 25. Loosen the two fixing screws (2) by 4 turns.
26. With pressurized air, push the piston (1) out until the
heads of fixing screws (2) are exposed.
24. Remove the circuit breaker from the hydraulic

blocking.
27. Remove the piston.
6-26 31200451
6.6 DIFFERENTIAL UNIT- WITH BLOCK

TO SPHERES 100% - ASSEMBLY
31200451 6-27
1. Insert the washer (5) and the gear wheel (6) on the 4. Insert the crossbolt (32) in the correct position.
crown wheel side.
5. Insert the bolts into position.

2. Insert the gear wheels (27)(8) with the spherical
washers (26)(7) and the bolts (28)(9) attached to
keep them in position.
6. Bring the pin holes in line with the help of a pin-

driver.
3. Insert the gear wheels(31)(35) with the spherical
washers(30)(11) and the bolt (12).
6-28 31200451
7. Insert pins to end of stroke. 10. Tighten the screws on the crown wheel using the
IMPORTANT: Insert carefully, do not damage. criss cross method. Torque wrench setting:128 -
142Nm (94 - 104 ft.lb)
8. Install the crown wheel (33).

IMPORTANT: Insert carefully, do not damage. 11. Insert the planetary gear wheel (14) (together with
washer). Insert the fixing ball(15) into the coupling.
9. Fix the screws (34) to the crown wheel.

12. Grease and insert the balls (3). Install the cover (18)
onto the blocking side.
31200451 6-29
13. Load the spring and the coupling and insert screws. 16. Using the special tool T4, insert the roll bearings to
end of stroke.
14. Tighten with torque wrench setting of 26,2Nm (19

ft.lb). 17. Place the piston (1) into position inside the box, and
partially turn the screw (2). Note the correct position.
15. Heat the roll bearings to 100° C (212° F) and insert it

onto the differential. 18. Lightly hammering on alternating points brings the
piston to the end of stroke. Tighten with a wrench
setting of 30 Nm (22 ft.lb).
6-30 31200451
6.7 NORMAL DIFFERENTIAL -

DISASSEMBLY
31200451 6-31
1. Remove the locking screws of planetary cover. 4. Sling the arm to be removed and connect it to a
hoist.
5. Loosen and remove screws and nuts.
2. Remove the cover.
6. Remove arm together with brakes and axle shafts;

lay down the arm vertically.
3. Remove the axle shaft.

6-32 31200451
7. Extract the whole differential unit. 10. Remove the crown wheel fixing screws (13).
8. Remove the opposite side arm. 11. Separate the crown wheel (10) from the differential
box (14).
9. Extract the bearing (35) from the differential carrier

(14).
31200451 6-33
12. Extract the bearing (12) partially and using a puller, 14. Remove the shim washer (33) and the planetary
remove the bearing (12) of the crown wheel side gear (32). Note direction of removal.
(10).
13. Remove the cover (34) from the blocking side of the
differential unit.
6-34 31200451
15. Remove the fixing pins (20)(24)(31) of the differential 18. Remove the two halves of the cross bolts (19) (26)
cross bolts (25). with the help of a drift.
16. With a pin-driver push the two bolts (19)(26) to the 19. Remove the cross bolts (25).
outside.
20. Remove the gear wheels (28)(21)(29)(18) and the

spherical washers (17)(30)(22)(27).
17. Remove the bolts with the help of a drift (23).
31200451 6-35
21. Remove the shim washer (15) and the planetary 22. The components of the differential unit.
gear (16). Note direction of removal.
6-36 31200451
6.8 NORMAL DIFFERENTIAL -

ASSEMBLY
31200451 6-37
1. Insert the washer (15) and the gear wheel (16) on 4. Insert the gear wheels (28)(21) with the spherical
the crown wheel side. Install in proper position. washers (27)(22) and the bolt (26)(19).
2. Insert the gear wheel (18) with the spherical washer 5. Insert the crossbolt (25) in the correct position.
(17) and the bolt (19) to keep them in position.
6. Insert the bolts in their position.

3. Insert the gear wheel (29) with the spherical washer
(30) and the bolt (26) to keep them in position.
6-38 31200451
7. Bring the pin holes in line with the help of a pin- 10. Apply Loctite 270 to the nuts (37)and install them.
driver.
11. Torque nuts to a setting of 58 Nm (42 ft.lb.).

8. Insert pins (20)(24)(31) to end of stroke.
IMPORTANT: Install carefully, do not damage.
9. Insert planetary gear wheel (32) together with

washer (33). Install in correct direction.
31200451 6-39
12. Install the crown wheel (10). 15. Heat up the roll bearings (12)(35) to 100°C (212°F)
13. Attach the screws (13) of the crown wheel. and insert it onto the differential.
Note: Use LOCTITE 270 on screws not treated with

DRILOC.
14. Tighten the screws of the crown wheel using the

criss cross method.
Torque wrench setting: 128-142 Nm (94-104 ft.lb.)
6-40 31200451
6.9 LIMITED SLIP DIFFERENTIAL (45%) -

DISASSEMBLY
31200451 6-41
1. Extract the bearing (25) from the differential carrier. 4. Extract the bearing (3) partially and using a puller,
IMPORTANT: Remove carefully, do not damage. remove the bearing (3) of the crown wheel side (1).
2. Remove the crown wheel fixing screws (2).

5. Remove the screws (26) jointing the differential unit.
3. Separate the crown wheel (1) from the differential

box (4).
6-42 31200451
6. Remove the differential cover (24).
9. Replace the whole pack to 17,10 mm.

7. Remove the bushing (22).
8. Remove the planetary gear (19) and the whole

friction unit (20)(27)(21).
31200451 6-43
10. Remove the fixing pins (14)(17)(28) of the differential 13. Remove the two halves of the cross bolts (13)(31)
cross bolts (10). with the help of a drift.
14. Remove the cross bolts (10).

11. With a pin-driver push the two bolts (31)(13) to the
outside.
15. Remove the gear wheels (11) (29) (15) (33) and the
spherical washers (32) (16) (30) (12). Note facing
12. Remove the bolts with the help of a drift (18). direction of components.
6-44 31200451
16. Remove the central gear wheel (9) and limited slip
package (8)(7)(34).
17. Remove the bushing (6).
18. Always check the thickness of braking discs (27)

(20) (21) and eventually replace the whole pack.
New limited slip package = 17.56 mm
Replacement pack = 16.90 mm
31200451 6-45
6-46 31200451
6.10 LIMITED SLIP DIFFERENTIAL (45%) -

ASSEMBLY
31200451 6-47
1. Limited Slip differential components. 4. Check for correct position.
2. Align disks (8)(7)(34) and bushing (6) on the 5. Insert the gear wheels (11)(29) with the spherical
planetary gear (9) in the correct position. washers (12) (30) and the bolts (13) (31) to keep
them in position.
3. Insert the planetary gear (9) into the differential

housing (4). 6. Insert the gear wheels (11)(29) with the spherical
IMPORTANT: Install carefully, do not damage. washers (12)(30) and the bolts (13)(31) to keep
them in position.
6-48 31200451
7. Insert the gear wheels (33)(15) with the spherical 9. Insert the bolts in their position (17)(13)(31).
washers(32)(16)and the bolt (17).
10. Bring the pin holes in line with the help of a pin-
driver.
8. Insert the crossbolt (10) in the correct position.

11. Insert pins to end of stroke (14)(17)(28).
31200451 6-49
12. Insert the planetary gear (19) and the whole friction 14. Install the differential cover (24).
unit (20)(27)(21).
15. Apply Loctite 270 to the screws (26).
13. Install the bushing (22). 16. Tighten screw with a Torque wrench setting of: 55,2 -
61,0 Nm (40-45 ft.lb.).
6-50 31200451
17. Install the screws (2) of the crown wheel.

Note: Use Loctite 270 on screws not treated with
DRILOC.
18. Tighten the screws (2) of the crown wheel to 78-86
Nm (57-63 ft.lb.) using the criss cross method.
19. Heat up the roller bearings (25)(3) to 100°C (212°F)

and insert it onto the differential.
31200451 6-51
6-52 31200451
Section 7
Bevel Pinion - Disassembly/Assembly
7.1 BEVEL PINION - DISASSEMBLY
31200451 7-1
1. Make positional marks across nut (1) and pinion (11) 4. Remove the sealing ring (3).
tang; If disassembly is difficult, heat the check nut (1) IMPORTANT: Remove carefully do not damage.
of the flange (2) at 80C° (176°F).
Note: Heating is meant to unloosen the setting of
threadlock on the nut (1).
5. Remove the sealing ring (3) and spacer (8A).

Note: Sealing rings (3) must be replaced each time the
unit is disassembled.
2. Position tool T5, to avoid pinion rotation. Loosen and
remove the nut (1); also remove the o-ring (6).
6. Remove the pinion (11), shims and distance piece.

3. Remove the flange (2) complete with guard (7) by
means of a puller.
7-2 31200451
7. Refer and keep to the positions marked during

disassembly.
10. Using a drift, remove the thrust blocks from the

housing.
8. Using a puller and a press, remove the inner bearing IMPORTANT: Remove carefully do not damage.
(4) from the pinion (11).
11. Remove the thrust block of the internal bearing (4)

9. Remove the thrust block of the external bearing (14). as well as the shim washers (10)(S).
31200451 7-3
12. Remove the snap ring (15). 13. Remove the cap (14).
7-4 31200451
7.2 BEVEL PINION - ASSEMBLY
31200451 7-5
1. CALCULATING PINION CENTER DISTANCE 3. Check nominal dimension “I” as marked on the
Using a faceplate, reset a centesimal comparator pinion. Add up to or subtract from “I” the variation
“DG” on a calibrated block (whose known thickness indicated as “Y” to obtain the actual center distance
is 30 mm.). Preload the comparator by about 3 mm. “I”.
EXAMPLE: I =INT ± Y ==98-0,1=97,9mm
Note: C61 = Match part number
2. Bring inner bearing (4), complete with thrust block,

under comparator “DG”.
IMPORTANT: Press the thrust block centrally and carry
out several measurements by rotating the thrust block. 4. C61 = bevel gear set matching number (-0,1)=Y
variation from the theoretical I =98
EXAMPLE: 30 - 0,55 = 29,45 = “D”.
7-6 31200451
5. Calculate shims “S” for insertion under the thrust 7. Connect the tension rod to the press and move the
block of the inner bearing using the following thrust block of bearings (4) (14) into the seats.
formula: 8. Disconnect the press and remove the tension rod.
S = X - (I + D) where: X = fixed dimension
I = actual pinion center distance Note: Before starting the next stage, make sure that the
D = Total bearing thickness; thrust block has been completely inserted into its seat.
EXAMPL E: S = 128 - (97,9 +29,45) = 0,65 mm
9. CALCULATING PINION BEARINGS ROLLING

6. Using special tool T8. Partially insert the thrust block TORQUE:
of the bearings (4) and shims (10). Introduce tool T9 complete with bearings (4) and
(14) into the main body (12); tighten by hand until a
rolling torque is definitely obtained.
31200451 7-7
11. Remove the comparator and take out the tool and
bearing kits from the main body.
12. Reinstall every part, also introducing a spacer
between bearings (4) and (14). Tighten the entire
pack by hand.
10. Introduce the tracer of a depth comparator “DDG”

into either side hole of tool T9.
Reset the comparator with a preload of about 3 mm.
13. Assemble on top of the tool T9 and between the two

bearings the shim (5) and the largest calibrated shim
(9).
7-8 31200451
14. Measure the difference H using a dial gauge DDG. 17. Fit the pinion (11), shim “S1” (10) and distance piece
E.g. H = A -B = 2.93 mm (5)(9) in the main body (12).
Note: The finer shims must be placed in- between the
thicker ones.
15. Calculate the shim S2 to be inserted.

E.g. S2 = H + X = 3.01 mm where
X = fixed value to obtain = 0.07...0.08 mm
18. Heat the external bearing (14) to a temperature of
about 100 C° (212°F) and fit it on to the pinion (11)
so as to complete the pack as shown in the figure.
Note: Lightly lubricate bearing with SAE85W90 gear oil.
16. Measure the difference H using a dial gauge DDG.

E.g. H = A - B = 2.9 3 mm
31200451 7-9
7.3 NORMAL FLANGE VERSION
4. Lock the wrench T5, rotate the pinion using a

dynamometric wrench, up to a minimum required
1. Insert the spacer (8A) torque setting of 260 - 300 Nm (192 - 221 ft.lb.).
2. Install the flange (2) onto the pinion (11) without 5. Apply onto the pinion (1) the bar-hold and with the
sealing ring. help of a torque meter, check the torque of the pinion
(1). Torque: 80-120 Nm (59 - 88 ft. lb.)
IMPORTANT: If torque exceeds the maximum value,
then the size of shim “S1” (4) between the bearing (9)
and the distance piece (3) needs to be increased.
If torque does not reach the set value, increase the
torque setting of the ring nut (10) in different stages to
obtain a maximum value of 500 Nm (368 ft.lb.).
IMPORTANT: If torque does not reach the minimum

value, then the size of shim “S1” (4) needs to be
reduced.
IMPORTANT: When calculating the increase or

decrease in size of shim “S1”, bear in mind that a
variation of shim of 0.01 mm corresponds to a variation
3. Install the nut (1) without any thread lock applied. of 60 Ncm (5.3 in.lb.) in the torque of the pinion (1).
7-10 31200451
6. Make positional marks across nut (1) and pinion (11) 10. Tighten the nut until the provisional marks made in
tang; then remove nut and flange (2) step 6 line up.
7. Apply Arexons rubber cement to the outer surface of

the new seal ring (3) and fit ring in the main body
(12) using driver T11.
8. Oil seal ring lips and install flange (2).

9. Mount o-ring (6) and apply Loctite 270 to pinion
tang; tighten nut (1).
31200451 7-11
7.4 REVOLUTION COUNTER VERSION
11. Apply Loctite 270 to the thread of the ring nut (8) and
screw the nut onto the pinion.
14. Apply Arexons rubber cement to the outer surface of

the new seal ring (3) and fit ring in the main body
(12) using driver T11.
12. Apply onto the pinion (11) the bar-hold and with the
help of a torque metre, check the torque of the pinion
(11). Torque: 400 - 500 Ncm (35 - 44 in.lb.)
IMPORTANT: If torque exceeds the maximum value,
then the size of shim “S1” (4) between the bearing (9)
and the distance piece (3) needs to be increased.
13. If torque does not reach the set value, increase the
torque setting of the ring nut (10) in different stages
to obtain a maximum value of 500 Nm (368 ft.lb.)
IMPORTANT: If torque does not reach the minimum
value, then the size of shim “S1” (4) needs to be
reduced.
IMPORTANT: When calculating the increase or 15. Oil seal ring lips and install flange (2).
decrease in size of shim “S1”, bear in mind that a
16. Mount o-ring (6) and apply Loctite 270 to pinion
variation of shim of 0.01 mm corresponds to a variation
tang; tighten nut (1).
of 60 Ncm (5 in.lb.) in the torque of the pinion (11).
7-12 31200451
17. Lock the wrench T5, rotate the pinion using a

dynamometric wrench, up to a minimum required
torque setting of 260-300 Nm (191- 221 ft.lb.).
31200451 7-13
7-14 31200451
Section 8
Differential Ring and Pinion Adjusting
8.1 STEP FOR PRE-LOADED

DIFFERENTIAL
31200451 8-1
1. Choose a pack of shims Sb with an initial value of 4. Remove cap.

about 0.37mm to place under the brake side IMPORTANT: Do not bend the cap
bearing´s cup.
5. Insert the complete differential

2. Assemble the shims Sb, the cup (1) and level.
Note: Attention do not damage the sealing surface of
the o-ring.
3. Remove the snap ring.
6. Choose a pack of shims Sc with an initial value of

about 0.84 mm to place under the crown wheel side
bearing´s cup.
8-2 31200451
7. Assemble the shims Sc, the (1) cup and level. 10. Apply torque meter TM to pinion nut and check that
torque will increase by 40-60 Ncm (29-44 ft.lb.) as a
result of differential bearing preload.
Example: pinion torque: 80-120 Ncm (59-88 ft.lb.)
Pinion + differential torque: 120-180 Ncm (88-133 ft.-
lb.)
8. Always replace the o-ring of the arm.
11. Position comparator on the center of one of the

crown teeth, preset it to 1 mm and reset it to zero.
Manually move the crown in both directions to check
the existing clearance between pinion and crown.
Gap= 0,13-0,20mm
In order to increase the gap while keeping the load

on the bearing unchanged, take off shims from the
crown wheel side and insert them on the opposite
side. In order to decrease the gap, act the other way
9. Assemble the arm and tighten temporarily with a round.
torque wrench setting of 128Nm (94 ft.lb.) at least 6
screws equally distributed. Introduce a comparator with rotary key through the
rear cap hole.
31200451 8-3
12. Assemble rubber cap and snap ring.
8-4 31200451
8.2 VERSION PINION COVER AND

SINGLE ARM
31200451 8-5
1. SETTING OF THE CROWN WHEEL AND PINION 4. Insert the thrust block and the shims into the arm.
Insert the thrust block of the bearing (6) into the
Note: Ensure they are at the end of stroke.
opposite side of the crown wheel shims (Sb)(7) with
an initial thickness of about 0,55mm. IMPORTANT: Insert carefully, do not damage.
2. Insert the thrust block (6) and the shims (Sb)(7) into 5. Insert complete differential (5).
the arm.
IMPORTANT: Do not damage the seat of the O-Ring
Note: Ensure they are at the end of stroke. with the gear wheel.
IMPORTANT: Insert carefully, do not damage. IMPORTANT: Insert carefully, do not damage.
3. SETTING OF THE CROWN WHEEL AND PINION 6. Replace and lubricate the o-ring (2).
Insert the thrust block (4) of the bearing shims
(Sc)(3) with an initial thickness of about 0,75mm. IMPORTANT: Insert carefully, do not damage.
8-6 31200451
7. Install the crown wheel side arm (1) without half- 10. Position a comparator on the center of one of the
axle. crown teeth, preset it to 1 mm and reset it to zero.
Manually move the crown in both directions to check
Note: To check the torque of the differential, neither of
both half-axles must be installed.
Gap = 0,13 - 0,20mm
Note: In order to increase the gap while keeping the
load on the bearing unchanged, take shims off of the
crown wheel side and insert them on the opposite side.
In order to decrease the gap, do the reverse.
Position a comparator with rotary key through the rear

cap hole.
8. Temporarily insert all screws in the arm (18).
11. + Sc (3) - Sb (7) = reduction gap ring and pinion
9. Apply torque meter TM to pinion nut and check that

torque will increase by 40 - 60 Ncm (0.3 - 0.4 lb.ft.)
as a result of differential bearing preload.
Example: pinion torque: 80 - 120 Ncm (0.6 - 0.9
lb.ft.) Pinion + differential torque: 120 - 180 Nm (88 -
133 lb.ft.).
31200451 8-7
12. - Sc (3) + Sb (7) = increase gap ring and pinion 15. Using a driver, fit the cap and position it in its seat
with the snap ring.
13. Check the flatness of the arms; then lock the arms
into their final position using screws adequately
coated with Cat Threadlock.
14. Torque wrench setting: 130Nm (96 lb.ft.)

Note: Tighten using the criss-cross method.
8-8 31200451
8.3 VERSION PINION INTEGRAL AND

DOUBLE ARM
31200451 8-9
1. SETTING OF THE CROWN WHEEL AND PINION: 4. Temporarily insert all screws of the arm (18).
Insert the thrust block of the bearing (6) opposite
side of the crown wheel shims (Sb)(7)of an initial
thickness of about 0,55mm.
5. Insert complete differential (5).

IMPORTANT: Do not damage the seat of the o-ring with
the gear wheel.
2. Using tool (T10) insert the thrust block (6) and the
shims (Sb)(7) into the arm.
Note: Check that the insert is completely seated.
3. Replace and lubricate the o-ring (2).
8-10 31200451
6. SETTING OF THE CROWN WHEEL AND PINION - 9. Temporarily insert all screws of the arm (18).
OPPOSITE SIDE:
Insert thrust block (4) of the bearing shims (Sc)(3) of
an initial thickness of about 0,75mm.
10. Apply torque meter TM to pinion nut and check that

torque will increase by 40-60 Ncm (3.5 - 5 in.lb.) as a
7. Insert the thrust block and the shims into the arm. result of differential bearing preload.
Example: pinion torque: 80-120 Ncm (7 - 10.5 in.lb.)
Note: Check that the insert is completely seated. Pinion + differential torque: 120-180 Ncm (10.5 - 26
in.lb.)
8. Install the crown wheel side arm (1)without half-axle.

Note: To check the torque of the differential, the half-
axles must not be installed.
31200451 8-11
11. Introduce a dial gauge with rotary key through the 14. Using a driver, fit the cap and position it in its seat
rear cap hole. Position dial gauge on the center of with the snap ring.
one of the crown teeth, preset it to 1 mm and reset it
to zero.
12. Manually move the crown in both directions to check
Gap =0,13 - 0,20mm
Note: In order to increase the gap while keeping the
load on the bearing unchanged, take off shims from the
crown wheel side and insert them on the opposite side.
In order to decrease the gap, do the opposite mentioned

above.
13. Tighten housing screw with a torque wrench setting

of 130Nm (96 ft.lb.)
Note: Tighten using the criss-cross method.
8-12 31200451
Section 9
Steering Cylinder - Disassembly/Assembly
9.1 STEERING CYLINDER - REMOVAL
1. Remove the centering sensor (21) of the steering 2. Remove the nuts (18) that lock the articulation pins
piston. (14).
31200451 9-1
3. Disconnect the tapered pins of the articulation (14) 6. Remove the securing screws (19) from the steering
from the steering case by means of a puller. cylinder (16).
7. Extract the cylinder (16) using a plastic hammer.

4. If the connection of the steering bars includes a IMPORTANT: Remove carefully do not damage.
safety collar, raise the border.
5. Disconnect left and right steering bars from the

piston.
9-2 31200451
9.2 STEERING CYLINDER -

DISASSEMBLY
IMPORTANT: Before attempting to disassemble the 2. Lightly tap the cylinder head (2) with a plastic
unit, drain the oil in the cylinder chambers completely. hammer so as to push it inside the cylinder (3).
1. Using a screwdriver, remove the snap ring (1) of the Note: Insert the cylinder head so it is flush with the
cylinder head. cylinder.
31200451 9-3
3. Using a punch, force the stop ring (4) located inside IMPORTANT: Note down direction of installation of the
the cylinder (3) and extract ring using a screwdriver. piston whose seal ring is oriented towards cylinder head.
5. Remove all seals, anti-extrusion rings and scraper

4. Take the cylinder unit apart by extracting the head rings from head (2), cylinder (3) and piston (5).
(2) first, followed by the piston. Note: 1 - All seals must be replaced every time the unit
is disassembled.
2 - Particular attention must be paid not to
damage the seats of both seals and piston slide.
9-4 31200451
9.3 STEERING CYLINDER - ASSEMBLY
4. Prepare piston (5) by fitting it with magnetic ring (11)

anti-extrusion ring (10) and piston seal (13).
1. Grease and install the piston rod seal ring (6), rod IMPORTANT: To ease installation, lubricate with grease.
wiper (8) and back up washer (7) into cylinder (3).
5. Center the shaft on the cylinder (3) so that it fits into

2. Grease and install the piston rod seal ring (6), rod the piston (5).
wiper (8) and anti-extrusion ring (7) into the head (2).
Note: Apply a little grease to seals and cylinder.
3. Fit seal (9) on the outside of the head (2).

IMPORTANT: 1 - To ease installation, grease the outer 6. Push the piston (5) into the cylinder for 100mm
surface of the piston. 2 - Do not roll the seal (9). (4 in.) using a plastic hammer.
31200451 9-5
7. Apply grease to head (2) seals, fit the head onto the
piston and push it into the cylinder (3) using a plastic 9. Using two screwdrivers or levers, force the head until
hammer. it is seated against the stop ring (4). Fit the snap ring
(1) on the head (2).
Note: Insert the head and line it up with the edge of the
cylinder. IMPORTANT: Make sure that the snap ring (1) is
securely fastened in its seat. If necessary, force it into its
IMPORTANT: Install carefully do not damage. seat using a drift and a hammer.
IMPORTANT: Be careful when inserting the head, do

10. Replace the o-ring at each reassembly.
not go beyond the feed hole with the ring gasket
because it could be cut.
11. Check that the o-rings (17)(15) of the axle unit are in
8. Insert the stop ring (4) and ensure that it sets in the good condition; lubricate the seats of the seals and
seat of cylinder (3). fit the steering cylinder (3).
9-6 31200451
12. Lock the cylinder by cross- tightening the screws (3), 14. Insert the pins (18) in the steering case and lock into
apply CAT Threadlock to screw threads. position using a torque wrench setting of 270 - 300
Torque wrench setting: 90-100 Nm (66 - 73 ft.lb.) Nm (199-221 ft.lb.).
15. Install the proximity switch (21) for checking piston

13. Apply CAT Threadlock to the screw threads and centering, if applicable and tighten the screws (20).
connect the steering bars by threading the terminals Torque wrench setting: 5±8 Nm (3.5 ft.lb.)
onto the piston stem.
Torque wrench setting: 240-270 Nm (177-199 ft.lb.)
Note: Versions with coupling require that the rim of the
articulation is riveted onto the surfaces of the piston
stem.
IMPORTANT: Eliminate the action of the negative

brake, if fitted.
16. Apply tools T16 to the hubs and lock them.
Using a level “B”, check that tools are perfectly flat
and parallel to each other.
31200451 9-7
17. Connect the sensor (21) to the inspection device 20. Center the piston by slowly moving it first in one
according to either diagram shown following. direction then in the other and position it half way on
the stroke, which is determined by the switching on
and off of the signal lamp of the inspection device in
the reversal stage.
18. STANDARD version.
21. Inspect stroke “C” on one side of the piston and write
down the measurement for checking later
adjustments.
Note: If cylinders come without a sensor, the centering
of the piston must be carried out on the basis of the
maximum stroke.
19. OPTIONAL version.
9-8 31200451
22. Without moving the piston, check front and rear size 24. Loosen the nuts and screw them onto the ball-and-
at the edge of tools T16. socket joints.
Max. difference: 0.6-0.7 mm
Note: In order to check the rear size, rotate the bevel
pinion and check that tools T16 are flat.
25. Hold the articulations still and rotate the ball-and-

socket joints. Once the convergency has been
adjusted, lock the nuts. Torque wrench setting for
nuts: 240 - 270 Nm. (177-199 ft.lb.)
23. If necessary, adjust convergency without moving the

centering of the piston and adjust the length of the
steering bars (14).
Note: With a half turn of screw, the front size is reduced
by about 3 mm, whereas the rear one is increased by
about 3 mm.
26. ADJUSTING THE STEERING ANGLE

Loosen the nut of one of the adjusting screws on
cylinder side of the axle.
Note: Perform the same operations on both sides (see
diagram).
31200451 9-9
27. Adjust the extending portion of the screw according 29. As you hold the adjusted screw in position against
to data shown in the table. Lock into the position with the arm stop, adjust the screw opposite, on non-
nut tightened to max. 148 Nm (109 ft.lb.). cylinder side, until it rests against the arm stop.
IMPORTANT: The screws must rest against the
respective arm stops all at the same time.
28. Perform one full steering operation until the adjusted

screw rests against the arm stop.
Requested Steering Angle:

25° 27° 30° 32° 35° 36° 40° 42° 45°
Value A
Steering cases versions Value W = Adjustment of the steering stop screw,

based on max. steering angle. steering cylinder side [mm].
35° max angle. 55.1 51.2 45.4 41.4 35.0
45° max angle. 57.4 47.0 44.7 35.8 31.2 24.6
IMPORTANT: The screws must lean against the respective arm stops all at the same time.
9-10 31200451
Section 10
Swinging Support - Disassembly/Assembly
10.1 SWINGING SUPPORT -

DISASSEMBLY
31200451 10-1
1. Make positional marks across nut and pinion tang; 4. Remove the flange complete with guard by means of
If disassembly is difficult, heat the nut on the flange a puller.
to 80C° (176°F).
Note: Heating is meant to release the setting of Loctite
on the nut.
5. Remove the swinging support from the drive side

(4).
2. Loosen and remove the nut; also remove the o-ring.
6. Remove the swinging support (4) on the side

opposite the drive.
3. Remove the nut and the o-ring.
10-2 31200451
7. Position the swinging support (4) under a press and 8. Mark bushing position before disassembly.
remove the complete bushing (3).
31200451 10-3
10.2 SWINGING SUPPORT - ASSEMBLY
2. Install the swinging support to the drive side (4).

Note: Check that support is properly oriented.
Note: If the bushing (3) is worn and needs replacing,

mark down the assembly side of the connection notch
“A“. 3. Install the swinging support (4) on the side opposite
the drive.
1. Position the swinging support (4) under a press and

4. Fit the flange and fasten it. For keying the flange, use
insert the complete bushing (3).
a plastic hammer if necessary.
IMPORTANT: Lubricate the bushing wear surfaces
before assembling swinging support to axle housing.
10-4 31200451
5. Install flange. 8. Disassembly marks aligned.

6. Mount o-ring and apply Loctite 270 to pinion tang;
tighten nut.
7. Tighten the nut until the disassembly marks line up.
31200451 10-5
10-6 31200451
Section 11
Special Tools
31200451 11-1
Special Tools
11-2 31200451
Special Tools
31200451 11-3
Special Tools
11-4 31200451
Special Tools
31200451 11-5
Special Tools
11-6 31200451
Special Tools
31200451 11-7
Special Tools
11-8 31200451
Special Tools
31200451 11-9
Special Tools
11-10 31200451

Manual de Servicio Mandos Finales Th255 - Axle D & A - Global - English

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Manual de Servicio Mandos Finales Th255 - Axle D & A - Global - English

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Disassembly/Assembly Manual

August 29, 2008 - A - Original Issue Of Manual

6.7 Normal Differential - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

1.1 INTRODUCTION 1.2 DISCLAIMER

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

1.6.2 Equipment Hazards

1.6.3 General Hazards appropriate container and dispose of in accordance with

This Page Intentionally Left Blank

2.1 INTRODUCTION CLASSIFICATION

2.2 DEFINITION OF VIEWPOINTS

2.3 DATA PLATE

2.4 MAINTENANCE POINTS

Table 2-1. MAINTENANCE INTERVALS

OPERATION INTERVAL LUBRICANT

Differential Every 250 Hours

SAE85W90 (API GL5 - MIL 2105-B)

* Initially after 100 working hours

OPERATION MEMBER CONDITIONS INTERVAL LUBRICANT

Normal Work Monthly

Table 2-2. ADJUSTMENT AND CHECKS

UNIT OPERATION INTERVAL SERVICE BRAKE CIRCUIT

Negative Brake Adjustment Every 1000 Hours *

* Initially after 100 working hours

Table 2-3. SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS

Table 2-4. WHEEL NUTS TIGHTENING TORQUES RECOMMENDED

3.1 REDUCTION GEAR - DISASSEMBLY

3.1.1 GENERAL DRAWING

3.1.2 Disassembly: Integral 603 Type Input

4. Lift off the cover (21).

1. Remove screws (14) (20) of the drive side flange

5. To remove the drive side shaft (1), remove the snap

2. Take off the drive side flange cover (21).

6. Using two levers, remove the drive side shaft (1)

3. Place two levers into the appropriate slots. NOTE:

14. Remove the flange (18) by means of a plastic

15. Remove the internal bearing (10).

3.2 REDUCTION GEAR - ASSEMBLY

3.2.1 GENERAL DRAWING

3.2.2 Assembly: Integral 603 Type Input

3. Fit the flange (18) and fasten it.

IMPORTANT: Install carefully do not damage, also note

5. Lubricate, then insert the bearing (10).

2. Insert the sealing ring (11) with (T12) tool.

6. Using a normal tool insert the bearing (10) and snap

12. Install drive side flange cover, apply CAT Gasket

13. Tighten side flange cover screws (hex and allen)

4.1 SERVICE BRAKE/NEGATIVE BRAKE/

4.1.1 General Drawing

4.1.2 Axle/Axle Housing - Removal

3. Insert block screws to end stroke and release

2. Loosen the unlocking screws (30) and remove both

4. Remove the screws of the planetary gearbox cover

4.1.3 Brake Piston Assembly - Removal

6. Remove the axle half shaft.

7. Sling the arm to be removed and connect it to a

8. Carefully, take off the arm and lay it down vertically.

12. Loosen the previously installed provisional screws in

4.1.4 Brake Piston Module - Disassembly

14. Pull out brake piston assembly module.

15. Inspect the locking screw (33) of the brake piston

16. Remove intermediate disc (2).

22. Unscrew the slotted nut (29).

19. Applying pressure to the third hole, remove the three