n 497 <> eel IN TORQUE SERVICE MANUAL11. 42, 13. Rock Torque Axle CONTENTS SPECIFICATIONS .. MAINTENANCE AND INSPECTION.. STRUCTURAL DRAWING. PARTS LIST. FASTENING TORQUE LIST TOOLS COATING, LUBE OIL, AND REPAIR MATERIAL MEASURING INSTRUMENT! ‘TROUBLESHOOTING. DISASSEMBLING. 10.1 Removing the Axle Assembly 10.2 Disassembling the Axle -..nnnnmnnnn 10.3 Disassembling the WHEEL HUB ASSY 10.4 Disassembling the SAHR BRAKE ASSY. 10.5 Disassembling the PLANETARY CARRIER ASSY. ....0nen24 10.6 Disassembling the RING GEAR ASSY. 24 10.7 Disassembling the DIFF. CARRIER 25 MAINTENANCE STANDARDS. ASSEMBLING. 12.1 Assembling the DRIVE PINION ASSY. seen Bt 12.2 Assembling the DIFF CASE ASSY 34 12.3. Fitting into the DIFF CARRIER... oe) 12.4 Adjusting SIDE BEARING Preload 36 12.5. Measuring Back Deflection of DRIVE GEAR. 37 12.6. Fitting the DRIVE PINION ASSY. 37 12.7 Checking and Adjusting DRIVE GEAR Tooth Contact 39 42.8 Fiing the DIFF CARRIER ASSY. 4 12.9 Assembling the RING GEAR ASSY. a1 12.10 Assembling the PLANETARY CARRIER ASSY. a2 12.11 Assembling the SAHR BRAKE ASSY. 43 12.12 Assembling the HOUSING ASSY.....un 48 12.13 Assembling the WHEEL HUB ASSY. 49 12.14 Fitting the WHEEL HUB ASSY. 50 12.15 Adjusting WHEEL HUB BEARING Preload 51 12.16 Assembling the PLANETARY CARRIER ASSY. 53 12.17 BRAKE COMPONENTS 54 LUBRICATION .. © 1993, Wagner Mining And Construction Equipment Co, Rev. 0993, 457 Series Table of ContentsRock Torque Axle 457 Series 1. SPECIFICATIONS item Speaiications Axle Type | Fallfloating, banjo housing type with wheel reduction First Type Spiral bevel gear B| rewston Reducionraio | —~=iaaSSSSC*S 5 Number of teeth 487 3 | Type “Planetary gear B) Scion Reduction rato 520 3)“ raio Number of teeth ~eareanis (24 for planetary gear) Differential Type Straight bevel gear _| ‘Number of teeth Pinion: 10; Gear: 16 Bele shat | 0.D-xlengih 0545x981 | B: 054.5 x 903 Type “| SAHR BRAKE #25000 Brakes OD. x1D. 0494 x 0825, Number of plates 4 (on one side) | Hub bolt ‘Screw size x pitch 7/8" 14UNF ‘Number of bolts lo o5 (on one side) « | lnside housing | SAEW90; API case GLS = Inside wheel hub SAE#90; API class GL-5 oiitype ana | | “inside bakes | Sel'bonae 10 Cit) Q] inside housing | + +—~—26iiters & Inside wheel hub | Sillers (on one sido) —— =] = Weight 9 ‘era eiiessy | Section 1 Paget © 1993, Wagner Mining And Construction Equipment Co, 7 2 a tev. 09.93Rock Torque Axle 457 Series 2. MAINTENANCE AND INSPECTION 2.1 Daily Inspection 1) Inspecting oil level ‘See SPECIFICATIONS for the standard oil quantity. For the appropriate oil level, check whether oil flows out from the lubrication opening (which also serves as the level plug) when the axle is held horizontal. If insufficient, ‘add oil up to the designated level. Oil type : SAEW90; API class 2) Checking for oil leaks ‘Check to see that no oil is leaking from the casing and cover joints, as well as from the bolt and plug pars. IF oil is leaking, fasten the bolts to the designated torque. 3). Checking for abnormal sound and heat abnormal sound or heat generates from the axle, the gear or bearing may be worn, Disassemble the axle and check; if necessary, replace the ‘components. 2.2 Periodic Inspection 1) Replacing lube oil Ding ioral Location | rita Every] Every) Typeotoit | Oil quantiy TOoOKM| A060KR| month | 24000Km | or grease a Housin | SAE #90 iter esos a [enue |S Oee| (apichaes Galilee cweane SAE #90 Siier Hub ° 7 c ° (API class GL-5) | _(on one side) 2%: Replacement after intial new vehicle operation (©: Inspection (O: Replacement 2.3 Supplying and Discharging 1) Discharge oil by removing the drain plugs (on the lef and right sides of the housing and wheel hub) while the oil is still warm after operation ‘Add oil until it flows out from the level plug, Since each plug has a magnet worn-out powder is drawn inside the casing, ‘Check each plug and clean as necessary. © 1993, Wagner Mining And Construction Equipment Co. Section 2 Rev. 09.93, Page 2Rock Torque Axle 457 Series 3. STRUCTURAL PRAWING “ Y Nemo as Oe Bien Section 3 (©1993, Waser Mining And Construction Equipment Co, Page 3 “en me 4 i -y.09.93Seation 3Rock Torque Axle 457 Series 4. PARTS LIST 7 QTYPER_| ITEM WiONO | W/NO No. | PART DESCRIPTION SPIN SPIN 1 HOUSING, AXLE 1 =m 2 PLUG, KIT, 7/8-14UNF. 3 3 PLUG, 7/8-14UNF si 3 4 | BREATHER janet 1 5__| DOWEL PIN, 6 13 251 [2 2 6 | DOWEL PIN, 0 27 51L 4 4 7__| SHAFT, AXLE B 1 a 8__| SPINDLE : 2 2 9 | O-RING 2. | 2 | 10 | COVER, SPRING 2 2 “11__|_ SPRING PIN 6 6 14__| PLUG, 9/4-16 4 aa 15 | O-RING 8 8 16 | BREATHER, Alf zie 2 17___| CAP, BREATHER Pe are 18__| SPRING 52 52 | 19 | SPRING [52 soeeal 20 | BOLT,M1axX1.585L 36 36 [21 | WASHER, HARD m | 72 22 | BOLT, M22 x1.5 82 40 40 | 23__| O-RING. 2 een) 24 | SEAL a 2 2 25 | PISTON 2a 2 26 | SEAL [2 2 | HOUSING, BRAKE 2 2 | | PLUG, 9/16-18 14 14 | O-RING 2 2 STATOR [40 40 | FRICTION PLATE [8 a | | COVER, FRICTION PLATE 2 | | (“3a ] sour, ma x 1.5 701 souaal| 35_[ FLOATINGSEAL | Section 4 © 1993, Wagner Mining And Construction Equipment Page § Rev. 0993Rock Torque Axle 457 Series [_QTY7PER__| | | ive (wio NO | W/NO NO. | PART DESCRIPTION ‘SPIN 38_| OU SEAL 4 ao__| BEARING { 40 | WHEEL HUB —41 | STUD BOLT, M20X1.5:78-14UNE 127L_| 46. 46 _42__| BEARING ee 2 43_| RETAINING RING 44 | BING GEAR HOLDER 45 | LOCK WASHER | 46 | BOLT.M12x1.25 251. ata —az_[couaR |48__| NUT SPINDLE {2} 2 |_49__| THRUST WASHER 2} | {so [Geanpave | ce | [os1 [RETAINING RING pas | ae | so | tHausTpiece | 53__| GEAR, RING 2 4 O-RING PLANETARY CARRIER ASSY —_ | PLANETARY CARRIER. GEAR. PLANET 58__| NEEDLE BEARING a_| THRUST WASHER 60_| SHAFT, PLANET GEAR 61_| O-RING z [2 2 62_| SET SCREW : 6 ae 63_| HEXAGONSOCKETBOLT,Mi0x1525. | 16. 16 | s4—| COVER. 165 | BOLT. Mi2x1.75951 [66 | BOLT. Miaxts 40. —67_| BOLT, M14 x 1.5 52 [ea | SPRING WASHER M14 71_| DIEE CARRIER ASSY —___ 72__| BOLT, M18 X 1.5 40L [73] DIFE case, SET 4 eee [74 | RING-PINION GEAR, SET 1 1 [75 _| WASHER, SIDE GEAR 2 - © 1993, Wagner Mining And Construction Equipment Co. Section 4 Rev. 0993, Page 6Rock Torque Axle 457 Series Sections Page? ~ } (PER ___| lrrem wioNo | W/NO NO. PART DESCRIPTION |_SPIN SPIN GEAR, SIDE [2 - WASHER, PINION GEAR, 4 : GEAR, PINION 4 - SPIDER oman _ DOWEL PIN, 0 8 2a 2 BOLT, M14 X 1.5 135. 8 BOLT, M10 X 1.25 25 “4 LOCK WASHER _ 2 LOCK PLATE - 2 | BEARING 2 | ‘ADJUSTABLE NUT 2 | DIFF CARRIER SET 1 ae = | 89_| BOLT. BEARING CAP 4 | 0_| RING, Lock z 1 o1_| BEARING (ae “92 | SHIM, KIT 1 | ¢3_| BEARING 4 [ 94_| RETAINER 4 | 98 | “COLLAR. Kit a 96| COLLAR, PINION BEARING | 1 97__| BEARING 4 [98 | oll SEPARATOR. 1 99 | ol SEAL 4 02 | BOLT. M14 X2-45L [8 103_|~ cover, bust. 1 104 | FLANGE, YOKE 1 105 | WASHER aI 106 | _NUT. 1 107 | SPLIT PIN, 6 660 4 108 _| DIFF CARRIER ASSY - 103 | NO SPIN ASSY : 110__| SPIDER, CAM ASSY 5 111__| HOLD OUT RING | 112 | _DRIVEN CLUTCH = 113_| SPRING - |7ira|“ sie GEAR, NO SPIN 115] SHAFT, AXLE A = “116 | BOLT, M14 x1.5 175L 4 [4 347 [NUT 12} 12 118 | BOLT,STUD MTax1.5 [2 2 sig [_ NUTMt4x1.5 2 ©1993, Wagner Mining And Construction Equipment Co. Rev 09.93,Rock Torque Axle 457 Ser 5. FASTENING TORQUE LIST Wo, [Patra Nerina] Wai | Faslonng | Rema ue | across | torque ints) Nem eaten PLUG, MAGNET Pre 14 55.9(6.2) Soaltape Emr er + | prea wie] 2 [4805 7 [usacis | nent | ves [9 | wore 20 | BOLT, Misx1sasL | Migxis | 27 392 (40) ‘tooktte 242 | ze [sot weaxisea | wees | 2 | 2c | token a [sunmen —[weaar] ex | m0 | vehow vo [portamensTa: | ments [a7 | o@00 | tetone a [pots | wenn 57 aun = [omosarsaT| wows | @aea 65 | BOLT, M12x1.75 ‘M12 1.75 7 | 63765) oe [eatanarisat | maxis [ve | esc | Teeeeaidis or [earn erss7a | waxes [v9] 17640) | Teetira 5 [port wrexrsaec | wants | a7 [roe | loaenta a [eorrwnaristea| wexas | 22 iar @ [satmmoxis | woxvs |v | oes] 89 | BOLT,BEARING CAP] M22x15 32 421.7 (43) 102 | BOLT, Mi4x1545L | Mi4x15 2 117.7 (12) ~ 6 [wT aries Mae nee wre fecctanariaa] waxes [22 ae wafer paws | | anne Rev. 0993, PageRock Torque Axle 457 Series 6. TOOLS Name Nominal Used tor Usedo Spanner Hexagon; width | Bolt and nut Untasten and fasten across flat bolts and nuts | __| 4233mm _ | Box wrench | Hexagon; width | Bolt and nut Fasten to | across fla designated torque. | | 32-50mm efit ‘Nut wrench Spindle nut ] Untasten and fasten nus. ————E———————— | t0.:30 Pipe 0.0. :40 Bolt and nut | Untasten bots. tongtn: 600 and nuts. Wood block | 150x500 | Axl proper Fastening torque Torque wrench | 4.9-735 N-m Bok and nut Fasten to | (05-75 kgtm) designated torque Socket adapter] Hexagon; width | Bolt and nut Fasten 10 across flat designated torque | 12.50mm | Chiset Spit pin Gut Pls Retaining Ring | Disassemble and | assomble Hoist wire rope} 1500 ko Main unit and each | Lit component } a Bearing puler Beating Disassemble | Section 6 © 1993, Wagner Mining And Construction Equipment Co. Page 9 Rev. 09.93Rock Torque Axle 457 Series 7. COATING, LUBE OIL, AND REPAIR MATERIAL Maker designation | Used for _ Used to: ] Fea ~ Looktte Locktte Co. Bolt and nut | Prevent oosening Three Bond | Three Bond Co; | Machined surface seal| Prevent oil rom #1215, imbolserew sections | leaking #1102 | | Gear oi SAEHOO: Beating, gear Lubricate API class GL-S | Brake oi Shel Brakes, friction plate | Coo! | Donax To Refined | IS K2209 : | clean Kerosene oil | No.2 Wiite pen Check and make matching marks. Red lead primer | (Blue pigment) Spiral gear Check tooth contact. Oilstone Finish surface, ‘Sandpaper Finish surtace, Waste cloth | (© 1993, Wagner Mining And Construction Equipment Co. Rev. 09.93 Section 7 Page 10Rock Torque Axle 457 Series Name Nominal Usedtor | Used to: Thickness Measure gauge clearance Spring balance (0-490 Nm Bearing Measure 0~50 Kot preload Outside Measure shaft micrometer 0~ 25+ 25 ~ 50 diameter | cylinder gauge Measure inside 18 ~ 35 +35 ~ 60 diameter | Calipers 200 - 1000 | Dial gauge Measure 5 backlash and deflection Magnet base _| Lever type Used as stand 50 x 48 x 60 for dial gauge Section © 1993, Wagner Mining And Construction Equipment Co. Page 1 Rev. 09.93Rock Torque Axle 457 Series 9. TROUBLESHOOTING ‘This section describes actions to be taken when a fault in the axle assembly is detected + Determine the nature of the fault before taking action. + When disassembling any part of the axle, make sure that no dust enters it. + All components are precision-finished, so be careful when handling them The following lists inspection items. Checking these items will help to detect a fault and locate its position. If any fault is found, disassemble the axle and replace components according to the maintenance standards, 9.1 Inspecting Gear Oil Drain gear ol from the axle proper and check whether the gear oil contains any ‘metal powder or other foreign matte. If it contains a large amount of metal pow- der or large fragments, the gear, shatt, or bearing may be broken. 9.2 Inspecting for Abnormal Sound Check whether any abnormal sound is generated from the axle proper. If an abnormal sound is generated, the gear, shalt, or bearing may be broken. 9.3 Inspecting the SAHR Brakes 1) If the pedal has excessive step-on allowance when applying the brakes, the brake plate or facing may be worn 2) If the brakes remain on or cause dragging during operation, a faulty piston seal may be leaking oll, or air may be improperly purged from the brake pipe. 9.4 Inspecting Oil Leakage If oll leaks from the axle proper, the O-ring or oil seal may be broken or bolts may be loose. © 1993, Wagner Mining And Construction Equipment Co. Rev. 08.93. Section Page — 12Rock Torque Axle 457 Series 9.5 Probable Causes and Actions to be Taken | _ Symptom Probable cause ‘Action to be taken Oitteaks from | + The oil evelis + Adjust tothe appropriate the of or t00 igh, |” tevel flange yoke, + The oil sealis broken or wom, + Replace the oi seal ] +The aif cariar and + Fasten the screw with the Cilleaks fromthe |” spindle fastering designated torque housing and ott- | _sorews are loose | carrier or housing + The Fquid packing is cracked. | + Repair and apply coating to-spinde iting. | + The housing is cracked + Replace the housing. | + The Oving is broken. + Replace the O-ring, Oil leaks trom | + The floating seal is Replace the floating seal the SAHR brakes.| _ broken or wor, | + The Ovingis broken + Replace the O-ing will not move) 2) Faulty Transmission (Unit {Symptom Probable cause ‘ction to be taken ‘The vehicle + The axle shaft is broken. + Replace the shaft does not move | + The final gear is broken. + Replace the gear. although + The planetary gearis broken.| + Replace the gear. the propeller shaft rotates. Section © 1993, Wagner Mining And Construction Equipment Co. Page 13 Rey. 09.95Rock Torque Axle 457 Series 3) Abnormal Sound ‘Symptom Probable cause Action to be taken ‘Abnormal sound is | + Backlash in the spiral + Adjust the backlash, generated when gear is excessive. starting or changing | Backlash in the + Replace the side gear speed. Giferential gear is, pinion gear, and thrust excessive, washer. + The spiral pinion is + Adjust preload, improperly preloaded, Abnormal sound | + The spiral gearteeth are + Adjust gear engagement or is generated improperty engaged. replace the whole gear set. |} continuouslyor | + Backlash in the spiral + Adjust the backlash intermittently gears insuticient. during operation. | + The pinion bearing and side | + Replace the bearing bearing are worn or broken + The wheel bearing is worn, | + Replace the bearing. broken, or seized up. + The gear lis insulfcient or | + Add the designated oll or inappropriate. replace the oil ‘Abnormal sound | + The side gear and pinion gear_| + Replace the gear. | is generated when | are abnormally worn or broken, turing. |+ The pinion gear and spider are | + Replace the gear. abnormally worn or broken. + The thrust washer is + Replace the washer. abnormally worn or broken. © 1993, Wagner Mining And Construction Equipment Co. « Rey. 09.93 Section Page — 4Rock Torque Axle 457 Series 10. DISASSEMBLING 10.1 Removing the Axle Assembly Follow the procedure described below to remove the axle assembly trom the vehicle. 41) Remove the wheels and ties from the axle. 2) Remove the brake hose on the chassis side of the SAHR brakes. ‘The brake oll may overflow, so be careful. 3). Disconnect the linkage between the axle and propeller shaft. 4) Remove the axle from the vehicle by extracting it to the rear or the left or fight side while supporting the axle with a garage jack or fork-lt ‘Axle weight: 1,674 kg (oil-less) 5) Place the axle on a stable block with its drain plug facing down, 10.2 Disassembling the Axle Locate the fault by manually turning the rotating part of the axle before disassem- bling it. 1) Remove oil and mud from the axle proper by steam cleaning, 2). Drain gear oil and brake oil from the axle. Note: Check the drained oil to see If It contains worn- out powder. It a large amount of worn-out powder is found, the axle is faulty; disassemble It and check. 3) The axle consists of a large number of components, and these components are specially designed for use on each side. Be careful not to get the left and right-side components mixed up. Each component has its own fitting alignment, so mark the matching faces with a white pen. Section © 1993, Wagner Mining And Construction Equipment Co, Page 15 Rey. 09.95Rock Torque Axle 10.3 Disassembling the WHEEL HUB ASSY Follow the procedure below to disassemble the WHEEL HUB ASSY. 1) Remove BOLT (63) from WHEEL HUB (40), then remove PLANETARY CARRIER ASSY (55) from the assembly. “Use an extracting bolt (M10 x 1.5) 2) Remove RETAINING RING (61) from AXLE SHAFT (7) and (115) then remove DRIVE GEAR (50) and WASHER (49) from the assembly. aul 3) Extract AXLE SHAFT (7) and (115) from SPINDLE (8) remove SPINDLE NUT (48) and LOCK WASHER (45), then remove RING GEAR HOLDER (44). © 1993, Wagner Mining And Construction Equipment Co, 3, Wa o ‘quip ce Rev. 09.93 Page — 16Rock Torque Axle 457 Series 4) Gently lift WHEEL HUB (40) using a hoist or other appropriate jig and remove RING GEAR HOLDER ASSY from WHEEL HUB. At this time, RING GEAR HOLDER ASSY comes off along with the inner races of COLLAR (47) and OUTER BEARING (42). aa 5) Demount WHEEL HUB ASSY from SPINDLE (8). At this time, WHEEL HUB ASSY comes off along with the outer race of OUTER BEARING (42), as well as with INNER BEARING (39), OIL SEAL (38), and FLOATING SEAL (35). 6) Remove {rom WHEEL HUB (40) the outer race of OUTER BEARING (42) and INNER BEARING (39) and OIL SEAL (38) by striking them out with a brass bar or other appropriate jig. “Do not remove these components unless necessary to replace the bearing Section © 1993, Wagner Mining And Construction Page 17 a a ment Co. ev. 09.93Rock Torque Axle 457 Series 7) Remove BOLT (22) from SPINDLE (8), then remove SAHR BRAKE ASSY after 8) untastening . Remove SPINDLE (8) from HOUSING (1). © 1993, Wagner Mining And Construction Equipment Co. Rev. 09.93 SAHR BRAKE ASSY Section Page — 18.Rock Torque Axle 457 Series 10.4 Disassembling the SAHR BRAKE ASSY WARNING! The procedures described here must be followed exactly. Failure to do so may result in personal injury. High internal spring tensions are basic to the SAHR brake's design. This makes improper disassembly of the brake unit very danger- ous. Have all necessary tools available and be famil- iar with the procedures belore starting the disassem- by. CAUTION! The front cover and backing plate must be “backed out” slowly to relieve inner spring tension. If these steps are not followed precisely, per- sonal injury may result! (1) NOTE: The front cover is under spring pressure {or approximately the first inch of bolt travel unless pressure (1500 psi) is applied to release the brake. If pressure is applied to the brake (by using a portapower, for example), you can simply loosen and remove all the bolts. Otherwise: Back-out the bolts from the front cover plate by loosening each bolt 1/2 to 1 turn at a time in a criss-cross pattern until all bolts are removed. Then iit off the front cover plate. NOTE: The pictures in this manual illustrate the disassemblyassembly procedures with the brake unit dismounted from the axle. If you are perform- ing these procedures with the brake assembly still mounted on the axle, make certain to exer- cise care in keeping all parts as clean as possible to avoid contamination. (2) Remove quad sealing ring from the housing. (3) Remove disks from the brake housing. Section © 1993, Wagner Mining And Construction Equipment Co. Page 19 Rev. 09.93,(4) Flip the brake assembly over. CAUTION! This step will release the spring force, so proceed with care. (5) Begin by removing every other bolt Then slowly release the backing plate by loosening the remaining bolts 1/2 0 1 turn at atime in a criss-cross pat- tern Make certain to criss-cross when loos- ening the bolts to minimize stress on the backing plate. Continue slowly loosening the bolts 1/2 0 1 tum at a time until all but three or four equally spaced bolts are removed. These bolts will hold the unit together when you flip it over. (6) Once you've flipped the unit over, remove the remaining bolts and fift the housing off the springs and backing plate. (© 1993, Wagner Mining And Construction Equipment Co. Rev. 09.93 Rock Torque Axle 457 Series Seton Page —20,Rock Torque Axle 457 Series (7) Remove springs from the brake housing, (8) Remove the O-ring from the backing plate. Section 10 © 1993, Wagner Mining And Construction Equipment Co. Page 21 . en 09.93Rock Torque Axle 457 Series (9) Remove the port O-rings from the brake housing, (10) Tap the piston from the housing with a rubber mallet, Separate the piston from the housing, (11) Remove outer piston seal & expander ring from the piston, {© 1993, Wagner Mining And Construction Equipment Co. Rev. 09.93. 7 anRock Torque Axle 457 Series (12) Remove inner piston seal and expander fing from the housing, CLEANING AND INSPECTION CLEANING: Clean all parts thoroughly using a solvent. Parts should be immersed in ‘cleaning fluid and moved up and down slowly unti all old tubricant and foreign matter is dissolved and parts are thoroughly cleaned. INSPECTION: Make a careful and thorough inspection of all parts. You can avoid costly failures at a later date by identifying and replacing all parts showing wear or fatigue, Carefully inspect all piston seal surfaces, grooves, edges of grooves, as well as housing bore and outer diameter of piston. Housing, Covers, etc. Make sure that all housings, covers, and bearing caps are thoroughly cleaned and that mating surtaces are free ot nicks or burrs. Check for cracks or other conditions which could result in oil leaks or failure. Piston and Housing Seals You should always use new Wagner replacement seals ‘when rebuilding the SAHR brake. Handle all sealing members caretully. Cutting, nicking, or overstretching can result in premature failure. Section 19, ©1983, Wagner Mining And Construction Equipment Cx Page 23 7.09.93Rock Torque Axle 457 Series jisassembling the PLANETARY CARRIER ASSY 1) Remove SET SCREW (62) from PLANETARY CARRIER (56). 2) Extract SHAFT (60) from inside the planetary cartier. 3) Remove GEAR (57), BEARING (58) and WASHER (59) from the planetary carter, 10.6 Disassembling the RING GEAR ASSY 1) Extract the inner race of BEARING (42) trom the RING GEAR ASSY. 2) Remove RETAINING RING (43) from the RING GEAR, then separate RING GEAR, (53) from RING GEAR HOLDER (44). (© 1993, Wagner Mining And Construction Equipment Co. Section 10 Rev. 0193) Page 24Rock Torque Axle 457 Series Section 10 Page 25 10.7 Disassembling the DIFF CARRIER ASSY 1) Remove DIFF CARRIER -fiting BOLTS (66) and (67), then extract CARRIER ASSYS (71) and (108) from the housing by using extracting bolts M16 x 2.0 al two locations. “Since the DIFF CARRIER ASSY weighs about 265 kg, use a hoist or other appropriate ig 2) Measure the following dimensions betore disassembling and record the measured values. a. Backlash in BEVEL GEAR SET (74) b. Back deflection of DRIVE GEAR (74) c. Tooth contact OF BEVEL GEAR SET (74) 3) Removing the BEARING CAP. a. Puta matching mark on BEARING CAP (87) b. Remove BOLT (82), then remove LOCK PLATE (84) and LOCK WASHER (83) from the BEARING CAP. c. Remove BEARING CAP-Itting BOLT (89), then remove BEARING CAP (87) from the DIFF CARRIER, “Keep the detached BEARING CAPS (87), ADJUSTING NUTS. (86), and BEARING (85) outer races so they are not mixed up on. the left and right sides. © 1993, Wagner Mining AndRock Torque Axle 457 Series 4) Removing the DIFF CASE ASSY Lift the DIFF CASE ASSY using a hoist or other appropriate jig and remove it from the DIFF CARRIER. To prevent the gear tooth surface from touching BEARING (91) at this time, move the DIFF CASE toward the other side betore extracting the DIFF CASE ASSY. 5) Removing the DRIVE PINION ASSY Remove DRIVE PINION ASSY-fiting BOLT (102), then remove the DRIVE PINION ASSY and SHIM (92) from the DIFF CARRIER. 6) Disassembling the DRIVE PINION ASSY ’. Fix FLANGE (104) into place, ramove NUT (108), and remove FLANGE (104), and OIL SEAL (89) from PINION GEAR (74). b, Extract DRIVE PINION (74) rom RETAINER (84) using a press or other appropriate jg. Atthis time, BEARING (93) inor race, and COLLAR (95) come off together. ¢. Extract the inner race of BEARING (83) rom the PINION DRIVE by using a bearing puller or press. © 1993, Wagner Mining And Construction Equipment Co. Section 10 Rev. 09,93 Page 26Rock Torque Axle 457 Series 7) Removing the PILOT BEARING Remove LOCK RING (90), mounted at the tip of the DRIVE PINION, from PINION DAIVE (74), then extract BEARING (91) by using a bearing puller. 8) Removing the bearing outer race Remove the outer race of BEARING (92) and (97) from inside the RETAINER, 9) Disassembling the DIFF CASE ASSY a. Remove the inner race of BEARING (85), which is fitted to DIFF CASE (73), by using a bearing puller. “Check to see that DIFF CASE (73) has a matching mark. If unclear, make a matching mark. ment Co. ©1983, Wagner Mining And Construction Equip ev. 09.93 Section 10 Page 27Rock Torque Axle 457 Series b. Loosen NUT (117), then remove BOLTS (61) and (116) from the DIFF CASE ASSY. + For without NO-SPIN AXLE: Disassemble the DIFF CASE, then remove PINION GEAR (78), PINION WASHER (77), SPIDER (79), SIDE GEAR (76), and SIDE WASHER (75). + For with NO-SPIN AXLE: Because the nose pin assembly jumps out due to spring action, fix Fy, ‘1, 116 408 nr a c. Remove DRIVE GEARMitting BOLT (72), then remove DRIVE GEAR (74) from DIFF CASE (73) “Do not remove the BOLT unless necessary to replace the DRIVE GEAR. ie ya k A \e 7 ‘ hs © 1993, Wagner Mining And Construction Equipment Co. Section 10 Rev, 0993 Page 28Rock Torque Axle 457 Series 11. MAINTENANCE STANDARDS Clean each disassembled component and dry with compressed air. I any component exceeds the decision criterion for that component, replace it with a new one. Parameter Unit | Decision [Usage | Remarks criterion _| simit_ | _ 2 @ [Backiash mm | 0.30-0.44 [Adjust with NUT (68). | 2 |Back deflection mm o7 (0.20 | Replace GEAR or \E4 _ DIFF CASE. _ 2 | Pretoad Nem | 098-392 ‘Adjust with COLLAR | g (kgtem)| _(0.10~0.4) (98). | [Play lative to lange | mm | 0.013-0.114 | 0.22 | Replace I in spine rotation drection | | tooth contact no good, sea the method of adjustment on page 40. sil no good, replaca the whole gear set, T Preload (side bearing) | Nem | 098~292 T Adjust with S| (kgiem)| _(0.10~0.4) ADJUSTABLE NUT (86) E/ Thrust washer] Gear | -mm [~ 28-30 | 26 | Replace ~ 2g Pinion [mm [15-17 | 1.3 Replace & | Gap between spider mm | 0.169-0.278 | 0.35 | Replace. [and pinion gear _ - 7 | 3] Gap between ait mm | 0200-0326 | 0.67 |Repiace. | ~ [case and side gear Play relalive to Side gear in axle shaft rotation direction mm | 0.127~-0.291 | 0.35 | Replace. E | Preload Nm | 294-588 ‘Adjust with 5 (kgtm)| (03-06) |_| NUT, SPINDLE (48). Bend, axieshat A&B | mm | 050 | 20 | Replace. Measure at _ |__| ine center ofthe shatt j [Each casing Replace it heavily worn, damaged, cracked, or deformed. | [each gear Replace i tooth contact is no good or the gear is | damaged, spit, chipped off, or heavily worn. | & [Each beaing. rong —] Replace if oling contacts no good or the =] 2) © [contact surtace of roller |_bearing is damaged, spilt, chipped olf, or heavily worn. 3) 3 [oltseal, O-ing Replace if heavily worn, damaged, swollen, or delormed \8 Do not reuse the removed oil sea - | § |Racoway suface of | Replace if heavily streaked or worn, liseal important sorews |" Replace if heavily damaged or cracked Section 11 nage 29 ©1983, Wagner Mining And Construction Fqulpment Co. ev. 09.93Rock Torque Axle 457 Series 12. ASSEMBLING To assemble the axle, perform the disassembling procedure described in the preceding sections in reverse order. The following lists the precautions to be taken when assem- bling the axle. ‘A) Thoroughly clean each component with washing oil and dry with compressed air. Avoid using a cloth as much as possible. if absolutely necessary, use a clean cloth and be careful not to leave fibers. B) Carefully check each component according to the component replacement criteria in MAINTENANCE STANDARDS. If any component exceeds the criterion or is found faulty, replace it. °) If any component is damaged during disassembling, be sure to repair the damaged part and replace all O-rings and oil seals used in that component 0) Apply a coaling of the following grease to the press-iting surfaces, rolling contact surtaces, oil eal ips, spline tooth surfaces, and O-rings before assembling: Recommended grease: Multipurpose Grease #NLG1-2 E)_ Fasten each fitting screw with the fastening torque listed in the FASTENING. TORQUE LIST. F) Assemble the left and right sides in the same way. Be careful not to assemble left or right-side components on the wrong side; check the matching marks made during disassembling G) The Locktite-coated screws may bear white powder generated when the ‘components are disassembled. When assembling, Locktite may be coated on top without any problem. However, Locktite powder sticking to the flange surface must be removed by using a steel brush or other appropriate tool. The surface must be finished with sandpaper or oilstone. The Three Bond-coated screws must be removed of rubber-ike film betore applying a new coating of Three Bond when assembling, © 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 0993 Page 30Rock Torque Axle 457 Series 12.1 Assembling the DRIVE PINION ASSY 1) Press-it BEARING (93) inner race and BEARING (91) to DRIVE PINION (74) by using a press, then fit LOCK RING (89) at the tip. 2). Fit preload-adjusting COLLAR (95) to DRIVE PINION (74), 78 85 3) Press-fit the outer race of BEARING (93) and (97) to RETAINER (94) Section 12 © 1993, Wagner Mining And Construction Equipment Co, Page 31 Rev.09.3Rock Torque Axle 457 Series 4) Set RETAINER (94) and the inner race of BEARING (93) and (97) to DRIVE PINION (74), then press them into position. 5)_ Put PINION BEARING COLLAR (96) and OIL SEPARATOR (98) into DRIVE PINION (74) , inset WASHER (105), then temporarily fix with NUT (106) (Fastening torque: 539-735 N-m) 6) Measuring bearing preload ‘a. Hook a spring balance in the bolt hole of RETAINER (94), gently pull the spring balance in the tangential direction, then read the scale of the spring balance when the RETAINER begins to rotate. 'b, Adjust the thickness of collar (95) until the measured preload reaches the designated value. ‘When using new When reusing old bearing bearing Preload 1.47-3.92 1.18~3.14 Nem (0.15~0.40) (0.12~0.32) Kgl. ~ Tengential force of bolt hole Nm 147-39. 11.8-31.4 (kg!) (1.50-4.00) (1.20-3.20) © 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 0993 Page 32Rock Torque Axle 457 Series 7 8) 9) 10) Section 12 Page 33 ‘Alter the thickness of COLLAR (96) is determined and preload adjustment ‘completed, remove NUT (106) from DRIVE, PINION and extract FLANGE (104) Fit OIL SEAL (99) into RETAINER 94under pressure. “Apply a coating of grease to the cil seal lip. 0 seal ingen Insert FLANGE (104) again and fix i into place, then fasten WASHER (105) and NUT (106) with the designated torque. (Fastening torque: 39-735 N-m.) ‘When the groove in NUT (106) is matched to the hole in DRIVE PINION (74), insert SPLIT PIN (107) and bend the split pin to lock. © 1993, Wagner ing And Construction Equipment Co, ev. 09.93Rock Torque Axle 457 Series 12.2 Assembling the DIFF CASE ASSY 4) Fitthe inner races of BEARINGS (85) into the left and right halves of DIFF CASE (73) under pressure, 2) Fit DRIVE GEAR (74) to DIFF CASE (73). Apply a coating of Locktite #242 or ‘equivalent to BOLT (72), then fasten it with the designated torque. (Fastening torque: 459-561 N-m) 3) Assembling the DIFF CASE ASSY + For without NO-SPIN AXLE: Fit SIDE WASHER (75) and SIDE GEAR (76) to the left and right halves of DIFF CASE (73). Fit PINION GEAR (78) and PINION WASHER (77) to ‘SPIDER (79), and fit them into the DIFF CASE. “Apply a sufficient coating of oil to each of the above components before assembling + For with NO-SPIN AXLE: Fit NO SPIN ASSY (109) into the DIFF CASE while holding it in place with a dedicated tool. (© 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 09,93 Page 34Rock Torque Axl 457 Series 4) Assemble the left and right halves of DIFF CASE (73) after aligning the matching marks each other, apply a coating of Locktite #242 or equivalent to BOLT (81) and (116), ft them to the DIFF CASE, then fasten nut (117) with the designated torque. (Fastening torque: 260 N-m) *Forthe NO-SPIN AXLE make sure that the NO SPIN ASSY holding tool is removed before assembiing, 12.3 Fitting into the DIFF CARRIER | 1) Fitthe outer race to BEARING (85) on both sides of the DIFF CASE ASSY, then {itt into DIFF CARRIER (87). 2) Alter fiting into the DIFF CARRIER, fit ADJUSTABLE NUT (66) from the left and right sides and have it closely contact the BEARING Section 12 © 1993, Wagner Mining And Construction Equipment Co. Page 35 Rev. 09,© 1993, Wagner Mining And Construction Equipment Co. Rock Torque Axle 457 Series 3) Fit BEARING CAP (87) to the DIFF CARRIER after aligning the marching marks, then temporarily fasten it with BEARING CAP BOLT (89) so thal the NUT rotates when turned with light force. Matching marks | 12.4 Adjusting SIDE BEARING Preload 1) Wind a flexible wire around the barrel of the DIFF CASE ASSY and fit a spring balance to it 2) Gently pull the spring balance in the tangential direction and read the scale of the spring balance when the DRIVE GEAR is rotating. Adjust the preload by turing the left and right ADJUSTABLE NUTS (86) until the following value is reached ~~] When using new | When reusing old bearing bearing Preload, | Nem 1.47-3.92 1.18-3.43 (kgt-m) (0.15~0.40) (0.12-0.35) Tensile force at | DIFF CASE 11.6-309 921-247 | position Nm (1.18-3.15) (0.94-2.52) (kot) * To prevent the hindrance of DRIVE PINION (74) assembly due to the absence of backlash, move the DIFF CASE ASSY toward the back of the ORIVE GEAR, bofore adjusting the preload. Section 12 Page 36Rock Torque Axle 457 Series 12.5 Measuring Back Deflection of DRIVE GEAR 1) Place a dial gauge against the back of DRIVE GEAR (74), then measure deflection when the DIFF CASE ASSY is rotated one revolution. * ithe measured deflection is greater than the standard value shown below, BEARING (85) may be faulty or DRIVE GEAR (74) may be improperiy fitted. Disassemble again and check. [Measurement item ‘Standard Value [ Usage limit Back deflection of DRIVE GEAR 0.07 0.02 12.6 Fitting the DRIVE PINION ASSY 4) Fit SHIM (92) to the DRIVE PINION ASSY, mount the DRIVE PINION ASSY into. DIFF CARRIER (87), then temporarily fix it with BOLT (102) AND SPRING WASHER (68). * The adjusting SHIM must be fitted in with its thickness retained as disassembled. Section 12 © 1993, Wagner Mining And Construction Equipment Co, Page 37 Rev. 0992{© 1993, Wagner Mining And Construction Equipm Rev. 09.93 2) 3) Rock Torque Axle 457 Series Place a dial gauge against the DRIVE GEAR, then measure backlash in the DRIVE PINION and DRIVE GEAR. It the measured backlash deviates from the standard value, adjust it with agjustable nut (66). “it the backlash is insufficient, oosen the nuts on the back of the gear and fasten in on the toothed side by turning the nuts at the same angle. IW excessive, reverse the above. Because the SIDE BEARINGS preload has already been adjusted at this time, be sure to turn the left and right ruts at the same angle Measurement item Backlash in DRIVE PINION and DRIVE GEAR Co, Seetlon 12 Page 38Rock Torque Axle 457 Series 12.7 Checking and Adjusting DRIVE GEAR Tooth Contact 1) 2) 3) 4) ‘Check DRIVE GEAR tooth contact and if the engagement position is inappropriate, increase or decrease the shim quantity for the DRIVE PINION 'ASSY or adjust the relative distance of the DRIVE GEAR to the DRIVE PINION, Wipe the tooth surface clean and apply a thin coating of red lead primer to the seven to eight teeth of the DRIVE GEAR. While pressing the DRIVE GEAR with your hand to apply brakes, turn the FLANGE of the DRIVE PINION in the jongitudinal direction, Check tooth contact conditions on the tooth surface and adjust the tooth contact, as necessary. Tooth Contact and Backlash Adjustments. Tooth contact condition Cause Method of A: Contact adjustment agjusiment |B: Backlash adjustment _ Correct tooth contact (Correct tooth contact + Langth of tooth contact: approx. 150% of tooth width + Width of tooth contact: approx. 50% of tooth height + Center of tooth contact: 40% positon from edge | Ki il the GEAR. i ‘A: Decrease SHIM (92) of the PINION, | B: Turn NUT (86) at the back of the GEAR to move in the direction of the arrow. Move the nut on the opposite side for that amount The PINION is too far from + a The PINION is ‘A: Inctease SHIM (92) of the PINION. 100 close to + the GEAR, to move in the direction of the arrow. a B: Turn NUT (86) al the back of the GEAR. Move the nut on the opposite side for that amount a l ve Section 12 Page 39 too close o i the PINION, We 100 far from 4 ‘to move in the direction of the arrow. bY the PINION | Move the ton the opposite side for ail! | _ that amount. all | to move in the direction of the arrow. Move the nut on the opposite side for that amount | 8: Decrease SHI ‘The GEAR is | {k: Turn NUT (86) atthe back of the GEAR | * c (92) of the PINION. ‘The GEAR is AA: Turn NUT (88) af the back of the GEAR, B: Increase SHIM (92) of the PINION, And Const tion Equipment Co ev 09.93Rock Torque Axle 5) When backlash and tooth contact have been determined, fasten the DRIVE PINION ASSY to the DIFF CARRIER with the designated torque using BOLT (102). (FASTENING TORQUE: 132-162 N-m) 6) Insert LOCK PLATE (88) into BOLT (89), fasten BEARING CAP (87) with the designated torque, then bend the tab of the LOCK PLATE. (FASTENING TORQUE: 459-561N-m) 7) Hook the tab of LOCK PLATE(84) onto the ADJUSTABLE NUT, fit LOCK WASHER (83) to BOLT (82), then fasten it with the designated torque. Then, bend LOCK WASHER (83) toward the bolt to lock. (Fastening torque: 30.9-37.7 N-m) © 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 0993) Page 40Rock Torque Axl 457 Series 12.8 Fitting the DIFF CARRIER ASSY 1) Clean the matching faces of HOUSING (1) and DIFF CARRIER ASSYS (71) and (108), then apply an even coating of liquid packing, 2) Apply a coating of Locktite #242 or equivalent to STUD BOLT (117) and screw it in (two locations as market by asterisk). +“ Atthis time, be careful not to take the nut side of the STUD BOLT for the stud side or vice versa 117 68118 Wy Nut side 17 68118 Ww 3) Fasten the DIFF CARRIER ASSY to the HOUSING with the designated torque using BOLTS (68) and (67) and NUT (118). *Apply a coating of Locktite #242 or equivalent to the threaded part of NUT (118). (Fastening torque: 229-280 N-m) 4) After attaching the DIFF CASE ASSY, fill he dowel holes and bolt tap holes with liquid packing, 12.9 Assembling the RING GEAR ASSY 1) Press-fi the inner race of BEARING (42) into RING GEAR HOLDER (44). 2) After RING GEAR HOLDER (44) is engaged with RING GEAR (53), fit RETAINING RING (43). 53 Seetlon 12 © 1983, Wagner Mining And Construction Equipment Cu Page 41 ev. 09.93Rock Torque Axle 457 Series 12.10 Assembling the PLANETARY CARRIER ASSY 1) Fit PLANET WASHER (59) to PLANETARY CARRIER (56) with its tongue fitted into the indentation in the PLANETARY CARRIER. 2). Fit PLANET BEARING (58) to PLANET GEAR (57), then slide it into the PLANETARY CARRIER unti fitted into the hole of SHAFT (60) so 57 59) 3)_ Fit O-RING (61) to SHAFT (60), then press it into the PLANETARY CARRIER with the smaller diameter side first. Al this time, make sure that the locking screw hole in the shaft is matched to the screw hole in the PLANETARY CARRIER. 4) Fasten SCREW (62) into the PLANETARY CARRIER SET & SHAFT, then caulk the screw holes al two locations in the PLANETARY CARRIER, © 1993, Wagner Mining And Construction Equipment Co. Section 12 Page 42Rock Torque Axle 457 Series 12.11 Assembling the SAHR BRAKE ASSY (1) Install expander ring and outer piston seal in the piston, Do not overstretch ‘or cut the rings. (2) Install expander ring and inner piston seal in the brake housing, (3) Insert the piston into the brake hous- ing. Use a press of C-clamps to install the piston evenly and to prevent seal damage. The piston must enter the housing evenly. Seetion 12 © 1993, Wagner Mining And Construction Equipment Co. Page 43 ev. 09.93Rock Torque Axle 457 Series (4) Clean all holes in the backing plate. (6) Insert O-ring onto backing plate. (6) Insert springs into the backing plate. There are two sizes of springs. Install so that the tops are even (7) Lower housing and piston assembly onto backing plate. Be sure to index the housing to the backing plate so the ports and dowel holes all ine up. © 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 09,93, Page 44Rock Torque Axle 457 Series (8) Insert and partial tighten three or four bolts through the backing plate into the housing. Evenly space these bolts to distribute the load as the brake unit is being turned over. (9) Tum the assembly over, (10) Install O-rings into the port grooves. (11) Install all mounting bolts with Loctite 262. CRITICAL! Siowly tighten the backing plate onto the housing by tum- ing each bolt 1/2 to 1 turnin a criss- crossing pattern. Do not use an Impact wrench. Just before the backing plate contacts the housing, install roll pin(s) thru backing plate into mating holes in the housing, Continue tightening until the backing plate is snug against the brake housing. (12) Torque the bolts to 300-330 tt./ibs. © 1993, Wagner Mining And Construction Equipment Co. Rev. 0993Rock Torque Axle 457 Series (13) Finish instaling rol pins, then flip the assembly over. (14) Install stationary and friction disks from the brake housing. CAUTION! Be certain that a stationary disk Is placed against the piston first. A friction disk against the piston will dam- age the piston. (15) Insert quad sealing ring into the housing © 1993, Wagner Mining And Construction Equipment Co, Section 12 Rev, 0893 Page 46Rock Torque Axle 457 Series (16) NOTE: To property secure the front plate to the housing, elther pressurize the brake to release it and simply install all bolts, or tighten bolts in a criss-cross pattern 1/2 to 1 turn ata time. Sot the front plate back on the housing, and insert ‘and tighten the bolts. Torque the bolls to 300-330 {bs Section 12 © 1993, Wagner Mining And Construction Equipment Co, Page 47 Rev. 09.93,Rock Torque Ax! 457 Series 12.12 Assembling the HOUSING ASSY 1) Lift SPINDLE (8) by using a hoist or other appropriate jg, align its hole with DOWEL PIN (6), and fit to HOUSING (1). 2). Fit O-RINGs (9) into the SAHR BRAKE ASSY and fit it to the SPINDLE & HOUSING. * Be careful not to damage the O-rings when assembling, 3) Apply a coating of Locktite #242 or equivalent to BOLT (22) and fasten it to the ‘SPINDLE & HOUSING & BRAKE with the designated torque. (Fastening torque: 652.7-797.7N-m) SAHA BRAKE ASSY 4) Fit FLOATING SEAL (35) to the edge of PLATE (33). @ 1993, Wagner Mining And Construction Equlpment Co. Section 12 Rev. 0993, Page 48Rock Torque Axle 457 Series 12.13 Assembling the WHEEL HUB ASSY 41) Press-t the outer races of BEARINGS (39) and (42) onboth sides of WHEEL | HUB (40). | 2). Fitthe inner race of BEARING (39) to the WHEEL HUB. | 3) Press-fit OIL SEAL (28) to the WHEEL HUB. + Pay attention to the assembly directions of the inner and outer seals 4) Sorew BOLT (41) into the WHEEL HUB. — re r —— | eae 1993, Wagner Mining And Construction Equipment Co, Page 49 eV.09.93(© 1993, Wagner Mining And Construction Equipment Co. Rock Torque Axle 457 Series 12.14 Fitting the WHEEL HUB ASSY 1) Fil FLOATING SEAL (35) to the edge of WHEEL HUB. 2) Lift the WHEEL HUB ASSY by using a hoist or other appropriate jig. After applying a coating of grease to the lip surface of OIL SEAL (38), align the SAHA BRAKE FRICTION PLATE with the WHEEL HUB spiine and fit them to the SPINDLE. * Be careful not to damage the oil seals when assembiing, 3) Align the spine of RING GEAR, HOLDER (44) with SPINDLE (8), then fit the RING GEAR ASSY to the SPINDLE. 4) Fit COLLAR (47) to the inside of RING GEAR HOLDER (44), Section 12 Page $0Rock Torque Axle 457 Series 12.15 Adjusting WHEEL HUB BEARING Preload { 1) Connect the chassis-side brake hose to the SAHR BRAKE inlet. 2) Loosen BREATHER, BRAKE (16) to purge ait. "Do this until air is completely drained. 3) Fasten in the BREATHER and apply hydraulic pressure trom the inlet to release the ‘SAHR BRAKES. 4) Fit the inner side NUT, SPRING (48) to SPINDLE (8), then tighten it so that the BEARING HUB touches the shoulder of the SPINDLE. 5) Tum SPINDLE NUT (48) back by about one revolution to remove the preload applied to the BEARING, 6) Tighten the SPINDLE NUT (48) with a fastening torque of 735 N-m, then rotate the WHEEL HUB two or three tums to stabilize the HUB BEARING. 7) Loosen SPINDLE NUT (48) about 30° to 45°, then repeat steps 6/ and 7/ twice. 8) Tighten the SPINDLE NUT with a fastening torque of 735 N-m. Section 12 ©1993, Wagner Mining And Construction Equipment Co, Page st ev. 0993Rock Torque Axle 457 Series | 9) Attach a spring balance to HUB BOLT (41), pullit in the tangential direction, and | check to see that he preload is within the value shown below [When using new ‘When reusing old bearing bearing Preload | | Nem 725-970 58-776 | (kgt-m) (74-919) (69-79) Tangential force | at bolt position 294-992 235.2-313.6 | Nm (30.0 - 40.0) (24-32) (kof) 40) Align theM 12 x 1.25 tap holes of RING GEAR HOLDER (44) with the holes of PLATE (45), apply a coating of Locktte #242 or equivalent to BOLT (46), then tighten it with the designated torque. “It the holes do not match, turn the nut in the fastening direction until matched. © 1993, Wagner Mining And Construction Equipment Co. Section 12 Rev. 0993) Page 52Rock Torque Axle 457 Series Sectlon 12 Page $3 12.16 Assembling the PLANETARY CARRIER ASSY 4) Insert AXLE SHAFT (7) and (115) from the edge of the SPINDLE until it engages with the spline of the DIFF SIDE GEAR. 2) Fit DRIVE GEAR WASHER (49) to the edge of the SPINDLE, engage DRIVE GEAR (50) with the spline of the AXLE SHAFT, and fix with RETAINING RING (51). 3) Fit 0-RING (54) into the groove in the PLANETARY CARRIER ASSY. “Apply a coating of grease to the O-RING. 4) Fit the PLANETARY CARRIER ASSY to WHEEL HUB (40) after fitting the notch, then fasten BOLT (63) with the designated torque. (Fastening torque: 54.7-66.9 N-m) 5) Apply a coating of Three Bond #1215 or equivalent to the matching face of COVER (64), ft the COVER to the PLANETARY CARRIER, and fasten BOLT (65) with the designated torque. (Fastening torque: §7.3-70.1 N-m) * Make sure the plug hole recess in the COVER is aligned with the PLANETARY CARRIER plug hole. ©1983, Wagner Mining And Construction Equipment Co ev.09.93Rock Torque Axle 457 Series 12.17 BRAKE COMPONENTS Roll Pin 1 2 Capscrew 3. Oring 4. Spacer Ring 5 Plug & Spring 7, Spring 8. Inner Seal Assy 9, Outer Seal Assy 10. Oring 11. Washer 12. Backing Plato 13, Piston 14, Housing—Brako 15. Blood Vane 16 Capscrew 17. Kit-Brake 18. Friction Dise 20. Reaction Dise RAIN POAT 21. Quad Sealing Ring SAENG 22, Washer y 23. Cover Plate SECTION A-A By itn ALEED PORT ‘oouNGouTPORT SAER IO RAKE RELEASE PORT SAERG RAKE RELEASE PORT oD NOTE 3: Lubricate threads of spin: dle hardware with loctte 262 & COOLNGNFORT Torque to 600 ft.-bs. SAE*8 Section 13, € 1993, Wagner Mining And Construction Equipment Co Page 54 Rev. 079:Rock Torque Axle 13. LUBRICATION 1) Remove PLUG (3) from the HOUSING, then supply oil until it oozes out from the plug hole, Oil type : SAEW90, API class GLS Oil quantity: 28 liters 2) Turn the WHEEL HUB until the "WIM" logomark on the COVER is horizontal. Remove MAGNET PLUG (2) from the PLANETARY CARRIER, then supply oil Lnti it 00zes out from the plug hole. il type: SAE#90, API class GLS (same type as used for the DIFF) il quantity: 5 ters (on one side) 3) Wind each plug with sealing tape and fasten with the designated torque. (Fastening torque: 50.3-61.5 N-m) Saeena, (© 1993, Wagner Mining And Construction Equipment Co. Page 55 2 a Rev.07.92