DRIVE TRAIN MODEL RR640

DBM 2000 EV, DBM 2500 EV

and DBM 3500 EV

DBM-GMEC.01 VALID FROM SAV B041511

 INDEX

INTRODUCTION ......................................................................................................................... 1
NECESSARY TOOLS AND REPAIR TIMES............................................................................... 2
REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL ........................................................................................................................... 3
2 SPEED GEARBOX ................................................................................................................... 4
HUB REDUCTION GEAR............................................................................................................ 5
PARKING BRAKE ....................................................................................................................... 6
SERVICE BRAKES ..................................................................................................................... 7
STEERING TIE RODS REPLACEMENT..................................................................................... 8
FRONT AND REAR AXLE REMOVAL........................................................................................ 9
DIFFERENTIALS....................................................................................................................... 10
HUB ALIGNMENT ..................................................................................................................... 11
 1 - INTRODUCTION

INDEX

SAFETY AND GENERAL INSTRUCTIONS...................................................................... 2

CONVERSION FACTORS ........................................................................................ 3

METRIC HARDWARE TORQUE SPECIFICATIONS ............................................................ 4

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS.............................................. 5

1-1
 1 - INTRODUCTION

This manual provides the information necessary for a correct and safe way to carry out maintenance works
not included in the "INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE"; it is addressed to
qualified fitters, who know enough about mechanical components and the functioning of hydraulic and
electrical systems for the machine on which it is operating. The action necessary to implement and
enforce the policies related to the Environment and Health and Safety procedures are left to the
responsability of the workshop manager.

SAFETY AND GENERAL INSTRUCTIONS

CAUTION !!!
This machine is designed and manufactured according to Merlo S.p.A. specifications. To avoid accidents
and to ensure optimum performance, the machine must not be modified or altered unless approved by
Merlo, nor should it be used in conditions or for purposes which it is not designed for. All information,
illustrations and specifications in this manual are based on the latest product information available at
the time of publication. The right is reserved to make changes at any time without notice.

CAUTION !!!
Always ensure any work carried out on the vehicle is carried out on level ground. If this is not possible
the ground should be as level as possible and the vehicle should be chocked to prevent any possibility of
the vehicle rolling.

CAUTION !!!
Servicing of the machine shall only be carried out by skilled and competent personnel. For repair of parts
that are not part of the normal scheduling, refer MERLO S.p.A. technical service.

CAUTION !!!
Always wear suitable protective clothing and safety equipment when using lubricants (gloves, masks,
goggles, overalls, etc.). Extra care should be taken to avoid burns when working with hot fluids or
elements.

CAUTION !!!
Always dispose of oils, filters or other mediums in an environmentally friendly manner. Use official
organisations for the disposal of such fluids.

1-2
 1 - INTRODUCTION

CONVERSION FACTORS

Units of Pressure Atm bar Pa Psi Nmm²

1 Atm 1 1 105 14,4 0,1
1 bar 1 1 10 5
14,4 0,1
1 Pa 0,00001 0,00001 1 0,000144 0,000001
1 Psi 0,069444 0,069444 6944,4 1 14,4
6
1 Nmm² 10 10 10 144 1

Units of Weight N daN kN Kg lbs

1N 1 0,1 0,001 0,102 0,225
1 daN 10 1 0,01 1,02 2,25
1 kN 1000 100 1 102 225
1 Kg 9,81 0,981 0,00981 1 2,205
1 lbs 4,448 0,448 0,00448 0,4536 1

Units of Torque Nm daNm kNm kgm lb-in

1 Nm 1 0,1 0,001 0,102 8,854
1 daNm 10 1 0,01 1,02 88,54
1 kNm 1000 100 1 102 8854
1 kgm 9,81 0,981 0,00981 1 86,8
1 lb-in 0,1129 0,01129 0,0001129 0,01152 1

Units of Length m cm yds inch ft

1m 1 100 1,094 39,37 3,280
1 cm 0,01 1 0,01094 0,3937 0,03280
1 yd 0,9144 91,44 1 36 3
1 inch 0,0254 2,54 0,0277 1 0,0833
1 ft 0,3048 30,48 0,333 12 1

Units of Power CV Hp Kw Watts

1 Cv 1 0,9863 0,7355 735,5
1 Hp 1,0139 1 0,7457 745,7
1 Kw 1,359 1,341 1 1000
1 Watt 0,00136 0,00134 0,001 1

Ohm's Law
I = Current intensity I=V/R
V = Electromotive force R=V/I
R = Resistance V=I*R

1-3
 1 - INTRODUCTION

METRIC HARDWARE TORQUE SPECIFICATIONS

Tightening torque Ma of a given bolt or nut is the necessary torque to put the bolt under a given preloading.
Tightening torque valve should be used to adjust dynemometric wrenches to avoid fatigue failures.
The following table contains tightening torque specifications relative to external diameter of metric thread.
Figure are approximate.

Unit = Nm

TYPE OF BOLT

SIZE OF BOLT 8.8 10.9 12.9

Standards - Standards - Standards - Standards - Standards - Standards -
Loctite 242 Loctite 270 Loctite 242 Loctite 270 Loctite 242 Loctite 270
M6 x 1 9,5 – 10,5 10,5 – 11,5 14,3 – 15,7 15,2 – 16,8 16,2 – 17,8 18,1 – 20,0
M8 x 1,25 23,8 – 26,2 25,6 – 28,4 34,2 – 37,8 36,7 – 40,5 39,0 – 43,0 43,7 – 48,3
M10 x 1,5 48 – 53 52 – 58 68 – 75 73 – 81 80 – 88 88 – 97
M12 x 1,75 82 – 91 90 – 100 116 – 128 126 – 139 139 – 153 152 – 168
M14 x 2 129 – 143 143 – 158 182 – 202 200 – 221 221 - 244 238 – 263

COARSE M16 x 2 200 – 221 219 – 242 283 – 312 309 – 341 337 – 373 371 – 410
PITCH M18 x 2,5 276 – 305 299 – 331 390 – 431 428 – 473 466 – 515 509 – 562
M20 x 2,5 390 – 431 428 – 473 553 – 611 603 – 667 660 – 730 722 – 798
M22 x 2,5 523 – 578 575 – 635 746 – 824 817 – 903 893 – 987 974 – 1076
M24 x 3 675 – 746 732 – 809 950 – 1050 1040 – 1150 1140 – 1260 1240 – 1370
M27 x 3 998 – 1103 1088 – 1202 1411 – 1559 1539 – 1701 1710 – 1890 1838 – 2032
M30 x 3,5 1378 – 1523 1473 – 1628 1914 – 2115 2085 – 2305 2280 – 2520 2494 – 2757

M8 x 1 25,7 – 28,3 27,5 – 30,5 36,2 – 39,8 40,0 – 44,0 42,8 – 47,2 47,5 – 52,5
M10 x 1,25 49,4 – 54,6 55,2 – 61,0 71,5 – 78,5 78,0 – 86,0 86,0 – 94,0 93,0 – 103,0
M12 x 1,25 90 – 100 98 – 109 128 – 142 139 – 154 152 – 168 166 – 184
M12 x 1,5 86 – 95 94 – 104 120 – 132 133 – 147 143 – 158 159 – 175
M14 x 1,5 143 – 158 157 – 173 200 – 222 219 – 242 238 – 263 261 – 289

FINE M16 x 1,5 214 – 236 233 – 257 302 – 334 333 – 368 361 – 399 394 – 436
PITCH M18 x 1,5 312 – 345 342 – 378 442 – 489 485 – 536 527 – 583 580 – 641
M20 x 1,5 437 – 483 475 – 525 613 – 677 674 – 745 736 – 814 808 – 893
M22 x 1,5 581 – 642 637 – 704 822 – 908 903 – 998 998 – 1103 1078 – 1191
M24 x 2 741 – 819 808 – 893 1045 – 1155 1140 – 1260 1235 – 1365 1363 – 1507
M27 x 2 1083 – 1197 1178 – 1302 1520 – 1680 1672 – 1848 1834 – 2027 2000 – 2210
M30 x 2 1511 - 1670 1648 - 1822 2138 – 2363 2332 - 2577 2565 - 2835 2788 - 3082

1-4
 1 - INTRODUCTION

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS

Locking, sealing and lubricating materials referred to in this manual are the same used in the shop floor.
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 trademarks.

DENOMINATION APPLICATION
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for
Loctite 242 medium-strength locking. Before using it, completely remove any lubricant by using the
specific activator.
The oleo compatible alternative to “242”. Does not require the activation of lubricated
Loctite 243
surfaces.
Anaerobic product for very-high strength locking of screw and nuts. Before using it,
Loctite 270 completely remove any lubricant by using the specific 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,
Loctite 275 bolts and stud bolts, for pipe sealing and for protecting parts against tampering; suitable
for sealing coupling surfaces with a maximum diametrical clearance of 0,25 mm.
Anaerobic product for the hermetic sealing of flanged units and screw holes
Loctite 510
communicating with fluids. Can seal clearances between flanges up to 0,2 mm.
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to
M80. Before using it, completely remove any lubricant by using the specific activator. After
Loctite 577
polymerisation, disassembly may result rather difficult, so heating may be necessary for
larger diameters.
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints. Can glue
Loctite 638
together parts with clearance ranging between 0,1 e 0,25 mm.
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints. Can
Loctite 648
glue together parts with radial clearance below 0,1 mm.
Lithium-based Applied to bearing, sliding parts and used to lubricate seals or parts during assembly.
grease
Highly adhesive synthetic grease, with silicone compounds added. Applied to adjustment
Silicone-based
screws with hole communicating with oil-type fluids. Used when frequent adjusting is
grease
required.

1-5
 2 - NECESSARY TOOLS AND REPAIR TIMES

INDEX

STANDARD TOOLS.............................................................................................. 2

SPECIAL TOOLS ................................................................................................. 3

REPAIR TIME .................................................................................................... 4

2-1
 2 - NECESSARY TOOLS AND REPAIR TIMES

STANDARD TOOLS

Spanner Hexagon head driver

10 – 13 – 15
17 - 19 – 22 4-6
27 – 36 – 41

Click lever Sliding lever

Bush external exagone Bush inner exagone

6 10 - 17 - 19

Torque wrench Extension

L = 100 mm
L = 200 mm

2-2
 2 - NECESSARY TOOLS AND REPAIR TIMES

SPECIAL TOOLS

Disassembly of self-locking ring nut F40x1,5 K8 on

Adjusting ring nut of differential exit
differential

022723 025100

Adjusting ring nut differential entry Adjusting ring nut on wheel pinion and differential

022722 026474

Tool to fit the oil splash guard gaskets on the wheel Tools for the reassembly of the block on the oil
reducer pinion splash guard of the wheel reducer

026472 042459

Wrenches for self locking ring nuts Puller

025105

601070
601914
601071

2-3
 2 - NECESSARY TOOLS AND REPAIR TIMES

REPAIR TIME

OPERATION DESCRIPTION ENVISAGED TIME REQUIRED

REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND DIFFERENTIAL

Removal 40 minutes

Re-assembly 50 minutes

GEARBOX REMOVAL

Removal 50 minutes

Re-assembly 1 hour

CONTROL PISTONS - REPLACEMENT

Removal 15 minutes

Re-assembly 20 minutes

FRONT AND REAR OIL SEAL REPLACEMENT

Removal 50 minutes

Re-assembly 1 hour

OVERHAULING THE GEARBOX

Removal 20 minutes

Re-assembly 30 minutes

HUB REDUCTION GEAR (OIL SEAL REPLACEMEN)

Removal 12 minutes

Re-assembly 18 minutes

REMOVAL AND RE-ASSEMBLY OF THE REDUCTION GEAR FROM THE AXLE

Removal 25 minutes

Re-assembly 35 minutes

PROPSHAFT REMOVAL AND RE-ASSEMBLY FROM THE REDUCTION GEAR

Removal 35 minutes

Re-assembly 40 minutes

PARKING BRAKE PAD REPLACEMENT

Removal 15 minutes

Re-assembly 15 minutes

PARKING BRAKE CALIPER DISMANTLING AND RE-ASSEMBLY

Removal 15 minutes

Re-assembly 20 minutes

2-4
 2 - NECESSARY TOOLS AND REPAIR TIMES

OPERATION DESCRIPTION ENVISAGED TIME REQUIRED

HAND BRAKE DISC REPLACEMENT

Removal 25 minutes

Re-assembly 35 minutes

BRAKE PAD REPLACEMENT

Removal 50 minutes

Re-assembly 1 hour

FRONT AXLE REMOVAL (cab side)

Removal 35 minutes

Re-assembly 40 minutes

REAR AXLE REMOVAL (drum side)

Removal 30 minutes

Re-assembly 35 minutes

FRONT BRAKE DISC REPLACEMENT (cab side)

Removal 1 hour and 10 minutes

Re-assembly 1 hour and 20 minutes

REAR BRAKE DISC REPLACEMENT (drum side)

Removal 1 hour

Re-assembly 1 hour and 10 minutes

FRONT DIFFERENTIAL GEAR REMOVAL (cab side)

Removal 1 hour

Re-assembly 1 hour and 5 minutes

REAR DIFFERENTIAL GEAR REMOVAL (drum side)

Removal 50 minutes

Re-assembly 1 hour

OVERHAUL OF THE DIFFERENTIAL INTERNAL PARTS

Removal 45 minutes

Re-assembly 45 minutes

STEERING TIE RODS REPLACEMENT

Removal 30 minutes

Re-assembly 35 minutes

2-5
 3 - REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL

INDEX

FRONT PROPSHAFT REMOVAL................................................................................ 2

REAR PROPSHAFT REMOVAL.................................................................................. 3

REASSEMBLY OF PROPSHAFTS................................................................................ 5

3-1
 3 - REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL

FRONT PROPSHAFT REMOVAL

NOTE !!! In order to unscrew the

propshafts screws use an allen key shortened to
30 mm as shown at "X" in the drawing.

1) Before separating the two parts (male and

female) and fully extracting the propshaft from
the machine, mark the two components so as
to ensure they are replaced in the correct
location.

2) Unscrew and remove the 6 bolts that hold the propshaft to the gear box flange; extract the propshaft from
its seat.

3-2
 3 - REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL

3) Extract the propshaft from its seat; unscrew and remove the six bolts which fix the propshaft to the front
axle.

REAR PROPSHAFT REMOVAL

1) Before separating the two parts (male and

female) and fully extracting the propshaft from
the machine, mark the two components so as to
ensure they are replaced in the correct
location.

2) Start the engine and release hand brake. Hold

the brake caliper chamber (E); fully loosen the
adjusting screw (F). Switch off the engine.

3-3
 3 - REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL

3) Unscrew and remove the 6 bolts that hold the propshaft to the gear box flange; extract the propshaft from
its seat.

4) Extract the propshaft from its seat; unscrew and remove the six bolts which fix the propshaft to the rear
axle.

3-4
 3 - REMOVING THE HIGH SPEED PROPSHAFT BETWEEN GEARBOX AND
DIFFERENTIAL

REASSEMBLY OF PROPSHAFTS

1) To avoid damaging the transmission make sure the propshaft splines are reassembled to the marks
previously made and the universal joint are in the correct position.
Flange bolts: 8.8 type - Tighten torque: 83,3Nm.

A - Correct positioning B - Front axle C - Gear box D - Rear axle

2) Reassemble the rear propshaft replacing and

tightening the six fixing bolts on the gear box
(tighten with a torque of 83,3Nm); insert the
hand brake disc in its original seat with the
chamfer towards the propshaft, then refit and
tighten the six fixing bolts on the rear axle side
(tighten with a torque of 83,3Nm).

3) Start the engine and release hand brake.

Holding the brake chamber still, tighten the
adjusting screw (see point 2 of the paragraph
"REAR PROPSHAFT REMOVING OPERATIONS");
check the system working.

3-5
 4 - 2 SPEED GEARBOX

INDEX

FIXED DISPLACEMENT HYDROSTATIC MOTOR.............................................................. 2

GEARBOX REMOVAL............................................................................................ 3

CONTROL PISTONS - REPLACEMENT ........................................................................ 5

FRONT AND REAR OIL SEAL REPLACEMENT ................................................................ 6

OVERHAULING THE GEARBOX ................................................................................ 8

GEARBOX INSTALLATION.....................................................................................11

4-1
 4 - 2 SPEED GEARBOX

FIXED DISPLACEMENT HYDROSTATIC MOTOR

1) HYDROSTATIC ENGINE 6) FLANGE PROPSHAFT ATTACHMENT

2) CONTROL PISTON 7) LOCKING FLANGE
3) CONTROL GEAR SHAFT 8) DOUBLE GEAR
4) CONTROL GEAR FORK 9) LOCKING FLANGE
5) SELFLOCKING RING NUT 10) GEARBOX SHAFT

4-2
 4 - 2 SPEED GEARBOX

GEARBOX REMOVAL

1) Disconnect all the connecting pipes from the hydrostatic motor.

2) Disconnect the gearbox propshafts.

4-3
 4 - 2 SPEED GEARBOX

3) Remove the connecting pipes from the pistons of the gearbox.

4) Using a screwdriver, unscrew the hose clamp of

the breather and remove.

5) Using suitable equipment, support the

gearbox/hydrostatic motor; remove the four
bolts securing the gearbox to the chassis.

4-4
 4 - 2 SPEED GEARBOX

5) Abbassare e rimuovere the gearbox/hydrostatic

motor.

CONTROL PISTONS - REPLACEMENT

1) Remove the connecting pipes from the pistons of the gearbox, see the section "GEARBOX REMOVAL".

2) Unscrew and extract the pistons; then replace

them.

3) The disassembly of the small pistons of the gearbox control is normally carried out; to substitute the "O"
ring (A) or to verify the correct mechanical movements (stroke 8,5 + 8,5 mm).
If the small piston is damaged or leaks from the inner seals, it is adviseable to replace the whole assembly;
do not tighten it in a clamp as you run the risk of deforming it.

4) Refill the gearbox with oil as described in section "GEARBOX INSTALLATION" of this chapter.

4-5
 4 - 2 SPEED GEARBOX

FRONT AND REAR OIL SEAL REPLACEMENT

1) Disconnect the gearbox propshafts, see the Chapter "REMOVING THE HIGH SPEED PROPSHAFT BETWEEN
GEARBOX AND DIFFERENTIAL".

2) By using the "C" spanner (special tool - 025105), unscrew the selflocking ring nut (A).

3) Extract the washer (B) and the O Ring (C).

4) Remove the flange (D) and the protection cap

(E).

4-6
 4 - 2 SPEED GEARBOX

5) Unscrew the four fixing screws (F) and remove

the flange.

6) Using a screwdriver, pull the oil seal out and

replace it.

7) Go on with the reassembly carrying out backwards all the operations described in the previous points.
3) Ensure oil seal is seated completely; re-fill with gearbox oil (see section "GEARBOX INSTALLATION" of this
chapter).

4-7
 4 - 2 SPEED GEARBOX

OVERHAULING THE GEARBOX

A) GEARBOX CONTROL PISTON H) SHAFT

B) SPIRAL PIN I) FLANGE
C) SELECTOR FORK L) FLANGE
D) SHAFT M) SEAL
E) FLANGE N) BEARING
F) RING NUT O) SHAFT
G) OIL-SEAL P) GEAR Z40

4-8
 4 - 2 SPEED GEARBOX

1) Remove the gearbox from the hydrostatic motor by removing the four securing bolts; remove the cover
from the gearbox by removing the eight bolts shown in the photograph. Remove the control pistons (A).

2) Using a suitable pin punch and hammer, remove the spiral pin from the selector fork (B); remove selector
fork from collar (C); remove the selector shaft (D).

3) Carry out point 2 to point 4, described in the section "FRONT ADN REAR OIL SEAL REPLACEMENT"; repeat
this operation on the other side of the gearbox.

4) Remove the flange (E) which contains the oil seal (G), unscrewing the four fixing screws (F).

4-9
 4 - 2 SPEED GEARBOX

5) By using a rubber hammer, extract the shaft (H) and replace the worn parts.

6) Remove the flange of the 2VM gear (I) unscrewing the four screws (L); replace the seal (M) and the bearing
(N).

7) Remove the gear by turning it over as in photos.

8) To reasemble the gearbox, carry out points 1 to 7 in reverse order.

Before reassembling the cover, apply some sealed paste like "LOCTITE 518" on the casing; reassemble the
hydrostatic motor on the gearbox, applying "LOCTITE 242 to fixing bolts.

4 - 10
 4 - 2 SPEED GEARBOX

GEARBOX INSTALLATION

1) Go on with the reassembly of the gearbox on the machine, carrying out backwards all the operations
described in the section "GEARBOX REMOVAL", bearing in mind the following:

- Do not assemble the upper drainage hose.

- Reassemble the propshafts on gearbox sides.

2) Carry out the oil topping up of the hydrostatic

motor from the hole for the attachment of the
upper connecting pipe of the case drain, by
using the oil type specificated in the chapter
"SAFETY AND GENERALS INSTRUCTIONS" of the
"INSTRUCTION HANDBOOK FOR OPERATING AND
MAINTENANCE".

3) On the hydrostatic motor, reassemble the upper connecting pipe of the case drain.

4) Remove the rubber support where the breather

pipe of the gear box engages, top up oil using
the oil type specificated in the chapter "SAFETY
AND GENERALS INSTRUCTIONS" of the
"INSTRUCTION HANDBOOK FOR OPERATING AND
MAINTENANCE".

5) Reassemble the rubber hose for the breather connecting pipe and tighten the clamp (see point n° 4 of the
paragraph "GEARBOX REMOVAL").

6) Carry out the system filling following the instructions in the chapter "EVERY 1600 HOURS"; section
"HYDROSTATIC TRANSMISSION OIL" of the "MANUALE DI ISTRUZIONI PER L'USO E LA MANUTENZIONE".

4 - 11
 5 - HUB REDUCTION GEAR

INDEX

OIL SEAL REPLACEMENT ...................................................................................... 4

REMOVAL OF THE REDUCTION GEAR FROM THE AXLE ..................................................10

PROPSHAFT REMOVAL FROM THE REDUCTION GEAR....................................................12

PROPSHAFT REASSEMBLY ON THE REDUCTION GEAR ...................................................13

REDUCTION GEAR REASSEMBLY ON THE AXLE............................................................14

5-1
 5 - HUB REDUCTION GEAR

1) Upper king pin bushing 6) Hub adjustment pin

2) Oil seal (special tool ref. 026472) 7) Hub
3) Pinion adjustment nut (special tool ref. 026474) 8) Flange
4) Pinion 9) O.Ring
5) Cap 10) Crown wheel

A = when assembling fill with grease type "CAZAR K2"

B = before mounting the oil seal, apply some mastic for gaskets type "LOCTITE 518" on the external ring.
C = when assembling put thread-locking type "LOCTITE 270"
D = when assembling fill with grease type "CAZAR K2" + oil type "GEAR OIL GX 80W/90" (~4 cl)

5-2
 5 - HUB REDUCTION GEAR

1) CAP 7) O.RING
2) DOWELS 8) FLANGE
3) HUB ADJUSTMENT PIN 9) OIL SEAL
4) O.RING 10) RING GEAR
5) BEARING 11) BEARING
6) BLOCK 12) WASHER

5-3
 5 - HUB REDUCTION GEAR

OIL SEAL REPLACEMENT

1) Jack up machine in a safe manner (see chapter 7 of the "INSTRUCTION HANDBOOK FOR OPERATING AND
MAINTENANCE", Section "HOISTING OF THE MACHINE").

2) Remove the wheel.

3) Drain the oil by removing the drain plug placed

in the lower part of the reduction gear.

4) Remove the three bolts and fixing washers of

the hub cap.

5-4
 5 - HUB REDUCTION GEAR

5) Unscrew the four grub screws that lock the hub adjuster (heat at 150° if necessary).

WARNING!!! There are two grub screws in each hole (A):

- the first is flat bottom(B).
- the second is tipped (C).

6) Remove the hexagonal bolt that attaches the protection cap.

7) Remove the remaining six fixing bolts of the

block.

5-5
 5 - HUB REDUCTION GEAR

8) By using two levers, extract the block (D); insert a screwdriver in oil drain hole, lever and extract the
flange (E).

9) Replace the O Ring (F); and the oil seal (G).

10) Grease the external surface of the new oil seal and the relative flange seat.

11) Put the oil seal on the flange, like shown in the picture. To correctly insert it it’s necessary to lean on it
a flat object (like a brake disc or a metal sheet), then hit it with a big hammer directly on the oil seal
position, (the disc or the metal sheet are needed to avoid to damage the oil seal). Verify that the oil seal
is correctly inserted in its seat.

5-6
 5 - HUB REDUCTION GEAR

12) Use two of the block fixing bolts as a grip to

extract the ring gear from the lower side of
the casing of the reduction gear.

13) Using a puller (Part No.601914), remove the bearing and washer.

14) To avoid pinching the O.Ring, reassemble the flange in its seat, as follows:
- Put a smear of oil on the contact surfaces of the casing and the flange.
- Insert the flange in the upper part of the casing.
- Press the flange slightly against the upper part of the casing using a screw M 16 x 1,5 to fit in the hole
of the locking grub screw which coincides with the hole of oil draining.
- Ease the flange into position by mean of a rubber hammer on the lower and lateral side.

5-7
 5 - HUB REDUCTION GEAR

15) Refit the oil drain plug and tighten.

16) Put the block on the reduction gear then screw

by hand the three screws M16x80, (rif.H -
included in the special equipment Part No.
042459) in order to guarantee the alignment
between the flange holes and the crown ones.

WARNING!!! The block must be only leaned

and not inserted on the oil seal; absolutely avoid
to tighten the three screws.

Replace the bearing (I) on the block.

17) Oil the contact surface between the buffer and

the relative washer (included in the special
equipment Part No. 042459), and then screw
the buffer (L) until the block is almost
completely inserted in the oil seal.

WARNING!!! Operate with extreme caution

in order to avoid to completely tighten the
block.

18) Remove the special buffer, then replace the

original buffer of the reduction gear and
tighten it deeply; use a rubber hammer to help
the block and bearing bedding.
Remove the three special screws then replace
again and screw, using torque wrench (M), at
the tightening torque (225,5 Nm) the six
screws without washers (N).
Loosen the buffer until the block can freely
rotates, then screw, using torque wrench (M),
at the tightening torque (24,5 Nm) ensuring the
grub screw holes align with the grooves in the
casing.

5-8
 5 - HUB REDUCTION GEAR

19) Replace the four tipped grub screws previously removed, inserting first the two tipped grubs (O) and then
the two flat bottom (after having applied on them thread-locking type "LOCTITE 270").

20) Replace the O.Ring (P) on hub cap, and

reassemble onto the block with the three bolts
and washer (225,5 Nm).

21) Refill with oil type "GEAR OIL GX 80W/90" as follows:

- Remove the breather plug and washer (Q).
- Pour in 1,3 litres of oil.
- Check the oil level with dip stick (R). The distance from the oil level mark on the outside casing and
the filler/plug hole (S) must not be over 93mm.

22) Reassemble the wheel.

5-9
 5 - HUB REDUCTION GEAR

REMOVAL OF THE REDUCTION GEAR FROM THE AXLE

1) Carry out points 1, 2 and 3 of the section "OIL SEAL REPLACEMENT".

2) Remove the split pin (A) from the pivot on the pivot of the steering arm; then unscrew the nut.

3) Turn steering to full lock to obtain more operating space; tap with a rubber hammer the steering arm (B)
in the indicated point (C), remove pivot from steering arm.

4) Support the reduction gear with a sling and

suitable lifting support; then unscrew the four
fixing bolts attaching the reduction gear to the
steering joint.

5 - 10
 5 - HUB REDUCTION GEAR

5) Remove the reduction gear from its seat

together with the propshaft.

6) By using a screwdriver, lift and extract the joint (D); replace the bushing (E); and grease it with grease
type "ESSO CAZAR K2", then reassemble the joint.

5 - 11
 5 - HUB REDUCTION GEAR

1) BEARING 4) O.RING
2) RETAINING HALF RING 5) RING NUT
3) BEARING 6) OIL-SEAL

PROPSHAFT REMOVAL FROM THE REDUCTION GEAR

1) Carry out points 1 to 5 of the section "REMOVAL OF THE REDUCTION GEAR FROM THE AXLE".

2) Using special tool - hub spanner (Part No.026474) unscrew the register ring nut; then extract the propshaft
with the pinion from the casing.

5 - 12
 5 - HUB REDUCTION GEAR

3) Tap the bearing with a hammer and a drift towards the spider, so as to separate retaining half rings.

4) With a plastic hammer, extract the register ring nut;remove and replace the O.Ring.

5) Remove and replace oil seal from adjusting ring nut.

PROPSHAFT REASSEMBLY ON THE REDUCTION GEAR

1) To prevent damaging the oil seal, a special sleeve (Part No. 026472) is available to fit over the pinion, see
chapter "NECESSARY TOOLS AND REPAIR TIMES" section "SPECIAL TOOLS".

2) Reassembly is the reversal of the removal procedure taking note of the following points 2 and 3 of the
section "PROPSHAFT REMOVAL FROM THE REDUCTION GEAR".

5 - 13
 5 - HUB REDUCTION GEAR

REDUCTION GEAR REASSEMBLY ON THE AXLE

1) Insert the propshaft into the spline ensuring

the correct position of universal joint is
maintained.

2) The locking tooth (A), must locate between the two teeth (B) of the retaining ring.

3) Refit the reduction hub to the axle (see point 4 of the section "REMOVAL OF THE REDUCTION GEAR FROM
THE AXLE"), replace the longer bolts in the two inside holes and the two shorter bolts in the outside holes
313,8 Nm.

4) Remove the sling from around the casing. Refit the bolt in the steering arm (see point 2 of the paragraph
"REMOVAL OF THE REDUCTION GEAR FROM THE AXLE") tighten lock nut and fit new split pin.

5) Refill hub with oil (see point 21 of the section "OIL SEAL REPLACEMENT").

6) Refit wheels.

5 - 14
 6 - PARKING BRAKE

INDEX

BRAKE PAD REPLACEMENT.................................................................................... 2

CALIPER DISMANTLING ........................................................................................ 4

CALIPER ASSEMBLY ............................................................................................ 4

PARKING BRAKE CONTROL VALVE / PRESSURE SWITCH ................................................. 6

HAND BRAKE DISC REPLACEMENT ........................................................................... 7

6-1
 6 - PARKING BRAKE

BRAKE PAD REPLACEMENT

Check brake pad wear through the opening (A) in the caliper. Pads must be replaced when slot (B) on pads has
worn away.

1) Start the engine and release hand brake. Hold

the brake caliper chamber (C); completely
loosen the adjusting screw (D); switch off the
engine.

2) Remove the fixing screws (E); extract the

caliper support ring (F) and its O.Ring.

6-2
 6 - PARKING BRAKE

3) Lift the locking spring (G) over the lock pin with a screw driver; withdraw the spring/locking pin (H)
assembly.

4) Remove caliper, taking care not to damage

hydraulic hoses (I); install new pad and the
thrust ring.

5) Fit back the caliper and the spring/locking pin assembly.

6) Insert the caliper support ring and its O.Ring; then screw fixing screws in half way.

7) Start the engine and release hand brake; screw in the adjusting screw. Depress the brake pedal a few
times; stop the engine.

8) Tighten the fixing screws 24,5 Nm.

6-3
 6 - PARKING BRAKE

CALIPER DISMANTLING

WARNING !!!
The washers inside the caliper give a preload of about 1500 Kg.

- Start the engine and, release hand

brake.
- Hold the brake caliper chamber (F)
and completely loosen the
adjusting screw (G).
- Stop the engine and disconnect oil
supply hose.
- Remove the caliper (as described
for brake pads replacement from
point 2 to point 5). Remove the
thrust ring (E).
- Using a vice, press the caliper
inside assembly (H) to remove the
snap ring (I).
- Extract the inside of the caliper
and the piston (L).
- For dismantling the spring pack
tight completely the setting
screw, then release the fixing nut
(M), paying attention that this is assembled by "LOCTITE 243".

CALIPER ASSEMBLY

WARNING !!!
The washers inside the caliper give a preload of about 1500 Kg.

Greasing all the surfaces with grease

type "ESSO CAZAR K2" with a brush.

- Grease the bottom of the chamber

(F) and the piston (N); insert the
ring (O) in the piston with the
flaring facing the bottom.
- Degrease carefully the thread M12
of the setting screw (G); insert the
bonded washer (P), and completely
tighten the screw in the chamber.

6-4
 6 - PARKING BRAKE

- Assemble the first washer (Q) as

shown; then assemble the other 12
washers greasing each surface.
- Insert the piston inside the
springs, applying on the fixing nut
(M) thread-locking type "LOCTITE
243"; then tight it without holding
the setting screw. This way you
press totally the springs releasing
at the same time the setting
screw.

- Grease the inside of the chamber

and the piston thrust pin (R).
- Fit the o.rings and insert the
piston (L) and the caliper (H) in
the chamber.
- Using a vice, press the caliper
assembly (H) into the brake caliper
chamber (F) fit snap ring (I) in the
groove.
- Put the caliper on the machine
operating as described in the
brake pad dismantling chapter
(from point 6 to point 9).
- Connect the oil supply hose; start
the engine and, operating the
brake valve lever, release hand
brake.
- Hold the brake caliper chamber (F)
and completely tighten the
adjusting screw (G).
- Check that the system is working correctly.

6-5
 6 - PARKING BRAKE

PARKING BRAKE CONTROL VALVE / PRESSURE SWITCH

B = to parking brake caliper

P = delivery from hydrostatic pump - connected to speed selection control valve.
T = return to hydrostatic pump - connected to speed selection control valve.
The function of the valve (103) is to control the
opening and the closing of the parking brake
caliper:
- with engine running, move the lever (L) to pos.
1 to open the passage of oil between P and B to
open the brake caliper; bringing the lever (L) to
pos. 2 the oil flows down from port T and the
brake caliper closes.
- by stopping the engine, the brake caliper closes
independently of the control lever position.

The pressure switch (104) is normally closed and it

is calibrated at 18 bar. When you release the
parking brake, the pressure switch opens the
electrical circuit switching the signal light off on
the dashboard.

The emergency pump (E) must be used only to

release the parking brake before towing the
vehicle:
- move the lever (L) to position 1
- unscrew the valve tumbscrew (G) to the stop
position (F), then operate the emergency pump
(E) in order to open the brake caliper.
Before restarting the vehicle screw in the
tumbscrew (G) and check that the system is
operating correctly.

EMERGENCY PUMP FAILS

Should it not be possible to release the parking
brake using the emergency pump, act as follows:
- hold the brake caliper chamber (H)
- completely unscrew the adjusting bolt (I)
Before restarting the vehicle screw in the adjusting
bolt (I) and check the system correct working.

6-6
 6 - PARKING BRAKE

HAND BRAKE DISC REPLACEMENT

1) Remove the caliper (as described for brake pads replacement from point 1 to point 4).

2) Remove the propshaft by unscrewing the 6

fixing screw on the rear axle; extract and
replace the disc.

3) Reassemble the new disc in its original seat

with is face (A) towards the propshaft.

4) Reassemble the propshaft; reassemble the caliper of the hand brake, carrying out from points 5 to 8,
previously described in the section "BRAKE PAD REPLACEMENT" of this chapter.

6-7
 7 - SERVICE BRAKES

INDEX

BRAKE PAD REPLACEMENT.................................................................................... 2

HOW TO BLEED THE BRAKE SYSTEM ........................................................................ 3

CALIPER ASSEMBLY ............................................................................................ 4

7-1
 7 - SERVICE BRAKES

BRAKE PAD REPLACEMENT

Check brake pads wear through the opening in the caliper (A). Pads must be replaced when slot (B) is worn out.

1) Remove the connecting pipe for the brake oil

(C) and blank it off; remove the connecting
pipe (D) that connects the two calipers
together.

2) With a screw driver lift the locking spring (E) over the lock pin; extract the bolts, which fix the calipers,
from the grooves.

7-2
 7 - SERVICE BRAKES

3) Remove caliper; push the brake control piston in; remove the pads from their seats; install the new pads;
reassemble.

4) Before replacing the left caliper pads of the rear brake, it will be necessary to remove the caliper of the
parking brake as described in points 1 to 4 of the section "BRAKE PAD REPLACEMENT" of the chapter
"PARKING BRAKE".

HOW TO BLEED THE BRAKE SYSTEM

It is necessary to bleed the braking system

everytime the hydraulic parts of the caliper are
disassembled.

- Depress the brake pedal.

- Loosen the bleeder screw (A).
- Close the bleeder screw (A).
- Apply the brake pedal intermittently.
- Repeat from the first point until the liquid is
free from air bubbles.

7-3
 7 - SERVICE BRAKES

CALIPER ASSEMBLY

1) Lubricate inner seal (1) with brake fluid and push into
groove.

2) Push piston (2) into position.

3) Assemble the dust cover (3), lubricating the seat with

"PBR RUBBER GREASE".

7-4
 8 - SOSTITUZIONE TIRANTI DI STERZATURA

INDICE

TIRANTI POSTERIORI........................................................................................... 2

TIRANTI ANTERIORI ............................................................................................ 3

8-1
 8 - SOSTITUZIONE TIRANTI DI STERZATURA

TIRANTI POSTERIORI

1) Togliere la copiglia (A) di fermo del perno del tirante di sterzatura, quindi svitare il dado.

2) Sterzare le ruote a fine corsa da un lato; con alcuni colpi di martello sull'orecchia (B) nel punto indicato
(C); far fuoriuscire il perno della testina di sterzatura.

3) Dalla parte del tirante da sostituire, smontare la condotta sul martinetto di sterzatura; quindi tappare sia
la condotta che il raccordo sul martinetto.

8-2
 8 - SOSTITUZIONE TIRANTI DI STERZATURA

4) Accendere il motore e sterzare, in modo da tenere in pressione il martinetto di sterzatura; quindi svitare il
tirante e sostituirlo.

5) Rimontare il tutto procedendo nel modo seguente:

- Rimuovere i tappi e ricollocare la condotta.
- Sterzare le ruote in modo da far rientrare il braccio del martinetto di sterzatura.
- Applicare "LOCTITE 242" sulla filettatura presente sul tirante.
- Riavvitare il tirante sul braccio del martinetto.
- Serrare bene utilizzando due chiavi.
- Sterzare nuovamente le ruote per far fuoriuscire il braccio del martinetto.
- Reinserire il perno del tirante all'interno dell'orecchia della testina di sterzatura.
- Riavvitare il bullone sul perno e reinserire la copiglia.

TIRANTI ANTERIORI

Per la sostituzione sterzare da un lato a fine corsa quindi eseguire i punti descritti nel paragrafo precedente
"TIRANTI POSTERIORI", omettendo il passaggio descritto neI punto n°3.

8-3
 9 - FRONT AND REAR AXLE REMOVAL

INDEX

FRONT AXLE REMOVAL (cab side) ........................................................................... 2

REAR AXLE REMOVAL (drum side) ........................................................................... 5

AXLE REINSTALLATION ........................................................................................ 7

9-1
 9 - FRONT AND REAR AXLE REMOVAL

FRONT AXLE REMOVAL (cab side)

1) Use either a bridge crane or another suitable

lifting device to lift the machine in the front
until the wheels are slightly lifted from the
ground. For further information about the
lifting procedure, you are advised to consult
chapter "OPERATING INSTRUCTIONS" of the
"OPERATION AND MAINTENANCE HANDBOOK".

2) Remove the front wheels.

3) Lift the machine just about enough to place two iron stands, each about 1 m tall, under it. Lower the
machine and rest it on the stands.

9-2
 9 - FRONT AND REAR AXLE REMOVAL

4) Disconnect the two steering cylinder connecting pipes (A) and plug them, then disconnect the brake oil
pipe (B) and plug it.

5) Remove the steering cable.

9-3
 9 - FRONT AND REAR AXLE REMOVAL

6) Use a suitable device (e.g. a fork truck) to place a pallet with wood blocks under the front axle, so that it
can be supported once it has been removed from the machine.

7) Unscrew the 8 screws that secure the axle to the chassis.

WARNING !!! Before removing the axle, mark somehow the two parts of the Cardan joint (male and
female) in any point of the joint, so that the Cardan joint is not offset by 180° during reinstallation (see
Chapter 3).

8) Lower the pallet slowly, and check that the two parts of the Cardan joint split correctly; remove the axle.

9-4
 9 - FRONT AND REAR AXLE REMOVAL

REAR AXLE REMOVAL (drum side)

1) Apply wood chocks to the front wheels.

2) Tilt the loader downwards, lower the loader boom until the loader rests on the ground; keep lowering the
loader boom until the rear part of the machine is lifted.

3) Remove the rear wheels.

4) Lift the machine just about enough to place two iron stands, each about 1 m tall, under it. Lower the
machine and rest it on the stands.

9-5
 9 - FRONT AND REAR AXLE REMOVAL

5) Start the engine and release the parking brake.

6) Hold the brake caliper chamber (A); fully loosen

the adjusting screw (B). Switch off the engine.

7) Disconnect the two steering cylinder connecting pipes (C) and plug them, then disconnect the brake oil
pipe (D) and plug it.

8) Remove the hydraulic hoses (E) from the

parking brake caliper.

9) Use a suitable device (e.g. a fork truck) to place a pallet with wood blocks under the rear axle, so that it
can be supported once it has been removed from the machine.

9-6
 9 - FRONT AND REAR AXLE REMOVAL

10) Unscrew the 8 screws that secure the axle to the chassis.

WARNING !!! Before removing the axle, mark somehow the two parts of the Cardan joint (male and
female) in any point of the joint, so that the Cardan joint is not offset by 180° during reinstallation (see
Chapter 3).

11) Lower the pallet slowly, and check that the two parts of the Cardan joint split correctly; remove the axle.

AXLE REINSTALLATION

1) For axle reinstallation perform the operations described in paragraphs "FRONT AXLE REMOVAL" and "REAR
AXLE REMOVAL" in reverse order. Pay particular attention not to damage the whole transmission
irreparably while reinstalling the Cardan joint. Make sure that the Cardan joints are installed in such a way
that the forks are oriented along the same axis and that the previously drawn marks match with each
other. For further information see chapter "REMOVAL OF CARDAN QUICK COUPLINGS BETWEEN THE
GEARBOX AND THE DIFFERENTIALS".

NOTE: Tighten the bolts of the "long-life" tie-rods to a torque of 686 Nm.

2) Drain the brakes (see chapter "SERVICE BRAKES").

9-7
 10 - DIFFERENTIALS

INDEX

DIFFERENTIAL GEAR DISMANTLING.......................................................................... 3

OVERHAUL OF THE DIFFERENTIAL INTERNAL PARTS ..................................................... 6

REASSEMBLY OF THE DIFFERENTIAL INTERNAL PARTS ..................................................12

DIFFERENTIAL ADJUSTMENT ................................................................................14

10 - 1
 10 - DIFFERENTIALS

A) When assembling put sealing paste type "LOCTITE 572".

10 - 2
 10 - DIFFERENTIALS

DIFFERENTIAL GEAR DISMANTLING

- Remove the tie rods following the operations described from point 1 to point 2 of the section "REAR TIE
RODS REPLACEMENT" of the chapter "STEERING TIE RODS REPLACEMENT".

- Remove the axle (front or rear) from the machine, see Chapter 9 "FRONT AND REAR AXLES REMOVAL".

REAR AXLE

- Remove the parking brake caliper following the operations described from point 2 to point 3 of the section
"BRAKE PAD REPLACEMENT" of the chapter "PARKING BRAKE".

- Remove the parking brake disc following the operations described to point 2 of the section "HAND BRAKE
DISC REPLACEMENT" of the chapter "PARKING BRAKE".

- Remove the service brake caliper (see points 2 to 3 of the section "BRAKE PAD REPLACEMENT" of the
chapter "SERVICE BRAKES".

FRONT AXLE

- Remove the service brake caliper (see points 2 to 3 of the section "BRAKE PAD REPLACEMENT" of the
chapter "SERVICE BRAKES".

10 - 3
 10 - DIFFERENTIALS

1) Remove the steering cylinder.

2) Remove the 8 bolts that secure the two axle

casings fitted on the differential.

10 - 4
 10 - DIFFERENTIALS

3) Remove the brake disc.

10 - 5
 10 - DIFFERENTIALS

OVERHAUL OF THE DIFFERENTIAL INTERNAL PARTS

1) By using the “C” spanner (Part No. 601071) unscrew the self locking ring nut, then extract the flange (A)
and the O.Ring (B).

2) Repeat point 1 on the other side of the differential gear.

3) Remove the bolt (C) from the block plate of the ring nut adjuster (D); then by means of the special tool -
hub spanner (Part No. 026474) unscrew and remove the ring nut. Repeat this operation on the other side
of the differential gear and replace, if necessary, the oil seal and the O.Ring on both ring nuts.

4) Extract the differential gear, tilting it as visualized in the picture ME 09.06A; replace, if necessary, the
two bearings and the ring nuts.

10 - 6
 10 - DIFFERENTIALS

5) Using a screw driver, lift the locking strips from

the twelve fixing bolts of the ring gear on the
short casing.

6) Unscrew the twelve fixing bolts of the ring gear on the short casing; remember, during the reassembly the
two longer bolts (F) must be screwed corresponding with the location of the side pinion rotation shaft
mounting (E).

10 - 7
 10 - DIFFERENTIALS

7) Extract, from the long casing, the bolt (E) and the two planetary gears (G) along with washer; then extract
the crown-wheel and the bushing.

8) Remove the Circlip (H); the locking sliding ring nut (L) and the compression spring (l), see pictures.

9) On the differential gear pinion, remove the cotter pin; after this operation, by mean of a special wrench
tool - hub (Part No.022722), remove the ring nut (N) from the pinion with the O. Ring (M).

10 - 8
 10 - DIFFERENTIALS

10) Extract the flange (O) with the protection cap

from the shaft (P).

11) Using a plastic hammer, tap the pinion from the casing.

12) Using a screw driver extract the oil seal (Q); then extract the bearing and replace it together with the
O.ring.

10 - 9
 10 - DIFFERENTIALS

13) On the pinion, extract the deformable spacer (R) and the bearing (S).

14) On the cover, remove the fixing nut from the fork which controls the differential gear locking (see picture
ME 09.16A); using a plastic hammer, extract the fork control lever of the locking of the differential gear
and the fork itself (see picture ME 09.16B).

15) Replace the two O.Rings (T) placed on the

lever.

10 - 10
 10 - DIFFERENTIALS

1) Self locking ring nut

2) O.Ring
3) Differential gear output flange
4) Supporting bearing
5) Adjusting ring nut
6) O.Ring
7) Oil seal

1) Bearing
2) Circlip
3) Locking coupling
4) Spring
5) Inner long casing
6) Planetary gears rotation shaft
7) Bearing
8) Inner narrow casing
9) Crown-wheel and shaft
10) Planetary gear and washer
11) Crown-wheel and shaft
12) Ring gear

1) Split pin
2) Pinion ring nut
3) O.Ring
4) Flange
5) Shaft protection cap
6) Oil seal
7) Bearing
8) Spacer
9) Differential gear lock fork control lever
10) Differential gear fork
11) Bearing
12) Pinion
13) O.Ring

10 - 11
 10 - DIFFERENTIALS

REASSEMBLY OF THE DIFFERENTIAL INTERNAL PARTS

1) Reassemble in the reverse of dismantling following points 1 to 15 described in the section "OVERHAUL OF
THE DIFFERENTIAL INTERNAL PARTS", for the bolts torque setting, see picture at page 9-11 of this chapter.

2) On reassembly of the locking fork on the differential gear, ensure the threaded hole is facing the inner
part of the cover; apply to the fixing bolt some nut-lock "LOCTITE 242";and tighten. To avoid faulty
operation of the fork, make sure that the bolt head flat is parallel with differential cover.

A = when assembling use nut-lock "LOCTITE 242".

3) Reassemble the cover replacing the external O.Ring.

10 - 12
 10 - DIFFERENTIALS

1) Nut (special tool ref. 025100)

2) Differential output adjustment nut (special tool ref. 022723)
3) Parking brake calliper rear differential
4) Differential input adjustment nut (special tool ref. 022722)
5) Diff input pinion
6) Diff input flange
7) Service brake calliper
8) Stop plate
9) Diff output adjustment nut (special tool ref. 022723)
10) Crown
11) Prop shaft flange
12) Spacer

10 - 13
 10 - DIFFERENTIALS

DIFFERENTIAL ADJUSTMENT

PINION GEAR SLACK ADJUSTMENT:

The deformable spacer (12), is designed to allow optimal backlash; it is crushed during assembly by means of a
purpose built machine. In case of bearings replacement (only one bearing replacement it is not suggested) the
spacer (12) must be removed, then follow these instructions:

Adjustment:
- tighten nut (4) with a torque of 118Nm
- loosen the ring nut by 1 turn.
- tighten nut with a torque of 39Nm, alligning a
notch with a split pin hole.
- Lock nut with split pin.

PINION GEAR AND RING BEVEL GEAR SLACK

ADJUSTMENT (see ME 09.24B and ME 09.23)

- Tighten the ring nut (9) until crown (10) has no

free play with the pinion (5). Verify that the ring
nut (2) is screwed in but not forced.
- Loosen the ring nut (9) by 8 notches aligning a
notch with stop plate (8).
- Tighten to 44 Nm the opposite ring nut (2).
- Verify in different positions of the ring bevel
gear that the clearance between pinion gear and
ring bevel gear keeps within fixed limits. The
exact clearance is equivalent to a movement
between 0,12 - 0,16 mm measured on the Ø 120
mm diameter of the input flange with ring bevel
gear blocked (the crown can be locked
introducing a screwdriver from the oil fillling
hole). If there is too much clearance, screw in 1
notch the ring nut (9) and unscrew 1 notch the
ring nut (2). If there isn't enough clearance,
proceed the other way.
- Loosen the ring nut (2) by 1 turn. With new bearings: tighten the ring nut (2) (at 44 Nm) aligning a notch
with stop plate (8). With running bearings: tighten the ring nut (2) with no slack aligning a notch with stop
plate (8).
- Block the two ring nuts with stop plate (8) and its screw.

10 - 14
 11 - HUB ALIGNMENT

If abnormal tyre wear occurs check hub alignment. The two measurements shown must be equal.

To check hub alignment (see picture ME 11.02):

- steering cylinder must be centralised: "A" must be equal on both side.
- operate the tie rod to correct hub alignment.
- release the lock nut (B).
- hold cylinder rod in position (C)
- adjust turning the bar of the tie rod (D).
- if necessary operate both steering bar length.
- tighten the locknuts (B).

11 - 1