DANA SPICER Axle 123 User manual

Service Manual
Axle 123
ASM-0007E
March 2013
Property of American Airlines

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3Dana Holding CorporationASM-0007E - 123 Axle Service Manual
CONTENTS
INTRODUCTION ................................................................................................................................ 5
SPECIFICATIONS ..............................................................................................................................6
DEFINITION OF VIEWPOINTS .................................................................................................................................... 6
DATA PLATE .............................................................................................................................................................. 6
CONVERSION TABLES ................................................................................................................................................... 7
TORQUE SPECIFICATIONS ............................................................................................................................................ 8
COARSE PITCH ......................................................................................................................................................... 8
FINE PITCH ................................................................................................................................................................ 8
WHEEL NUT TIGHTENING TORQUES ...................................................................................................................... 9
MAINTENANCE ................................................................................................................................................................ 10
MAINTENANCE POINTS ............................................................................................................................................ 10
MAINTENANCE INTERVALS ...................................................................................................................................... 11
ADJUSTMENT AND CHECKS .................................................................................................................................... 11
LUBRICANT & SEALANT SPECIFICATIONS ............................................................................................................. 12
SAFETY PRECAUTIONS ...................................................................................................................13
BRAKE WEAR CHECK PROCEDURE .............................................................................................. 15
OLD VERSION ................................................................................................................................................................. 15
NEW VERSION ................................................................................................................................................................. 16
SPECIAL TOOLS .............................................................................................................................................................. 17
T1 ............................................................................................................................................................................... 17
SERVICE BRAKE ............................................................................................................................... 19
EXPLODED VIEW ............................................................................................................................................................. 19
DISASSEMBLY ................................................................................................................................................................ 20
ASSEMBLY ...................................................................................................................................................................... 22
PLANETARY REDUCTION ................................................................................................................ 25
EXPLODED VIEW ............................................................................................................................................................. 25
DISASSEMBLY ................................................................................................................................................................ 26
ASSEMBLY ...................................................................................................................................................................... 30
SPECIAL TOOLS .............................................................................................................................................................. 33
T1 ............................................................................................................................................................................... 33
T2 ............................................................................................................................................................................... 34
T3 ............................................................................................................................................................................... 35
DIFFERENTIAL UNIT ........................................................................................................................ 37
EXPLODED VIEW ............................................................................................................................................................. 37
DISASSEMBLY ................................................................................................................................................................ 38
ASSEMBLY ...................................................................................................................................................................... 42
SPECIAL TOOLS .............................................................................................................................................................. 48
T1 ............................................................................................................................................................................... 48
BEVEL PINION ................................................................................................................................... 49
EXPLODED VIEW ............................................................................................................................................................. 49
DISASSEMBLY ................................................................................................................................................................ 50
ASSEMBLY ...................................................................................................................................................................... 53
SPECIAL TOOLS .............................................................................................................................................................. 58
T1 ............................................................................................................................................................................... 58
T2 ............................................................................................................................................................................... 59
T3 ............................................................................................................................................................................... 59
T4 ............................................................................................................................................................................... 60
T5 ............................................................................................................................................................................... 61
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4Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
FLANGED BEVEL PINION ................................................................................................................ 63
EXPLODED VIEW ............................................................................................................................................................. 63
DISASSEMBLY ................................................................................................................................................................ 64
ASSEMBLY ...................................................................................................................................................................... 66
SPECIAL TOOLS .............................................................................................................................................................. 71
T1 ............................................................................................................................................................................... 71
T2 ............................................................................................................................................................................... 72
T3 ............................................................................................................................................................................... 72
SWINGING SUPPORT .......................................................................................................................73
EXPLODED VIEW ............................................................................................................................................................. 73
DISASSEMBLY ................................................................................................................................................................ 74
ASSEMBLY ...................................................................................................................................................................... 75
SERVICE BRAKE AND NEGATIVE PARKING BRAKE ....................................................................77
EXPLODED VIEW ............................................................................................................................................................. 77
RELEASE ......................................................................................................................................................................... 78
ADJUSTMENT ................................................................................................................................................................. 78
DISASSEMBLY ................................................................................................................................................................ 79
ASSEMBLY ...................................................................................................................................................................... 82
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5Dana Holding CorporationASM-0007E - 123 Axle Service Manual
INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on
efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have
been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is
necessary to assemble only individual components, when partial repair work is needed. The manual provides a
quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the ope-
rations, allows accurate work to be performed.All the information needed for correct disassembly, checks and as-
sembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the
manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is pre-
sumed that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use pro-
per equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and
specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly
clean the unit, removing any encrusted or accumulated grease.
INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate
products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly
check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (o-rings,
oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time
a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge.
In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other
one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained.
CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification
is indicated as follows:
= up to the part number
 = from the part number on
When no classification is given, disassembly and assembly operations are the same for all versions.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair
work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or
directly from the Service Centers or Authorized Distributors of SPICER.
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6Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
SPECIFICATIONS
DEFINITION OF VIEWPOINTS
DATA PLATE
1 - Type and model unit - modification index
2 - Serial number
3 - Lubricant
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
3
2
1
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CONVERSION TABLES
7Dana Holding CorporationASM-0007E - 123 Axle Service Manual
CONVERSION TABLES
UNITS OF PRESSURE
1 ATM=1 BAR=105PA=14.4 PSI
UNIT OF WEIGHT
UNITS OF TORQUE
NdaN kN kg lbs
1N 1 0,1 0,001 0,102 0,225
1daN 10 1 0,01 1,02 2,25
1kN 1000 100 1 102 225
1kg 9,81 0,981 0,00981 1 2,205
N·m daN·m kN·m kg·m lb·in
1N·m 1 0,1 0,001 0,102 8,854
1daN·m 10 1 0,01 1,02 88,54
1kN·m 1000 100 1 102 8854
1kg·m 9,81 0,981 0,00981 1 86,8
1 lb·in 0,1129 0,01129 0,0001129 0,01152 1
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8
TORQUE SPECIFICATIONS
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
TORQUE SPECIFICATIONS
COARSE PITCH
FINE PITCH
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m
M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m
M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m
M12 x 1,75 mm 82 – 91 N·m 90 – 100 N·m 116 – 128 N·m 126 – 139 N·m 139 – 153 N·m 152 – 168 N·m
M14 x 2 mm 129 – 143 N·m 143 – 158 N·m 182 – 202 N·m 200 – 221 N·m 221 – 244 N·m 238 – 263 N·m
M16 x 2 mm 200 – 221 N·m 219 – 242 N·m 283 – 312 N·m 309 – 341 N·m 337 – 373 N·m 371 – 410 N·m
M18 x 2,5 mm 276 – 305 N·m 299 – 331 N·m 390 – 431 N·m 428 – 473 N·m 466 – 515 N·m 509 – 562 N·m
M20 x 2,5 mm 390 – 431 N·m 428 – 473 N·m 553 – 611 N·m 603 – 667 N·m 660 – 730 N·m 722 – 798 N·m
M22 x 2,5 mm 523 – 578 N·m 575 – 635 N·m 746 – 824 N·m 817 – 903 N·m 893 – 987 N·m 974 – 1076 N·m
M24 x 3 mm 675 – 746 N·m 732 – 809 N·m 950 – 1050 N·m 1040 – 1150 N·m 1140 – 1260 N·m 1240 – 1370 N·m
M27 x 3 mm 998 – 1103 N·m 1088 – 1202 N·m 1411 – 1559 N·m 1539 – 1701 N·m 1710 – 1890 N·m 1838 – 2032 N·m
M30 x 3,5 mm 1378 – 1523 N·m 1473 – 1628 N·m 1914 – 2115 N·m 2085 – 2305 N·m 2280 – 2520 N·m 2494 – 2757 N·m
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m
M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m
M12 x 1,25 mm 90 – 100 N·m 98 – 109 N·m 128 – 142 N·m 139 – 154 N·m 152 – 168 N·m 166 – 184 N·m
M12 x 1,5 mm 86 – 95 N·m 94 – 104 N·m 120 – 132 N·m 133 – 147 N·m 143 – 158 N·m 159 – 175 N·m
M14 x 1,5 mm 143 – 158 N·m 157 – 173 N·m 200 – 222 N·m 219 – 242 N·m 238 – 263 N·m 261 – 289 N·m
M16 x 1,5 mm 214 – 236 N·m 233 – 257 N·m 302 – 334 N·m 333 – 368 N·m 361 – 399 N·m 394 – 436 N·m
M18 x 1,5 mm 312 – 345 N·m 342 – 378 N·m 442 – 489 N·m 485 – 536 N·m 527 – 583 N·m 580 – 641 N·m
M20 x 1,5 mm 437 – 483 N·m 475 – 525 N·m 613 – 677 N·m 674 – 745 N·m 736 – 814 N·m 808 – 893 N·m
M22 x 1,5 mm 581 – 642 N·m 637 – 704 N·m 822 – 908 N·m 903 – 998 N·m 998 – 1103 N·m 1078 – 1191 N·m
M24 x 2 mm 741 – 819 N·m 808 – 893 N·m 1045 – 1155 N·m 1140 – 1260 N·m 1235 – 1365 N·m 1363 – 1507 N·m
M27 x 2 mm 1083 – 1197 N·m 1178 – 1302 N·m 1520 – 1680 N·m 1672 – 1848 N·m 1834 – 2027 N·m 2000 – 2210 N·m
M30 x 2 mm 1511 – 1670 N·m 1648 – 1822 N·m 2138 – 2363 N·m 2332 – 2577 N·m 2565 – 2835 N·m 2788 – 3082 N·m
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TORQUE SPECIFICATIONS
9Dana Holding CorporationASM-0007E - 123 Axle Service Manual
WHEEL NUT TIGHTENING TORQUES
Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material.
**RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS. IT IS THE OPTIMUM MA-
TERIAL FOR TIGHTENING THE RIM TO THE HUB.
*THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY
(DANA AXLES ARE 10.9 ONLY).
WHEEL NUT TIGHTENING TORQUES
CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD
RECOMMENDED WHEEL NUTS TORQUE
RIM MATERIAL QUALITY
ST 37 **ST 52
WHEEL NUTS WITH
INTEGRATE
SPHERICAL COLLAR
M18 x 1,5 mm 330 N·m 460 N·m
M20 x 1,5 mm 490 N·m 630 N·m
M22 x 1,5 mm 630 N·m 740 N·m
FLAT COLLAR WHEEL
NUTS WITH SEPARATE
SPHERICAL LOCK
WASHER
M18 x 1,5 mm 270 N·m 360 N·m
M20 x 1,5 mm 360 N·m 450 N·m
M22 x 1,5 mm 460 N·m 550 N·m
WHEEL NUTS WITH IN-
TEGRATE SEAT
CAPTIVE WASHER
M18 x 1,5 mm 260 N·m 360 N·m
M20 x 1,5 mm 350 N·m 500 N·m
M22 x 1,5 mm 450 N·m 650 N·m
NOTE:
The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant).
NOTE:
The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of
the rim material.
THE DANA OFFICIAL TIGHTENING TORQUE TABLE, THAT IS INCLUDED IN EACH SERVICE MANUAL, SHOWS THE TORQUE FIGURE
RELATED TO THE BOLT CHARACTERISTIC ONLY.
DANA OFFICIAL TIGHTENING TORQUE TABLE
NUT MATERIAL QUALITY 8.8 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE
M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m
M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m
M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m
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10
MAINTENANCE
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
MAINTENANCE
MAINTENANCE POINTS
1 - Oil filling plug
2 - Oil draining plug
3 - Check level plug
4 - Check brake disc wear
Minimum thickness between counter discs is 5.2 mm.
NOTE:
For details see BRAKE WEAR CHECK PROCEDURE p. 15
2
42
1 3
2 4
2
1 3
44
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MAINTENANCE
11Dana Holding CorporationASM-0007E - 123 Axle Service Manual
MAINTENANCE INTERVALS
If working in severe duty conditions half intervals should be used
* Initially after 100 working hours
** When it starts sounding noisy
ADJUSTMENT AND CHECKS
* Initially after 100 working hours
** Initially after 10 working hours
OPERATION FREQUENCY LUBRICANTS
Check levels
Differential Monthly SAE85W90 (API GL4 - MIL L-2105)
With additives for oil-bath brakes
SAE85W90 (API GL5 - MIL 2105-B)
With additives for oil-bath brakes, for units
presenting hypoid crown wheel and pinion
and/or self-locking differential gear
Planetary reduction Every 200 hours
Oil change
Differential Every 800 hrs *
Planetary reduction Every 1000 hrs *
L.S. Differential Every 700 hrs */**
OPERATION MEMBER CONDITIONS FREQUENCY LUBRICANTS
Greasing Articulations
Normal work Monthly
NLGI 3 EP
Severe duty Weekly
UNIT OPERATION FREQUENCY SERVICE BRAKE CIRCUIT
Negative brake Adjustment Every 1000 hours* Only for mineral oil use e.g. ATF Dexron II. Make
sure that master cylinder seals are suitable for mine-
ral oil.
Service brake Adjustment Every 500 hours
Wheel nuts Tightening Every 200 hours**
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12
MAINTENANCE
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
LUBRICANT & SEALANT SPECIFICATIONS
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate repla-
cement with similar products marketed by different brand names with different trade marks.
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Be-
fore using it, completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubri-
cant by using the specific activator.
To remove parts, it may be necessary to heat them at 80° C approximately.
LOCTITE 275
Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for
pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum dia-
metrical clearance of 0.25 mm.
LOCTITE 510
Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal
clearances between flanges up to 0.2 mm.
LOCTITE 577
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it,
remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so
heating may be necessary for larger diameters.
LOCTITE 638
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with clearance ranging between 0.1 and 0.25 mm.
LOCTITE 648
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with radial clearance below 0.1 mm.
AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS)
Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter
of sealing rings for rotating shafts with outer metal reinforcement.
SILICONE
Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and phy-
sical elements. Polymerises with non-corrosive dampness.
TECNO LUBE/101 (SILICONE-BASED GREASE)
Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
MOLIKOTE (DOW CORNING)
Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sti-
cking and oxidation of parts that are not lubricated on a regular basis.
(LITHIUM-BASED) GREASE
Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.
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13Dana Holding CorporationASM-0007E - 123 Axle Service Manual
SAFETY PRECAUTIONS
1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po-
sitioned and that the machine is locked lengthways.
4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the igni-
tion key from the machine.
5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure
that all torque wrenches have been checked and calibrated.
6 - Always wear gloves and non-slip rubber shoes when performing repair work.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste
and dispose of them according to the relative law provisions obtaining in the country where the axles are being
overhauled.
9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol,
xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment
friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some
of the diagrams.
11 - After repair work has been completed, accurately touch up any coated part that may have been damaged.
12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.
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14
MAINTENANCE
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
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15Dana Holding CorporationASM-0007E - 123 Axle Service Manual
BRAKE WEAR CHECK PROCEDURE
OLD VERSION
Perform all operations on both arms.
FIGURE 1: Remove the oil drain plug and discharge oil.
FIGURE 2: Apply the parking brake (or have someone hold
the service brake) and with either brake applied, check the di-
stance between discs using tool T1 (See drawing T1 p. 17).
Minimum distance: 5,2 mm
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE p. 19.
FIGURE 3: Checking brake distance with the T1 go / no-go
gauge.
CAUTION
T1
CAUTION
FIGURE 4: Fill with oil.
Install the oil drain plug.
Torque wrench setting for screws: 35 - 50 N·m.
35 - 50 N·m
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16 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
NEW VERSION
Perform all operations on both arms.
FIGURE 1: Remove the inspection plug.
FIGURE 2: Apply the parking brake (or have someone hold
the service brake) and with either brake applied, check the di-
stance between discs using tool T1 (See drawing T1 p. 17).
Minimum distance: 5,2 mm
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE p. 19.
FIGURE 3: Checking brake distance with the T1 go / no-go
gauge.
CAUTION
T1
CAUTION
FIGURE 4: Install the inspection plug.
Torque wrench setting for screws: 35 - 50 N·m.
35 - 50 N·m
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SPECIAL TOOLS
17Dana Holding CorporationASM-0007E - 123 Axle Service Manual
SPECIAL TOOLS
T1
32
32
32
32
10 5.4
25
45 °
110 160
25
1
5.2
45 °
8
1
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18
SPECIAL TOOLS
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
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19Dana Holding CorporationASM-0007E - 123 Axle Service Manual
SERVICE BRAKE
EXPLODED VIEW
56
9
10 11
12 13
14
7
8
1
3
2
4
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20
DISASSEMBLY
Dana Holding Corporation ASM-0007E - 123 Axle Service Manual
DISASSEMBLY
FIGURE 1: Sling the arm to be removed and connect it to a
hoist. Loosen and remove screws.
FIGURE 2: Write down the order of assembly and remove the
counterwasher (1).
FIGURE 3: Write down the counterwasher (1) position.
1
Down SideDown Side
FIGURE 4: Write down the flange (4) position.
FIGURE 5: Remove braking discs (2, 3), noting down direc-
tion of assembly.
NOTE:
If disks are not to be replaced, avoid changing their posi-
tion.
FIGURE 6: Remove the flange (4) complete with the discs.
Differential side
Differential side
Arm side
Arm side
3
4
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