Installing the Rear Axle

Prepare and Position the Machine

•
1.
Make sure that the machine is isolated and, if necessary, isolate the machine with the battery isolation switch.

Lifting and Installation

•
1.
Install the necessary fittings and parts to the rear axle.
•
2.
Make sure that the axial plays between the rear axle and trunnion bracket bearings are maintained according to the specification.
NOTE
The axial play must not exceed 0.5 millimeters (0.02 inches).
•
3.
WARNING
Crushing Hazard
Can cause personal injury.
Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.
Be careful when you lift heavy components.
Attach an approved lifting device to the rear axle and lift it.
•
4.
WARNING
Crushing Hazard
Unexpected movement of parts can cause personal injury or death.
Do not put any part of your body on the object when lifting, moving, or lowering it.
Do not go in, reside, or put body parts below unsecured, moveable, or lifted parts.
Do not put hands and fingers in the pinch point areas when installing or tightening the parts.
Stay away from moving parts.
Put the rear axle onto the approved workshop dolly (Figure 18).
Figure 18
•
5.
Remove the attached lifting device from the rear axle.
•
6.
WARNING
Pinch Points
Can cause serious injury.
Keep hands and fingers away from the moving parts during removal and installation of the component.
Put on the applicable Personal Protective Equipment (PPE).
Move the workshop dolly with the rear axle below the machine and align it in the correct position (Figure 19).
Figure 19
•
7.
WARNING
Crushing Hazard
Can cause personal injury.
Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.
Be careful when you lift heavy components.
Attach an approved lifting device to the rear axle and lift it.
•
8.
WARNING
Pinch Points
Can cause serious injury.
Keep hands and fingers away from the moving parts during removal and installation of the component.
Put on the applicable Personal Protective Equipment (PPE).
Align the rear axle trunnion brackets in the correct position.
•
9.
Remove the workshop dolly from below the machine and put it in a safe location.
•
10.
WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle strains.
Position the body accordingly to support the weight of the component.
Put the approved adjustable maintenance stands below the rear axle and support it (Figure 20).
Figure 20
•
11.
WARNING
Pinch Points
Can cause personal injury during installation.
Keep hands clear of mounting surfaces while positioning the parts.
Install the washers (Figure 21, item B) and lock nuts (item C), and insert the screws (item A) to attach the rear axle trunnion brackets with the machine frame.
Figure 21
A
Screw
B
Washer
C
Lock nut
NOTE
Tighten the inner screws first.
•
12.
Torque the screws to 333 Nm (246 Ib-ft) dry.
•
13.
Remove the attached lifting device from the rear axle.

A	Screw
B	Washer
C	Lock nut

Preparation of the Component

•
1.
Remove the air receiver tank as follows:
1. WARNING
  Heavy Components
  Lifting the heavy components by hand can cause body or muscle strains.
  Position the body accordingly to support the weight of the component.
  WARNING
  Pinch Points
  Can cause serious injury.
  Keep hands and fingers away from the moving parts during removal and installation of the component.
  Put on the applicable Personal Protective Equipment (PPE).
  Install the air receiver tank (Figure 22A, item E) with a strap (item D) onto the left cover plate.
  NOTE
  Two service technicians are required to lift the air receiver tank.
  Figure 22A
  A
  Screw
  B
  Washer
  C
  Lock nut
  D
  Strap
  E
  Air receiver tank
2. Install the air receiver tank (item E) with a strap (item D) onto the left cover plate.
3. Install the washers (item B) and lock nuts (item C), and insert the screws (item A) to attach the air receiver tank (item E).
4. Torque the lock nuts to 20 Nm (15 Ib-ft) dry.
5. Connect all hoses (Figure 22B, item A) to the air receiver tank.
  Figure 22B
  A
  Hose
•
2.
WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle strains.
Position the body accordingly to support the weight of the component.
WARNING
Pinch Points
Can cause serious injury.
Keep hands and fingers away from the moving parts during removal and installation of the component.
Put on the applicable Personal Protective Equipment (PPE).
Put the hood cover (Figures 23A and 23B, item C) onto the machine and align them in position.
Figure 23A Cabletec LC
Figure 23B Boltec EC, E, M, Boomer M1D, E2C, Simba M6C, E7C, Cabletec M and E
A
Screw
B
Washer
C
Hood cover
•
3.
Install the washers (item B), and the screws (item A) to attach the hood cover (item C).
•
4.
Torque the screws to 20 Nm (15 Ib-ft) dry.
•
5.
WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle strains.
Position the body accordingly to support the weight of the component.
WARNING
Pinch Points
Can cause serious injury.
Keep hands and fingers away from the moving parts during removal and installation of the component.
Put on the applicable Personal Protective Equipment (PPE).
Install the cover plate (Figure 24, item C).
Figure 24
A
Screw
B
Washer
C
Cover plate
•
6.
Install the screws (item A) and the washers (item B) to attach the cover plate.
•
7.
Torque the screws to 20 Newton meters (15 foot-pounds) dry.
Optional step
For Boltec M, E, EC, Cabletec M and Simba E Machines:Install the camera kit and the cover plate to the rear frame as follows:
1. Put the cover plate (Figures 25A and 25B, item C) from the rear frame and put it in a safe location.
  Figure 25A Boltec M, E, EC, Cabletec M
  Figure 25B Simba E
  A
  Screw
  D
  Washer
  B
  Washer
  E
  Screw
  C
  Cover plate
  F
  Camera kit
  A
  Screw
  B
  Washer
  C
  Cover plate
  D
  Washer
  E
  Screw
  F
  Camera kit
2. Install the screws (item E) and the washers (item D) to attach the cover plate (item C) to the rear frame.
3. Torque the screws to 20 Nm (15 Ib-ft) dry.
4. Put the camera kit (item F) in position onto the cover plate.
5. Install the screws (item A) and the washers (item B) to attach the camera kit (item F) to the cover plate.
6. Torque the screws to 20 Nm (15 Ib-ft) dry.
7. Connect the cable to the camera, if necessary.
•
8.
WARNING
Crushing Hazard
Can cause personal injury.
All lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.
Be careful when you lift heavy components.
Attach an approved lifting device to the hood.
•
9.
WARNING
Crushing Hazard
Unexpected movement of parts can cause personal injury or death.
Do not put your hand or any other body parts on the object when lifting, moving, or lowering it.
Do not go in, reside, or put body parts below the unsecured, moveable, or lifted parts.
Do not put any part of your body in the path of the pinch point area when you remove or install the parts.
Stay away from the moving parts.
Lift the hood and put it in position on the machine frame.
•
10.
Install the hood as follows:
1. Alternative step
  For Boltec M, Boomer M1D,Simba M6C, Simba E7C and Cabletec M Machine: Install the screws (Figure 26A, item D) and the washers (item D) holding the hood (item F).
  Figure 26A
  A
  Washer
  D
  Washer
  B
  Screw
  E
  Screw
  C
  Plate
  F
  Hood
  A
  Washer
  B
  Screw
  C
  Plate
  D
  Washer
  E
  Screw
  F
  Hood
2. Alternative step
  For Cabletec E, Boltec E and Boltec EC Machine: Install the screws (Figure 26B, item E) and the washers (item F) holding the hood (item G).
  Figure 26B
  A
  Screw
  E
  Screw
  B
  Washer
  F
  Washer
  C,D
  Plate
  G
  Hood
  A
  Screw
  B
  Washer
  C,D
  Plate
  E
  Screw
  F
  Washer
  G
  Hood
3. Alternative step
  For Boomer E2C Machine: Install the screws (Figure 26C, item E) and the washers (item F) that attach the hood to the machine.
  Figure 26C
  A
  Screw
  D
  Hood
  B
  Washer
  E
  Screw
  C
  Plate
  F
  Washer
  A
  Screw
  B
  Washer
  C
  Plate
  D
  Hood
  E
  Screw
  F
  Washer
4. Alternative step
  For Cabletec LC Machine: Install the screws (Figure 26D, item A) and the washers (item B) holding the hood (item C).
  Figure 26D
  A
  Screw
  B
  Washer
  C
  Hood
•
11.
Remove the lifting device from the hood and place it in a safe location.
•
12.
WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle strains.
Position the body accordingly to support the weight of the component.
Put the plates in position on the hood.
Optional step
Install the plate as follows:
1. For Boltec M, Boomer M1D,Simba M6C, Simba E7C and Cabletec M Machine: Install the screws (Figure 26A, item A) and the washers (item B) to attach the plate (item C) to the hood.
2. For Cabletec E, Boltec EC and Boltec E Machine: Install the screws (Figure 26B, item A) and the washers (item B) to attach the two plates (items C and D) to the hood.
3. For Boomer E2C Machine: Install the screws (Figure 26C, item A) and the washers (item B) to attach the plate (item C) to the hood.
•
13.
Torque the hood as follows:
1. Alternative step
  For Boltec M, Boomer M1D,Simba M6C, Simba E7C and Cabletec M Machine: Torque the screws (Figure 26A, item E) to 69 Nm (51 Ib-ft) dry.
2. Alternative step
  For Cabletec E, Boltec EC and E Machine: Torque the screws (Figure 26B, item E) to 69 Nm (51 Ib-ft) dry.
3. Alternative step
  For Boomer E2C Machine: Torque the screws (Figure 26C, item E) to 69 Nm (51 Ib-ft) dry.
4. Alternative step
  For Cabletec LC Machine: Torque the screws (Figure 26D, item A) to 171 Nm (126 Ib-ft) dry.
Optional step
Torque the plates as follows:
1. For Boltec M, Boomer M1D,Simba M6C, Simba E7C and Cabletec M Machine: Torque the screws (Figure 26A, item B) to 20 Nm (15 Ib-ft) dry.
2. For Cabletec E, Boltec EC and Boltec E Machine: Torque the screws (Figure 26A, item D) to 40 Nm (30 Ib-ft) dry.
3. For Boomer E2C Machine: Torque the screws (Figure 26C, item A) to 40 Nm (30 Ib-ft) dry.
Optional step
For Cabletec LC Machine: Install the side hatch as follows:
1. Put the hatch (Figure 27, item A) in position on the machine.
  Figure 27 Cabletec LC
  A
  Hatch
2. Install the screws (item A), washers (item B), and lock washers (item C) that attach the hatch (item D) from the machine.
•
14.
Close the hood (Figures 28A and 28B, item A) on the side.
Figure 28A Boltec M, Cabletec M, and Cabletec E
Figure 28B Cabletec LC
A
Hatch
Optional step
For Cabletec LC Machine: Install the air filter set as follows:
1. Put the air filter set (Figure 29A, item C) in position onto the hood.
  Figure 29A
  A
  Screw
  B
  Plain washer
  C
  Air filter set
2. Install the four screws (item A) and the plain washers (item B) that attach the air filter set (item C) to the hood.
3. Torque the screws to 40 Nm (30 Ib-ft) dry
4. Install the hose clips (Figure 29B, item B) and the rubber socket (item C) to attach the inlet port to the air filter set.
  Figure 29B
  A
  Pressure switch
  B
  Hose clip
  C
  Rubber socket
5. Release the stored energy from the air filter set using pressure switch (item A).
Optional step
For Cabletec LC Machine: Install the exhaust system in accordance with the procedure.
NOTE
Refer to Exhaust System Removal and Installation.
•
15.
WARNING
Slipping Hazard
Fluid leaks or spills can cause personal injury.
Cover all of the open ports.
Wipe off any spilled fluid immediately.
Put the container or oil absorbent materials below the rear axle to collect the spilled oil.
NOTE
Some oil remains in all of the hoses. Connect the hose connections with caution.
•
16.
Connect the two hydraulic brake hoses (Figure 30, item A) to the rear axle.
Figure 30
A
Hoses
•
17.
Connect the lubrication hoses (Figure 31, item A) to both the trunnion brackets.
Figure 31
A
Lubrication hoses
•
18.
CAUTION
Environmental Contaminant
Oil is an environmental contaminant and must be discarded correctly.
Do not let the used oil drain onto the ground.
Discard the used oil in accordance with local environmental regulations.
Remove the container or oil absorbent materials from below the rear axle.
•
19.
Remove the strap that secures the driveline to the transmission.
•
20.
Make sure that the driveline flanges are clean.
•
21.
WARNING
Pinch Points
Can cause serious injury.
Keep hands and fingers away from the moving parts during removal and installation of the component.
Put on the applicable Personal Protective Equipment (PPE).
Align the driveline flange to the rear axle with an approved tool (Figure 32).
Figure 32
A
Screw
B
Lock nut
•
22.
Lubricate all of the driveline mounting screws.
•
23.
Install the lock nuts (item B), and insert the screws (item A) to secure the driveline flange.
•
24.
Torque the screws to 113 Nm (83 Ib-ft) lubricated.
•
25.
Fill the rear axle with oil.
•
26.
Install the rear wheels to the machine.
NOTE
Refer to Rear Wheel Removal and Installation.
•
27.
WARNING
Energized Machine
Can cause serious injury.
The machine must be fully energized and the engine must be switched on to complete this procedure.
Be careful around moving parts and pinch points.
Inform the supervisor, lead hand, and all other persons who are concerned of the intent to restart the machine.
NOTE
Make sure that all personnel and bystanders are clear of the machine before start-up.
•
28.
Remove the safety locks and tags from the machine in accordance with the site-specific procedures.
•
29.
Start the machine.
•
30.
Release the brakes.
•
31.
Bleed the brakes as per instruction in the maintenance manual.
•
32.
Apply the park brake.
•
33.
WARNING
Heavy Components
Lifting the heavy components by hand can cause body or muscle strains.
Position the body accordingly to support the weight of the component.
Remove the adjustable stands from under the rear axle.
•
34.
Retract the front and rear support legs to lower the machine onto the ground (Figures 33A and 33B).
Figure 33A
Figure 33B
•
35.
Retract the front jack support legs fully into the jack beam (Figure 34).
Figure 34
•
36.
Stop the machine.
•
37.
Set the battery isolation switch to the OFF position.
•
38.
Attach safety locks and tags to the machine in accordance with the site-specific procedures.
•
39.
Block the wheels with wheel chocks.
NOTE
Extra requirements can apply. Refer to the local regulations.
•
40.
Put a tag onto the battery isolation switch stating that the rear axle is replaced.