Removing the Rear Axle

Standard Operating Procedure

Removing the Rear Axle

Removing the Rear Axle

Prepare and Position the Machine

Precondition

  • The rear wheels are removed in accordance with the Rear Wheels Removal and Installation procedure.

  • For Cabletec LC Machine: The exhaust system is removed in accordance with the Exhaust System Removal and Installation procedure.

  1. 1.
    Make sure that the machine is isolated and, if necessary, isolate the machine with the battery isolation switch.
  2. 2.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Make sure that the adjustable maintenance stands support the rear axle (Figure 1).
    Figure 1

Isolation of the Component

  1. 1.
    Drain oil from the rear axle and the wheel hubs in accordance with the procedure in the Maintenance manual.

    NOTE

    Make sure to collect the oil sample from the rear axle and the wheel hubs.

  2. 2.
    Put a tag onto the battery isolation switch stating that the oil is drained from the rear axle.
  3. 3.
    Remove the screws (Figure 2, item A) and the lock nuts (item B) that attach the driveline flange to the rear axle. Discard the hardware.
    Figure 2

    A

    Screw

    B

    Lock nut

  4. 4.
    Use an approved tool to disengage the driveline flange from the rear axle.
  5. 5.
    Secure the driveline to the transmission with an approved strap.
  6. 6.

    WARNING

    Slipping Hazard

    Fluid leaks or spills can cause personal injury.

    1. Cover all of the open ports.

    2. Wipe off any spilled fluid immediately.

    Put the container or oil absorbent materials below the rear axle to collect the spilled oil.
  7. 7.
    Clean, label, and disconnect the lubrication hoses (Figure 3, item A) from both the trunnion brackets. Plug the hoses and cap the ports immediately.
    Figure 3

    A

    Lubrication hoses

    NOTE

    Some oil remains in all of the hoses. Disconnect the hose connections with caution.

  8. 8.

    WARNING

    High Pressure

    Residual pressure can cause personal injury.

    1. Loosen the fittings carefully to release the pressure fully before you disconnect and cap the hoses.

    Clean, label, and disconnect the two hydraulic brake hoses (Figure 4, item A) from the rear axle. Plug the hoses and cap the ports immediately.
    Figure 4

    A

    Hose

  9. 9.

    CAUTION

    Environmental Contaminant

    Fluid is an environmental contaminant and must be discarded correctly.

    1. Do not let the fluid drain into the ground.

    2. Discard the used fluid in accordance with local environmental regulations.

    Remove the container or oil absorbent materials from below the rear axle.
  10. Optional step
    For Cabletec LC Machine: Remove the air filter set as follows:
    1. Release the stored energy from the air filter set using pressure switch (Figure 5A, item A)
      Figure 5A

      A

      Pressure switch

      B

      Hose clip

      C

      Rubber socket

      NOTE

      Make sure that there is no pressure in the air filter set.

    2. Remove the hose clips (item B) and the rubber socket (item C) that attach the inlet port to the air filter set.
    3. Remove the four screws (Figure 5B, item A) and the plain washers (item B) that attach the air filter set (item C) to the hood.
      Figure 5B

      A

      Screw

      B

      Plain washer

      C

      Air filter set

    4. Remove the air filter set (item C) from the hood.
  11. 10.
    Open the hatch (Figures 6A and 6B, item A) from the side and secure it.
    Figure 6A Boltec M,E,EC, Boomer M1D, E2C, Simba M6C, E7C, Cabletec M, and Cabletec E
    Figure 6B Cabletec LC

    A

    Hatch

  12. Optional step
    For Cabletec LC Machine: Remove the other side hatch as follows:
    1. Remove the screws (Figure 7, item A), washers (item B), and lock washers (item C) that attach the hatch (item D) from the machine.
      Figure 7Cabletec LC

      A

      Screw

      B

      Washer

      C

      Lock washer

      D

      Hatch

    2. Remove the hatch and store in safe location.
  13. Optional step
    For Cabletec LC Machine: Make sure that the exhaust system is removed from the hood.
  14. 11.
    Remove the plate as follows:
    1. Alternative step
      For Boltec M, Boomer M1D,Simba M6C, Simba E7C, and Cabletec M Machine: Remove the screws (Figure 8A, item B) and washers (item A) that attach the plate (item C) to the engine hood. Discard the hardware.
      Figure 8A

      A

      Washer

      B

      Screw

      C

      Plate

      D

      Washer

      E

      Screw

      F

      Hood

    2. Alternative step
      For Cabletec E, Boltec EC and Boltec E Machine: Remove the screws (Figure 8B, item A) and washers (item B) that attach the two plates (items C and D) to the engine hood. Discard the hardware.
      Figure 8B

      A

      Screw

      B

      Washer

      C,D

      Plate

      E

      Screw

      F

      Washer

      G

      Hood

    3. Alternative step
      For Boomer E2C Machine: Remove the screw (Figure 8C, item A) and washers (item B) that attach the plate (item C) to the engine hood. Discard the hardware.
      Figure 8C

      A

      Screw

      B

      Washer

      C

      Plate

      D

      Hood

      E

      Screw

      F

      Washer

  15. 12.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the plates (items C and D) and put them in a safe location.
  16. 13.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. All lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the hood and support it.
  17. 14.
    Remove the hood as follows:
    1. Alternative step
      For Boltec M, Boomer M1D,Simba M6C, Simba E7C and Cabletec M Machine: Remove the screws (Figure 8A, item E) and washers (item D) holding the hood (item F). Discard the hardware.
    2. Alternative step
      For Cabletec E, Boltec E and Boltec EC Machine: Remove the screws (Figure 8B, item E) and washers (item F) holding the hood (item G). Discard the hardware.
    3. Alternative step
      For Boomer E2C Machine: Remove the screws (Figure 8C, item E) and washers (item F) holding the engine hood (item D). Discard the hardware.
    4. Alternative step
      For Cabletec LC Machine: Remove the screws (Figure 9, item A) and the washers (item B) that attach the hood (item C) to the engine hood. Discard the hardware.
      Figure 9

      A

      Screw

      B

      Washer

  18. 15.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put your hand or any other body parts on the object when lifting, moving, or lowering it.

    2. Do not go in, reside, or put body parts below the unsecured, moveable, or lifted parts.

    3. Do not put any part of your body in the path of the pinch point area when you remove or install the parts.

    4. Stay away from the moving parts.

    Remove the hood with the attached lifting device and put it in a safe location.
  19. 16.
    Remove the lifting device from the hood.
  20. Optional step
    For Boltec M, E, EC, Cabletec M and Simba E Machines: Remove the camera kit and the cover plate from the rear frame as follows:
    1. Disconnect the cable from the camera, if necessary.
    2. Remove the screws (Figures 10A and 10B, item A) and the washers (item B) that attach the camera kit (item F) to the cover plate. Discard the hardware.
      Figure 10A Boltec M, E, EC, Cabletec M
      Figure 10B Simba E

      A

      Screw

      B

      Washer

      C

      Cover plate

      D

      Washer

      E

      Screw

      F

      Camera kit

    3. Remove the camera kit (item F) from the cover plate and put it in a safe location.
    4. Remove the screws (item E) and the washers (item D) that attach the cover plate (item C) to the rear frame. Discard the hardware.
    5. Remove the cover plate (item C) from the rear frame and put it in a safe location.
  21. 17.
    For Boomer E2C, M1D, Simba M, Cabletec E and LC Machines: Remove the screws (Figure 11, item A) and the washers (item B) that attach the cover plate (item C). Discard the hardware.
    Figure 11 For Boomer E2C, M1D, Simba M, Cabletec E and LC

    A

    Screw

    B

    Washer

    C

    Cover plate

  22. 18.
    Remove the cover plate (item C) and put it in a safe location.
  23. 19.
    Remove the screws (Figures 12A and 12B, item A) and the washers (item B) that attach the hood cover (item C). Discard the hardware.
    Figure 12A Cabletec LC
    Figure 12B Boltec EC, E, M, Boomer M1D, E2C, Simba M6C, E7C, Cabletec M and E

    A

    Screw

    B

    Washer

    C

    Hood cover

  24. 20.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the hood cover (item C) from the machine and put them in a safe location.
  25. 21.

    WARNING

    High-Pressure System

    Working with pressurized systems can cause personal injury.

    1. Do not do the maintenance work when you operate the machine.

    2. Make sure that the hydraulic, water, and air systems are depressurized before you start to work on these systems.

    3. Put on the applicable gloves.

    Release the stored energy from the air receiver tank.

    NOTE

    Make sure that there is no pressure in the system.

  26. 22.
    Remove the air receiver tank as follows:
    1. Clean, label, and disconnect all hoses (Figure 13A, item A) from the air receiver tank. Plug the hoses and cap the ports immediately.
      Figure 13A

      A

      Hose

    2. Support the air receiver tank (Figure 13B, item A) manually.

      NOTE

      Two service technicians are necessary to lift the air receiver tank.

      Figure 13B

      A

      Screw

      B

      Washer

      C

      Lock nut

      D

      Strap

      E

      Air receiver tank

    3. Remove the screws (item A), lock nuts (item C) and washers (item B) that attach the air receiver tank (item E) with the left cover plate. Discard the hardware.
    4. Remove the straps (item D) and store them in a safe location.

    5. WARNING

      Heavy Components

      Lifting the heavy components by hand can cause body or muscle strains.

      1. Position the body accordingly to support the weight of the component.

      Remove the air receiver tank (item E) from the machine and store it in a safe location.

Lifting and Removal

  1. 1.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the rear axle and support it (Figure 14).
    Figure 14
  2. 2.
    Remove the sixteen screws (Figure 15, item A), washers (item B), and lock nuts (item C) that attach the rear axle trunnion brackets to the machine frame. Discard the hardware.
    Figure 15

    A

    Screw

    B

    Washer

    C

    Lock nut

  3. 3.
    Put an approved workshop dolly with wheels below the rear axle (Figure 16).
    Figure 16
  4. 4.

    WARNING

    Heavy Components

    Lifting the heavy components by hand can cause body or muscle strains.

    1. Position the body accordingly to support the weight of the component.

    Remove the adjustable maintenance stands from below the rear axle.
  5. 5.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Lower the rear axle onto the workshop dolly with the attached lifting device.
  6. 6.
    Remove the attached lifting device from the rear axle.
  7. 7.

    WARNING

    Pinch Points

    Can cause serious injury.

    1. Keep hands and fingers away from the moving parts during removal and installation of the component.

    2. Put on the applicable Personal Protective Equipment (PPE).

    Move the workshop dolly with the rear axle from below the machine and put them in a safe location.
  8. 8.
    Remove all necessary fittings and parts from the rear axle.
  9. 9.
    Cover all open ports on the rear axle to prevent oil leaks.
  10. 10.

    WARNING

    Crushing Hazard

    Can cause personal injury.

    1. Lifting equipment must be adequately sized, have the correct lifting capacity, and be in good condition.

    2. Be careful when you lift heavy components.

    Attach an approved lifting device to the rear axle (Figure 17).
    Figure 17
  11. 11.

    WARNING

    Crushing Hazard

    Unexpected movement of parts can cause personal injury or death.

    1. Do not put any part of your body on the object when lifting, moving, or lowering it.

    2. Do not go in, reside, or put body parts below unsecured, moveable, or lifted parts.

    3. Do not put hands and fingers in the pinch point areas when installing or tightening the parts.

    4. Stay away from moving parts.

    Lift the rear axle from the workshop dolly and put it in a safe location.
  12. 12.
    Remove the attached lifting device from the rear axle.
  13. 13.
    Put a tag onto the battery isolation switch stating that the rear axle is removed from the machine.