32005100[1] Service Bolleton Threaded Rods

CONFIDENTIAL

SUBJECT

Page 1 of 11

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

3 2005 100

EH4500-227EH5000-213

SERVICE BULLETIN CODE

FILING LOCATION

Rear Axle Tie Rod Maintenance(HTM SB4600-10)

Rear Axle Tie Rods partially hold the spindle assemblies onto the rear axle box and share clamp

load. Specific assembly instruction must be followed to properly install and torque the rear axle Tie

Rods. If a single Tie Rod is damaged or broken, all Tie Rods should be replaced as a matched set.

Replacement of a single Tie Rod may create a secondary failure due to a Tie Rod being over

stressed during hauler operation. To alleviate this possibility always replace Tie Rods as a set.

SA/GI: EH4500-028,EH5000-015

When performing the described rework, place an order with the EUCLIC-HITACHI Parts Department.

Charge to the customer.

PARTS

EXPENSES

DESCRIPTION

Refer to the following page(s).

DESCRIPTION

OUTLINE

Machine Model(s): EH4500, EH5000 Series

Machine Serial Nos.: Refer to the following page.

DWN

APPDCHKD

WHITE

Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.Welding work, if any, should only be done by qualified welders.

CONFIDENTIAL

Page 2 of 11

DESCRIPTIONSERVICE BULLETIN CODE

FILING LOCATION

3 2005 100

EH4500-227EH5000-213

Hitachi Construction

Truck Manufacturing Ltd.

Service Bulletin Distribute to PARTS and SERVICE Department Employees

MODELS GROUP NO. DATE PAGE

EH4500 (411/412 MD), EH5000 (401/402 RD) 4600 10 02/05 1/10

Hitachi Construction Truck Manufacturing Ltd. Technical Center

Cleveland, Ohio

Template Last revised 3/5/04

SUBJECT: Rear Axle Tie Rod Maintenance

PURPOSE:

Rear Axle Tie Rods partially hold the spindle assemblies onto the rear axle box and share clamp load. Specific assembly instruction must be followed to properly install and torque the rear axle Tie Rods. If a single Tie Rod is damaged or broken, all Tie Rods should be replaced as a matched set. Replacement of a single Tie Rod may create a secondary failure due to a Tie Rod being over stressed during hauler operation. To alleviate this possibility always replace Tie Rods as a set.

EFFECTIVE POINTS: The described change has been incorporated effective with the serial numbers listed: EH4500 (411/412MD) 77165 and above EH5000 (401/402MD) 77299 and above

DETAILS: The Tie Rod mounting system has been improved to simplify service. Early haulers require the Traction Drive Spindle Assembly be removed to replace Tie Rods. Reason for the Traction Drive Spindle Assembly removal is because the threaded spacer on early units is located inside the axle box mounting flange. The Traction Drive Spindle Assembly must be removed to be able to slide the Tie Rod out of the axle box. As a product improvement current production units incorporate a special plate that captivates the threaded spacer. The special plate is reversible and can be easily replaced if galling occurs beneath the Tie Rod washers. The improved installation now allows for Tie Rod replacement without removal of Traction Drive Spindle Assembly. This dramatically reduces labor required to service a damaged Tie Rod. Therefore it is highly recommended that former units be upgraded to incorporate this feature during a Traction Drive Spindle Assembly service or during a Tie Rod repair.

Mandatory Update Technical Information

CONFIDENTIAL

Page 3 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 2/10


Cleveland, Ohio


Recommend a thorough visual inspection of the axle structure be performed whenever Axle Tie Rod is found broken. Clean the entire axle box, spindle assemblies, and inspect for damage or evidence of crack development. Special attention should be used during inspection of all welds. Any area suspect of crack development should additionally be inspected using NDT method to verify crack is not present.

Caution: Never install a Tie Rod without the proper threaded spacer in place. In the event of a Tie Rod break the threaded spacer dissipates force.

Figure 1 Former Tie Rod Installation Figure 2 Current Tie Rod Installation

Before working on the machine, park it on a level surface and put it in the SERVICE POSITION.

1. Engine stopped, ignition key removed

(except when service requires engine

operation).

2. Tag the machine following local lockout &

tag procedures. Identify machine as Out

of Service.

3. If body is raised, use body prop cable or

pin.

4. The wheels blocked.

5. Body control lever in FLOAT position.

6. Parking brake applied.

7. Allow machine to cool down.

8. Pressure released from all lines,

tanks, and accumulators.

CONFIDENTIAL

Page 4 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 3/10


Cleveland, Ohio


Please pay attention to the safety instructions in the Operators and Service Manuals

concerned.

CONFIDENTIAL

Page 5 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 4/10


Cleveland, Ohio


MATERIAL REQUIRED:

The components listed in Table 1 are required for the field upgrade of one unit.

Table 1. Rework Parts List

ITEM NO. PART NO. DESCRIPTION QTY

1 E12639017 THREADED ROD 6

2 E13813968 NUT SLOTTED 12

3 E12001555 COTTER PIN 12

4 E4025147 WASHER 24

5 E12633971 THREADED SPACER 12

6 E12640944 SPECIAL PLATE 10

REQUIRED TOOLS: Standard mechanics toolbox. Magnetic base drill press capable of boring 39 mm [1.500] holes through steel plate Alignment fixture for magnetic base drill, fabricated from mild steel plate 20long x 12wide x 1 thick Pilot rods of all thread -13 approximately 610 mm [24] long Tire handler Support stands Six, diameter cap screws, grade eight material, with hardened nuts

CONFIDENTIAL

Page 6 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 5/10


Cleveland, Ohio


INSTALLATION: Figures 3 through 5 illustrate the upgrade. Standard assembly instruction is outlined in attached drawing 12634292. All item numbers listed refer to Table 1 under MATERIAL REQUIRED.

1. The hauler must be properly cleaned and the body empty of all material. It is preferred to have the body removed or resting on the frame when performing this upgrade.

2. The rear of the hauler must be raised and supported on properly fabricated and rated saddle style stands.

3. Inspect and isolate all potential energy sources prior to repair. Follow all local regulations with regard to Risk assessment documentation and work assignment review. Inspect Electrical, Hydraulic, Mechanical, and Pneumatic sources for potential energy release and isolate system or component prior to commencement of upgrade.

4. Using a properly rated tire handler remove the rear tire/rim equipment from both left and right sides. Refer to appropriate section of service manual for model specific information.

5. Remove traction drive cables and wiring from one Traction Drive Spindle Assembly. Mark all connections using tags for easy identification during assembly.

6. Remove drain and vent hoses from Traction Drive Spindle Assembly.

7. Loosen all Spindle to axle box mounting cap screws and Tie Rod Nuts.

8. Paint mark clocking reference marks across the flange between the Spindle and axle box to aid assembly.

9. Paint mark holes on Spindle where the Tie Rods are located. These holes are identified for drilling to a larger diameter later.

10. Use either a Traction Drive Spindle Assembly transport stand [Hedweld] or overhead crane with properly selected rigging to support Traction Drive Spindle and prepare for removal.

Note: Mass EH5000 Spindle Assembly approx. = 17,395 kg [38,950 lbs]

11. Remove balance of mounting hardware and then remove Traction Drive Spindle Assembly.

12. Remove the Tie Rods from the axle box.

Photo Spindle Assembly Removal

Note: Only one Traction Drive Spindle Assembly should need to be removed from axle box to perform upgrade. If rear of hauler is supported by stands under the

CONFIDENTIAL

Page 7 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 6/10


Cleveland, Ohio


axle box do not remove both Traction Drive Spindle Assemblies at the same time. Drill holes in both the removed Spindle and opposite mounted Spindle at same time. Then slide new Tie Rods into place. Removal of both Traction Drive Spindle Assemblies together at the same time may allow axle box distortion to occur. This could make assembly difficult.

13. Locate the fabricated drilling fixture over the Tie Rod hole and bolt fixture to mating flange of Traction Drive Spindle Assembly. Use a 33, 32 mm [1.312] drill to pilot and center the drill press over the hole. Remove and change drill bit after setup is locked in place. Enlarge the Tie Rod holes only to 38,10 mm [1.500] diameter drilling from inside flange through to outside using the magnetic base drill.

Photo Magnetic Drill & Attachments

14. Now center the drilling fixture over the Tie Rod holes of the Traction Drive Spindle Assembly still mounted to the axle box. Again drill the holes oversize to 38,10 mm [1.500] diameter drilling from outside of flange through towards center of axle box.

Photo Magnetic Base Drill Alignment Fixture

Note: Table 1 item 6 can be used as hole locating template to fabricate alignment fixture shown.

15. Thoroughly clean all machining debris from the holes and deburr edges using a die grinder.

16. Screw the threaded spacers onto the Tie Rod at both ends (note 3 and view C of drawing 12634292). Screw threaded pilot rod (special tool) into end of Tie Rod and slide Tie Rod into place from open cavity side of axle box. Use the pilot rod to guide the Tie Rod into place then remove the pilot rod.

Photo -13 Pilot Rod, Grade #8 Bolts, Plate Item 6, Shown for Clarity

CONFIDENTIAL

Page 8 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 7/10


Cleveland, Ohio


17. After all Tie Rods are in place in axle box, with threaded spacers in place, install nuts and cotter pins following note 4 of drawing 12634292.

Note: Instead of installing the cotter pins, use grade #8 bolts and nuts in cotter pin holes during the process of tightening the Tie Rod nuts. The Tie Rod nuts can be retained from rotation during the tightening torque sequence by use of an open end wrench.

18. Install pilot rods in the opposite ends of the Tie Rods just before hoisting Traction Drive Spindle Assembly back into place. Use pilot rods as guides for Tie Rods during assembly.

19. Install mounting cap screws into Traction Drive Spindle Assembly and lubricate and torque all mounting Tie Rod nuts as described in Wheel Motor Mounting drawing 12634292. Tighten additional cap screws evenly to specified torque using alternating criss- cross torque pattern.

Note: When final torque is achieved on Tie Rod nuts, remove the bolts and replace with cotter pins (Table 1 item 3) for final assembly.

20. Reconnect balance of traction cables, hoses etc. to Traction Drive Spindle Assembly.

21. Start unit and bleed both the parking brake circuit and service brake hydraulic circuits.

22. At engine idle speed check Traction Drive system operation for correct wheel travel direction with range select.

23. Reinstall tires/rim equipment. Torque each dagger nut [star pattern] until torque measurement is stabilized and nut does not yield.

24. Perform hauler systems operational check.

25. Operate unit a minimum of 15 minutes without pay load to verify hauler performance.

26. Begin 100% re-inspection of wheel nut torque. If nuts have not stabilized at torque value, repeat step 25~26 until wheel nut torque is stabilized.

27. Record operational hours and date of upgrade on service work order. Return unit to operation.

28. Destroy all Tie Rods removed by cutting in half with torch.

CONFIDENTIAL

Page 9 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 8/10


Cleveland, Ohio


Figure 3

CONFIDENTIAL

Page 10 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 9/10


Cleveland, Ohio


Figure 4

CONFIDENTIAL

Page 11 of 11


FILING LOCATION

3 2005 100

EH4500-227EH5000-213


EH4500 (411/412 MD), EH5000 (401/402 RD)

4600 10 02/05 10/10


Cleveland, Ohio


Figure 5

32005100[1] Service Bolleton Threaded Rods

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Transcript of 32005100[1] Service Bolleton Threaded Rods