Usage:
Challenger 65C, 65D (2ZJ);
Challenger 65E (6GS);
Challenger 70C (2YL);
Challenger 75 (4CJ);
Challenger 75C (4KK);
Challenger 75D (5AR);
Challenger 75E (6HS);
Challenger 85C (9TK);
Challenger 85D (4GR);
Challenger 85E (6JS);
Challenger 95E (6KS) Agricultural Tractors;
MT116 (3YL);
MP73 (3YL);
MT73 (8KL);
MP116 (9HL);
MP128 (8ZL) Mobil-Trac Systems
Introduction
This instruction provides the necessary information for the removal of damaged axles from all Large Tillage Tractor minor bogie axle assemblies and the use of the 4C-8701 and 151-1273 Axle Installation Fixture Groups to install a new axle.
Illustration 1. Large Tillage Tractors
Challenger 65, Challenger 65B, Challenger 65C, Challenger 65D, Challenger 65E, Challenger 70C, Challenger 75, Challenger 75C, Challenger 75D, Challenger 75E, Challenger 85C, Challenger 85D, Challenger 85E, and Challenger 95E Agricultural Tractors.
NOTE: In this Special Instruction the term "large tillage tractor" refers to Challenger 65, Challenger 65B, Challenger 65C, Challenger 65D, Challenger 65E, Challenger 70C, Challenger 75, Challenger 75C, Challenger 75D, Challenger 75E, Challenger 85C, Challenger 85D, Challenger 85E, and Challenger 95E Agricultural Tractors.
The 4C-8701 Axle Installation Fixture Group accommodates the 3W-5775 Axle and 3W-5776 Seal Retainer, and the 8R-8780 Axle and 8R-9006 Seal Retainer on the 8R-9002 Axle Assembly. The 151-1273 Axle Installation Fixture Group accommodates the 8R-8780 Axle and 8R-9006 Seal Retainer on the 100-3153 Axle Assembly.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.
Reference: Service Manual SENR3335, Service Manual SENR5263, Service Manual SENR9439, Service Manual SENR4973.
NOTE: In addition to Large Tillage Tractors, the axle installation fixture groups will accommodate several mobile trac system (MTS) configurations.
Use the following chart to determine which axle installation fixture group accommodates Large Tillage Tractors and MTS configurations.
Axle Installation Fixture Group
Illustration 2.
4C-8701 axle installation fixture group shown, 151-1273 axle installation fixture group is similar.
The Axle Installation Fixture Group is required to accurately install the axle into the axle support.
The distance from the end of the axle to the axle support is critical.
The components for the 4C-8701 Axle Installation Fixture Group are:
The components for the 151-1273 Axle Installation Fixture Group are:
Nomenclature
Illustration 3.
This instruction refers to various parts of the axle assembly. The name used for each part is:
8. Support
9. Seal Retainer
10. Axle
11. "Support Boss" - The part of the support that the axle passes through.
Removal Of Damaged Axle From Axle Assembly
* Refer to the following Service Manual modules for the procedure to remove the Minor Bogie Axle Assembly from the tractor.
Illustration 4.
1. Place axle assembly in shop press as shown.
* The shop press should have a minimum capacity of 50 tons.
Illustration 5.
NOTE: Plates (A) must be in contact with the smaller face of the seal retainer (9). Otherwise, the retainer will deflect when force is applied to the axle causing the retainer to bind on the axle.
Illustration 6.
2. Use a welding torch with a heating tip to evenly heat support (8) and seal retainers (9) to 232°C (450°F).
Illustration 7.
* A 1U-8865 Infrared Thermometer may be used to check the temperature of the parts.
Illustration 8.
Illustration 9.
3. When they have reached the specified temperature, press the axle down through support (8) and seal retainers (9) until the axle is in the position shown in illustration 9.
| NOTICE |
|---|
DO NOT press axle (12) completely out of support (8). Axle (12) is not to be moved beyond the position shown in the illustration above. Pressing the axle beyond that point will damage the bores in support (8). |
Illustration 10.
4. Remove the axle assembly from the shop press and place it on a work table in the position shown.
The section of the axle that is exposed in the center of support boss (11) is to be removed
Illustration 11.
(B) First Cut. (C) Second Cut.
5. Cut the section out with a torch, fitted with a No. 3 cutting tip.
Make the cuts in the order and at the locations shown.
| NOTICE |
|---|
Care should be exercised to not damage the support boss when cutting the axle. Use less oxygen than normally used when making cuts. Rotate the axle rather than cutting completely through from one side. |
Illustration 12.
6. When the first cut is completed, remove the longer section of the axle from the support.
Illustration 13.
7. To provide better access for making the second cut, chamfer the cut end as shown.
Illustration 14.
8. Move the axle so that chamfered end fits into the open bore.
Illustration 15.
9. When the second cut is completed, lift out the cut-out section through the center opening in the support.
Illustration 16.
10. Remove the remaining section of axle from the support.
NOTE: Because of slag buildup on the end of the axle, it may be necessary to trim (chamfer) the end of the axle before removing it from the support.
Installation Of 3W-5775 Axle And 3W-5776 Seal Retainer, and 8R-8780 Axle And 8R-9006 Seal Retainer
NOTE: The axle must be chilled before installing it into the support. Place the axle in an insulated container and pack with dry ice. Chill the axle for one hour (60 minutes) prior to installing.
Illustration 17.
1. Smooth the bores in the support using a grinder fitted with an 8T-7767 Grinding Wheel (or equivalent).
Illustration 18.
2. Remove any rough edges or burrs from the inside of the bores.
Illustration 19.
3. Smooth both faces (13) of the support boss.
NOTE: A Go/No-Go gauge may be used to ensure the bores in the support have been adequately prepared (cleaned-up) to accept a new axle. Make the gauge from a discarded axle by machining the major O.D. Of the axle to 48.235 ± 0.025 mm (1.899 ± 0.001")
Illustration 20.
4. Adjust the depth of gauging sleeve (14). Use depth micrometer (15) to set the dimension to:
NOTE: If spacer assembly (2) is to be used at the gauging sleeve position, the depth setting must be made with the spacer in place as shown.
Illustration 21.
The setting is adjusted by loosening locknut (16) and turning bolt (17).
* After the setting is made, hold the bolt and tighten the locknut. Check the setting and readjust if necessary.
Use Of Spacer Assemblies
Illustration 22.
(D) Spacers. (E) NO SPACERS REQUIRED. Both axles removed. (F) TWO SPACERS REQUIRED. One axle removed. (G) ONE SPACER REQUIRED. One axle and seal retainer installed. In position to install second retainer.
The illustration above shows when spacer assemblies are required for the variations that may be encountered when replacing axles and seal retainers.
When using the 4C-8701 Axle Installation Fixture Group:
- * Use 4C-8696 and 4C-8697 Spacer Assemblies with 3W-5775 Axle and 3W-5776 Seal Retainer.
- * Use 4C-8698 and 4C-8699 Spacer Assemblies on the 8R-9022 Axle Assembly.
When using the 151-1273 Axle Installation Fixture Group:
* Use 142-1665 and 4C-8698 Spacer Assemblies on the 100-3153 Axle Assembly.
Illustration 23.
5. Install the required spacer assemblies (2) and (3) on the Axle Installation Fixture Assembly.
Position the axle assembly on the fixture so the end that is to receive a new axle is located above gauging sleeve (14).
6. With the axle assembly supported from overhead, swing (rotate) that end of the axle assembly away from the fixture a small distance so that it clears the fixture as shown.
Illustration 24.
7. Use a welding torch with a heating tip to evenly heat the support boss to 232°C (450°F).
A 1U-8865 Infrared Thermometer may be used to check the temperature of the boss.
Illustration 25.
8. When the support boss reaches the specified temperature, quickly swing (rotate) the axle assembly back onto the fixture.
Install the 8R-8831 Pin (4) into the pin boss and fixture, and remove the supporting chain sling.
NOTE: Pin (4) is more easily handled if an FT-2369 Handle Assembly (5) is installed in the end of the pin.
9. Remove the chilled axle (18) from the dry ice and install it into the support. The axle will drop through the bores in the support and down into the gauging sleeve.
Illustration 26.
10. Use an induction type bearing heater (19) to heat seal retainer (9) to 232°C (450°F).
Illustration 27.
11. Drop seal retainer (9) onto the axle.
Illustration 28.
12. Place FT-2335 Driver Assembly (6) over axle and strike with a hammer to fully seat the retainer onto the face of the support boss.
Illustration 29.
13. Flip (turn over) the axle assembly so that the boss with the new axle is at the opposite location on the fixture.
14. Heat seal retainer (9), as in Step 10, and install onto the axle.
Illustration 30.
15. Place FT-2335 Driver Assembly (6) over axle and strike with a hammer to fully seat the retainer onto the face of the support boss.
16. Refer to the following Service Manual Modules for the remaining steps to assemble and lubricate the bogie assemblies.
