Manitou DANA Axle 212 47983EN Repair Manual – PDF DOWNLOAD
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Manitou DANA Axle 212 47983EN Repair Manual – PDF DOWNLOAD
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Pages : 226
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Manitou DANA Axle 212 47983EN Repair Manual – PDF DOWNLOAD
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 operations, allows accurate work to be performed.All the information needed for correct disassembly, checks and assembly 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 presumed 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 proper 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.
TABLE OF CONTENTS:
Manitou DANA Axle 212 47983EN Repair Manual – PDF DOWNLOAD
INTRODUCTION ……………………………………………………………………………………………………………………. 7
VERSION TRACKING ……………………………………………………………………………………………………………………….. 8
MANUAL APPLICABILITY AND SUPPORTED MODELS ……………………………………………………………………….. 8
SPECIFICATIONS ………………………………………………………………………………………………………………….. 9
DEFINITION OF VIEWPOINTS ……………………………………………………………………………………………………….. 9
DATA PLATE ……………………………………………………………………………………………………………………………….. 9
CONVERSION TABLES …………………………………………………………………………………………………………………… 10
TORQUE SPECIFICATIONS …………………………………………………………………………………………………………….. 11
COARSE PITCH …………………………………………………………………………………………………………………………. 11
FINE PITCH ……………………………………………………………………………………………………………………………….. 11
WHEEL NUT TIGHTENING TORQUES ………………………………………………………………………………………….. 12
MAINTENANCE ……………………………………………………………………………………………………………………………… 13
MAINTENANCE POINTS …………………………………………………………………………………………………………….. 13
MAINTENANCE POINTS (HEAVY DUTY) ………………………………………………………………………………………. 14
OIL DRAINING MANDATORY PROCEDURE ………………………………………………………………………………………. 15
CENTRAL HOUSING ………………………………………………………………………………………………………………….. 15
PLANETARY GEAR REDUCTION …………………………………………………………………………………………………. 15
END-STOP PLIER SETTING …………………………………………………………………………………………………………….. 16
RETAINING SNAP RING FOR BORES ………………………………………………………………………………………….. 16
RETAINING SNAP RING FOR SHAFTS …………………………………………………………………………………………. 16
MAINTENANCE INTERVALS ……………………………………………………………………………………………………………. 17
LUBRICANT & SEALANT SPECIFICATIONS ………………………………………………………………………………….. 18
SAFETY PRECAUTIONS ………………………………………………………………………………………………………. 19
TRUNNION ………………………………………………………………………………………………………………………….. 21
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 21
DISASSEMBLY ………………………………………………………………………………………………………………………………. 21
ASSEMBLY ……………………………………………………………………………………………………………………………………. 21
CHECKING WEAR AND REPLACING THE BRAKING DISCS ………………………………………………….. 23
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 23
DISASSEMBLY ………………………………………………………………………………………………………………………………. 24
ASSEMBLY ……………………………………………………………………………………………………………………………………. 26
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 28
T1 …………………………………………………………………………………………………………………………………………….. 28
T2 …………………………………………………………………………………………………………………………………………….. 28
STEERING KNUCKLE ADJUSTMENT …………………………………………………………………………………… 29
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 29
DISASSEMBLY ………………………………………………………………………………………………………………………………. 30
ASSEMBLY ……………………………………………………………………………………………………………………………………. 31
(HEAVY DUTY) STEERING KNUCKLE ADJUSTMENT ……………………………………………………………. 33
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 33
DISASSEMBLY ………………………………………………………………………………………………………………………………. 34
ASSEMBLY ……………………………………………………………………………………………………………………………………. 36
DOUBLE U-JOINT ……………………………………………………………………………………………………………….. 39
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 39
DISASSEMBLY ………………………………………………………………………………………………………………………………. 40
ASSEMBLY ……………………………………………………………………………………………………………………………………. 42
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 44
T1 …………………………………………………………………………………………………………………………………………….. 44
T2 …………………………………………………………………………………………………………………………………………….. 44
4 Dana Incorporated ASM-0025E – 212 Axle Service Manual
PLANETARY REDUCTION GEAR …………………………………………………………………………………………. 45
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 45
DISASSEMBLY ………………………………………………………………………………………………………………………………. 46
ASSEMBLY ……………………………………………………………………………………………………………………………………. 50
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 54
T1 …………………………………………………………………………………………………………………………………………….. 54
T2 …………………………………………………………………………………………………………………………………………….. 54
T3 …………………………………………………………………………………………………………………………………………….. 55
T4 …………………………………………………………………………………………………………………………………………….. 56
T5 …………………………………………………………………………………………………………………………………………….. 56
(HEAVY DUTY) PLANETARY REDUCTION GEAR ………………………………………………………………….. 57
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 57
DISASSEMBLY ………………………………………………………………………………………………………………………………. 58
ASSEMBLY ……………………………………………………………………………………………………………………………………. 62
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 66
T1 …………………………………………………………………………………………………………………………………………….. 66
T2 …………………………………………………………………………………………………………………………………………….. 66
T3 …………………………………………………………………………………………………………………………………………….. 67
T4 …………………………………………………………………………………………………………………………………………….. 68
STEERING CYLINDER …………………………………………………………………………………………………………. 69
WRENCH DIMENSIONS OPTIONS …………………………………………………………………………………………………… 69
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 69
OPTICAL SENSOR AND MAGNETIC SENSOR …………………………………………………………………………………… 70
DISASSEMBLY ………………………………………………………………………………………………………………………………. 71
ASSEMBLY ……………………………………………………………………………………………………………………………………. 74
ADJUSTING THE STEERING ANGLE ……………………………………………………………………………………………. 80
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 82
T1 …………………………………………………………………………………………………………………………………………….. 82
T2 …………………………………………………………………………………………………………………………………………….. 83
(HEAVY DUTY) STEERING CYLINDER ………………………………………………………………………………….. 85
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 85
DISASSEMBLY ………………………………………………………………………………………………………………………………. 86
ASSEMBLY ……………………………………………………………………………………………………………………………………. 88
SPECIAL TOOLS ……………………………………………………………………………………………………………………………. 93
T1 …………………………………………………………………………………………………………………………………………….. 93
T2 …………………………………………………………………………………………………………………………………………….. 93
DIFFERENTIAL UNIT …………………………………………………………………………………………………………… 95
EXPLODED VIEW ……………………………………………………………………………………………………………………………. 95
DISASSEMBLY ………………………………………………………………………………………………………………………………. 96
ASSEMBLY ……………………………………………………………………………………………………………………………………. 98
HEAVY DUTY …………………………………………………………………………………………………………………………… 101
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 102
T1 …………………………………………………………………………………………………………………………………………… 102
T2 …………………………………………………………………………………………………………………………………………… 102
T3 …………………………………………………………………………………………………………………………………………… 103
ASM-0025E – 212 Axle Service Manual Dana Incorporated 5
BEVEL PINION …………………………………………………………………………………………………………………… 105
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 105
DISASSEMBLY …………………………………………………………………………………………………………………………….. 106
ASSEMBLY ………………………………………………………………………………………………………………………………….. 109
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 115
T1 …………………………………………………………………………………………………………………………………………… 115
T2 …………………………………………………………………………………………………………………………………………… 116
T3 …………………………………………………………………………………………………………………………………………… 116
T4 …………………………………………………………………………………………………………………………………………… 117
T5 …………………………………………………………………………………………………………………………………………… 117
T6 …………………………………………………………………………………………………………………………………………… 118
T7 …………………………………………………………………………………………………………………………………………… 119
T8 …………………………………………………………………………………………………………………………………………… 120
T9 …………………………………………………………………………………………………………………………………………… 120
MANUAL EMERGENCY RELASE ………………………………………………………………………………………… 121
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 121
RELEASE …………………………………………………………………………………………………………………………………….. 122
ADJUST ………………………………………………………………………………………………………………………………………. 123
MECHANICAL PARKING BRAKE ……………………………………………………………………………………….. 125
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 125
VIEWPOINT DEFINITION ……………………………………………………………………………………………………………….. 126
DISASSEMBLY …………………………………………………………………………………………………………………………….. 127
ASSEMBLY ………………………………………………………………………………………………………………………………….. 130
EXTERNAL HYDRAULIC NEGATIVE BRAKE ……………………………………………………………………….. 137
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 137
DISASSEMBLY …………………………………………………………………………………………………………………………….. 138
ASSEMBLY ………………………………………………………………………………………………………………………………….. 139
EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE …………………………………… 141
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 141
DISASSEMBLY …………………………………………………………………………………………………………………………….. 142
ASSEMBLY ………………………………………………………………………………………………………………………………….. 144
INCOMING DRUM BRAKE …………………………………………………………………………………………………. 147
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 147
DISASSEMBLY …………………………………………………………………………………………………………………………….. 148
ASSEMBLY ………………………………………………………………………………………………………………………………….. 150
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 152
T1 …………………………………………………………………………………………………………………………………………… 152
T2 …………………………………………………………………………………………………………………………………………… 153
4″ INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS) ………………………………………………………. 155
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 155
DISASSEMBLY …………………………………………………………………………………………………………………………….. 156
ASSEMBLY ………………………………………………………………………………………………………………………………….. 161
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 167
T1 …………………………………………………………………………………………………………………………………………… 167
T2 …………………………………………………………………………………………………………………………………………… 167
T3 …………………………………………………………………………………………………………………………………………… 168
NORMAL DIFFERENTIAL UNIT …………………………………………………………………………………………… 169
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 169
DISASSEMBLY …………………………………………………………………………………………………………………………….. 170
ASSEMBLY ………………………………………………………………………………………………………………………………….. 172
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 175
T1 …………………………………………………………………………………………………………………………………………… 175
T2 …………………………………………………………………………………………………………………………………………… 175
T3 …………………………………………………………………………………………………………………………………………… 176
T4 …………………………………………………………………………………………………………………………………………… 176
6 Dana Incorporated ASM-0025E – 212 Axle Service Manual
LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) …………………………………………………………… 177
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 177
DISASSEMBLY …………………………………………………………………………………………………………………………….. 178
ASSEMBLY ………………………………………………………………………………………………………………………………….. 181
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 185
T1 …………………………………………………………………………………………………………………………………………… 185
T2 …………………………………………………………………………………………………………………………………………… 185
T3 …………………………………………………………………………………………………………………………………………… 186
T4 …………………………………………………………………………………………………………………………………………… 186
HYDRAULIC DIFFERENTIAL LOCK …………………………………………………………………………………….. 187
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 187
DISASSEMBLY …………………………………………………………………………………………………………………………….. 188
ASSEMBLY ………………………………………………………………………………………………………………………………….. 191
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 194
T1 …………………………………………………………………………………………………………………………………………… 194
T2 …………………………………………………………………………………………………………………………………………… 194
HYDRAULIC NEGATIVE BRAKE …………………………………………………………………………………………. 195
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 195
DISASSEMBLY …………………………………………………………………………………………………………………………….. 196
ASSEMBLY ………………………………………………………………………………………………………………………………….. 200
INCORPORATED REDUCTION GEAR AND PINION 602 & 603 ……………………………………………… 207
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 207
DISASSEMBLY …………………………………………………………………………………………………………………………….. 208
ASSEMBLY ………………………………………………………………………………………………………………………………….. 212
SPECIAL TOOLS ………………………………………………………………………………………………………………………….. 215
T1 …………………………………………………………………………………………………………………………………………… 215
T2 …………………………………………………………………………………………………………………………………………… 216
T2A ………………………………………………………………………………………………………………………………………… 216
T2B ………………………………………………………………………………………………………………………………………… 217
T3 …………………………………………………………………………………………………………………………………………… 218
T4 …………………………………………………………………………………………………………………………………………… 219
T5 …………………………………………………………………………………………………………………………………………… 220
T6 …………………………………………………………………………………………………………………………………………… 221
COUNTER REVOLUTION SENSOR (DROP-IN TYPE) …………………………………………………………… 223
EXPLODED VIEW ………………………………………………………………………………………………………………………….. 223
DISASSEMBLY …………………………………………………………………………………………………………………………….. 224
ASSEMBLY ………………………………………………………………………………………………………………………………….. 224
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V