Task Sheet Printed: 12/12/12 Page 1 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Resources Ownership

People Required: 1 Author:

Task Time (mins): 0.00 Authorised By:

DRAFT - NOT
Warnings

FOR
Safety Gloves Eye and Ear Low Harmful or Hot Surface
Protection Temperature irritant materials Hazard

Cutting hazard

Tools Used
Lubricants
PRODUCTION Copper Grease
Hammers Hammer 2Lb Ball pein
Screwdirvers 8mm Flat

USE
Hex Keys 5/16" ½" Drive
Miscellaneous Centre punch
Measuring Equipment HN433 1.246" thick straight edge

0PLI7831 15007650 SHIM 2

9419496 NUT 24 15007651 SHIM 2
9113457 LOCKWIRE (MULTIPLE ISSUES 2 9245142 LOCK 2
25GRAM (=100^) 9245234 ADJUSTER 2
139191 SET SCREW 3
15007634 HOUSING 1
223775 BOLT 24
15007623 BRG ASM 1
271567 BOLT 14
9428202 BEARING ASSY-LIST OUT PART 2
15019463 GEAR SET 1
15007624 BRG ASM 1
9114897 SCREW 4
15337440 BODY ASSEMBLY DIFFERENTIAL 1
9170517 BOLT 4
15000417 SEAL OIL 1
15007635 RETAINER 1
15007646 SHIM 2
15007647 SHIM 2
15007648 SHIM 2
15007649 SHIM 2

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 2 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Warning
1 For operation below heat resistant hand
protection must be worn.
Collect Parts

DRAFT - NOT
Remove bearings 15235836 and 15235837
from swip cart and place in freezer.

Bearings cups require to be in freezer

no less that 8 hours before they are
fitted.

FOR
Warning
2 For operation below heat resistant hand
protection must be worn.
Collect Parts
Remove Bearing cones 15235835
and 15235837 from swip cart and place in
hot oven.

PRODUCTION
Bearings require to be in oven for
approximately of 30 minutes before they
are used.

PartCode PartDesc Qty

3 15019463 GEAR SET 0

USE
Collect Parts
Remove pinion gear from box gear set
15019463 supplied from stores and place
on work bench
Record
Record the ID number on the work sheet.
Example = M1 21.

Rotate
4 Rotate The pinion to position shown.

Record
Record GD size on work sheet.
See photo for locations.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 3 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Wash
5 Wash pinion gear from top to bottom with
loctite 7076 cleaner.
Wipe off excessive cleaner with a clean
cloth and allow to dry.

DRAFT - NOT
FOR
Quality Control
6 Inspect bearing surfaces on pinion for
damage I.E Dents or marks.
Dress up any light marks if present.
If damage cannot be repaired Report issue
to line team leader .

PRODUCTION
PartCode PartDesc Qty
7 15007635 RETAINER 0

USE
Warning
For operation below heat resistant hand
protection must be worn.
Collect Parts
Remove retainer 15007635 from pallet that
is supplied by machine shop and place in the
parts washer.
Wash
Wash reatainer in Hot water wash for 5
minutes

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 4 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Warning
8 For operation below heat resistant hand
protection must be worn.
Blow

DRAFT - NOT
Blow dry the retainer

Place
Remove from parts washer and lay it on the
work bench.

FOR
Warning
9 For operation below heat resistant hand
protection must be worn.
Assemble
Remove Bearing cup 15235836 ( the larger
of the two) from freezer, and fit in to retainer
With the taper side facing up as per photo.

PRODUCTION
Visual Check
Once fitted ensure the cup is resting on the
retainer shoulder all the way round.

PartCode PartDesc Qty

10 15000417 SEAL OIL 1

USE
Collect Parts
Place seal installer G32859 bench

Wipe
Wipe clean face of tool with a clean cloth

Collect Parts
Remove seal 15000417 from cart.

Insert
Clean seal with a clean cloth.
fit seal to driver as shown on photo

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 5 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Apply
11 Apply a light coating of loctite 5922 to outer
face of seal as per photo.

DRAFT - NOT
FOR
Insert
12 Insert tool and seal into retainer as shown in
photo

PRODUCTION
Push
13 Drive seal home by chapping the tool with a

USE
large drift as shown.

Remove
14 Remove tool and store

Visual Check
Check the seal is full installed and remove
any excess loctite.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 6 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Rotate
15 Rotate pinion assy into position shown

Warning

DRAFT - NOT
Before carring out next task heat
resistant gloves must be worn
Remove
Remove small bearing 15235837 from oven
and position it on to pinion as shown
Visual Check
Ensure the bearing is seated properly on

FOR
shaft.

Rotate
16 Pinoin gear in position shown.

Warning
For operation below heat resistant hand

PRODUCTION
protection must be worn.
Heat
Remove large bearing 15235835 from hot
oven and install to pinion as shown
Visual Check
Ensure the bearing is correctly seated on the
pinion

USE
Chap it down into position if required with a
drift and hammer.
Cool
Allow the bearing to cool and shrink on to the
pinion before moving it

PartCode PartDesc Qty

17 9245234 ADJUSTER 2

Collect Parts
Remove bearing adjusters 9245234 from
pallet and take them to work bench.
Debur/File
With a file remove ragged edges from the
start of the threads on both adjusters

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 7 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Consumables: Lubricants
18 Copper Grease

Apply
Apply a light coating of copper slip grease

DRAFT - NOT
on to threads of both adjusters..

FOR
Lift
19 Attach lifting tackle J00037108 to tapped
hole in top of housing 9253506, Then lift it off
the pallet using the overhead crane.

PRODUCTION
Place
20 Place the housing on cardboard on the floor

USE
in position shown

Measure
21 Using a large mic (19"-20") measure across
the machined faces of the bearing caps as
shown.
Mark
Record dimensions on work sheet.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 8 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Hand Tools: Hammers

22 2Lb Ball pein Hammer
Hand Tools: Miscellaneous
Centre punch

DRAFT - NOT
Mark
With a centre punch and a hammer teep one
bearing cap with 2 dots and then teep 2 dots
below on the housing

FOR
Loosen
23 Loosen And remove the bolts from the end
caps using 1 x 1x1/2 inch 3/4 drive socket
with a 3/4 drive air gun.
Remove
Remove both bearing caps by knocking
them with a large drift as shown.

PRODUCTION
Place
Place the parts to one side as they are not
required utill later.

Lift
24 Attach lifting sling J3701 to housing as

USE
shown.
Attach sling to overhead crane.

Wash
25 Lift housing into hot water washer.
Remove sling.
Wash housing for 10 minutes.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 9 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Warning
26 Before carring out next task heat
resistant gloves must be worn.
Assemble

DRAFT - NOT
Assemble lifting tackle tool J00037108 onto
housing
Lift
Lift housing up right by attaching overhead
crane to lifting tackle.
Then allow the housing to drain.

FOR
Blow
27 Blow dry housing

Lift
Lift housing out of hot water wash.

PRODUCTION
Insert
28 Insert housing into assy stand

USE
Allign
29 Allign holes in housing with holes in assy
stand.
Using bolts that are on the stand, Insert one
bolt through top hole as shown and secure
with nut.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 10 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Remove
30 Remove tooling and store.

Rotate

DRAFT - NOT
Rotate stand into position shown.

Allign
Allign housing with holes on assy stand.
insert and secure the second bolt on bottom
of the housing.
Tighten both bolts that hold housing to assy

FOR
stand.

Debur/File
31 Remove any marks on mounting face with a
file as per photo.
If the damage is excessive report it to the
team leader.

PRODUCTION
Visual Check
32

USE
Check all oil galleries are clear from
obstrucuion.
Clear any obstructions if found.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 11 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Mark
33 MARK SERIAL NUMBER ON HOUSING AS
FOLLOWS

Diff part number 15337441

DRAFT - NOT
Diff ratio = 2.16:1
Terex Newhouse = TN
Month of build A = January B = febuary and
so on (the letter I is not used as it may lead to
confusion)
Build sequence number ETC 1 first one built
in that month 2 second diff built that month

FOR
Year of build 2012 = 12

Lift
34 Attach lifting shackle J3914 to crown wheel
15019463 Lift it from pallet and place it into

PRODUCTION
hot water washer

35
USE Visual Check
Check the ID numbers on the crown wheel
match the numbers on the pinion gear as
recorded earlier

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 12 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Wash
36 Wash crown wheel in hot water washer for 5
minuits.

DRAFT - NOT
FOR
Blow
37 Blow dry the crown wheel before lifting it from
the washer.

PRODUCTION
Lift
38 Lift crown wheel from hot wash and lay on

USE
assembly jig.
Allign
Lower crown wheel on to assy jig
Allign the crown wheel in the centre of the jig
as shown.

Tighten
39 Secure crown wheel to jig with the 4 fixing
points using a 1" 5/16 AF spanner.
Remove
Remove lifting tackle and store.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 13 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Collect Parts
40 locate plane and flange 15019476 from
pallet
Lift

DRAFT - NOT
Attach sling J3702 as per photo and lift with
over head crane.
Warning
Before removing assembly from washer
heat resistant gloves must be worn
Wash
Wash assembly in hot washer for 5 minutes.

FOR
Blow dry with air duster and lift assy to work
bench

Warning
41 Allow asembly to cool down before handling

Disconnect
Remove retaining bolts and seperate

PRODUCTION
caseings as shown.
Lay the parts on the bench as shown.

USE
Collect Parts
42 sorce washer 15334185 x 2 and pin dowl
15334410 x 4 from parts racking.
Lay both washers face down on a clean work
surface.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 14 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Insert
43 Insert dowels 15334410 into washer with
tappered edge facing up.
Insert

DRAFT - NOT
Fully drive the dowel home until they are level
with the bottom face of the washer, as shown
on photo.
Repeat
Repeat task as above with all 4 dowels.

FOR
Wipe
44 Wipe clean the washer and pin assembly.

Repeat
Repeat the task above with the other half of
the housing.
Insert

PRODUCTION
Insert the assy into the housing and drive the
pins into the housing until they are just bellow
the washer face.using a hammer and small
punch.
Wipe
Wipe clean washers on both housings

USE
Lubricate
45 Apply a light coating of gear oil to washers in
both housings.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 15 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

46
:

DRAFT - NOT
Safety
Before carring out task below heat resistant hand protection must be worn.

Collect Parts
Place 4 bearings part number 137393 into oven for a minimum of 15 minutes.

FOR
Collect Parts
47 source 2 side gears 9272352 from cart.

Insert
Insert 1 of the gears into the large housing
and check it for free rotation, as shown in
photo

PRODUCTION
Collect Parts
48 Source spider 9272346 x 1 and gear
9272386 x 4 from cart.

USE
Insert
Position spider and 1 gear in position shown
in photo.

Safety
49 Before carring out task heat resistant hand
protection must be worn.
Place
Remove 1 of the bearings from the oven and
fit it to the spider with the taperface down

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 16 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Repeat
50 Repeat the above process and fit all the
gears and bearings as shown in photo

DRAFT - NOT
FOR
Allign
51 Align spider assy in housing as shown.

Slide
Position the bearings against the housing by
chapping them into position with a punch and
a hammer.

PRODUCTION
Repeat the process untill all bearings are
positioned against the housing.

Place
52 The other side gear on top of assy as shown.

USE
Lubricate
Apply a light coating of gear oil over the
gears.

Assemble
53 Lift the top caseing on to the bottom part and
ensure the casing ID marks line up.

Tighten
Tighten both casings together with the bolts
that were removed when the cases were
split.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 17 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Visual Check
54 Insert tool STDPD1171 into housing and
rotate the tool.
The tool should rotate freely.
If the tool is difficult to turn strip down

DRAFT - NOT
assy and repair issue.
Rebuild and test

FOR
Apply
55 Apply a light coating of loctite 648 to face of
crown wheel.

PRODUCTION
Lift
56 Attach lifting tool MLT161 through center of

USE
housing as shown.Lift the housing off the
bench with the over head crane.

Insert
57 Insert housing in to crown wheel as shown.

Allign
Align the holes up with the holes on the
crown wheel

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 18 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Insert
58 Insert bolts 223775 up through the bottom
and nuts 9419496, 1 at 12 o'clock position
and 1 at 6 o'clock positon
Tighten

DRAFT - NOT
fit both bolts but do not fully tighten at this
stage
Remove
Remove lifting tackle and store.

Rotate
Rotate assembly 180deg

59 FOR PartCode
223775
PartDesc
BOLT
Qty
14

Insert
Insert 22 bolts 223775 in to housing.

PRODUCTION
Allign
Allign all the bolt heads with the flats on the
heads are facing the housing as shown.

USE
Assemble
60 Position fixture J2015 over housing
Secure fixture to housing with 4 off bolts
9430926
Rotate
Rotate full assembly 180deg.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 19 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

PartCode PartDesc Qty

61 9419496 NUT 24

Assemble
Fit nuts 9419496 x 24 to the bolts.

DRAFT - NOT
Torque the 24 nuts with J127 torque driver to
515lbs/lb.

FOR
Rotate
62 Rotate the assembly 180 degress

Remove
Remove fixture J2015 from housing and
store.

PRODUCTION
Wash
63 Wash 8 off bolts 9430296 with loctite 7063

USE
cleaner
Blow
Blow dry all bolts.

Apply
Loctite 277 to all 8 bolts.

Assemble
64 Fit 4 of the bolts into the plane and flange
and tignten the with a 3/4 drive air gun and a
1" 1/8 3/4 drive socket.
Remove
Remove the bolts that were fitted without
loctite, and store
Assemble
Fit the other remaining 4 bolts in to housing.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 20 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Torque
65 Torque all 8 bolts to 280lbs/ft using torque
tool RDFTW1.

DRAFT - NOT
FOR
Visual Check
66 Insert tool STDPP1171 into housing and
check the assembly for free rotation.
Should ther be a problem contact your team
leader.

PRODUCTION
67

USE
:

Warning
Before carring out next task heat resistant gloves must be worn.

Collect Parts
From cart place 2 cone bearings 9428203 in hot oven for 30 minuits.

Warning
68 Before carring out next task heat
resistant gloves must be worn.
Assemble
Remove 1 bearing 9428203 from hot oven
and fit to houising with large area to bottom.
Allow it to cool for approx 3 minuites.
Rotate
Rotate the assembly 180 degrees and fit the
second bearing.
This assemble is now complete.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 21 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Insert
69 Insert dummy cup with shim pack of 0.060
inches into main diff housing.

DRAFT - NOT
FOR
Assemble
70 Assemble lifting tackle J3329 on to top of
pinion gear assembly.
Lift pinion gear assembly with over head
crane

PRODUCTION
Assemble
71 Secure assembly to housing with bolts

USE
271567 x 7.evenly spaced.
Torque
Torque all bolts to 115lbs/ft with torque tool
RDFTW2

Rotate
72 Rotate the assembly 180 degrees.

Visual Check
Check bearing cap faces are clean and free
of damage.
Dress any ragged edges if present with a file
as shown.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 22 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Calibrated Equipment: Measuring Equipment

73 1.246" thick straight edge HN433

Place
Lay a straight edge across the end cap

DRAFT - NOT
faces as shown.

FOR
Measure
74 With a dept mic measure the distance from
the end of the pinion gear shaft to the straight
edge.
record this dimension on the worksheet.

PRODUCTION
75

USE
:

Info
Calculations for shim pack

Record above dimension as dimension A

Record the dimension etched on pinion as dimension B
Shim pack (0.060) under dummy cup as dimension X
Measure the thickness of the straight edge as dimension C
Dimension X + B-C-A = shim pack size required

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 23 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Remove
76 Remove all measuring equipment from
housing and store safely
Rotate

DRAFT - NOT
Rotate assembly 180 degrees.

FOR
Remove
77 Remove the 7 retaining bolts and lift the
pinion assy out of the housing and lay on
bench.

PRODUCTION
PartCode PartDesc Qty
78 15007646 SHIM 0

USE
15007647 SHIM 0
15007648 SHIM 0
15007649 SHIM 0
15007650 SHIM 0
15007651 SHIM 0

Remove
Remove the dummy cup and shims.
fit shims to dimensions calculated in
previous task into housing.
Warning
Before doing the next task heat resistant
gloves must be worn.
Collect Parts
Remove bearing cup 9428206 from freezer
and fit to housing.
Drive the cup home using a large drift as
shown.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 24 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Lift
79 Lift pinion assembly from bench and refit to
housing.
Secure housing with 7 bolts as before.

DRAFT - NOT
FOR
Torque
80 Torque all 7 bolts to 115lbs/ft with torque tool
RDFTW2.

PRODUCTION
Remove
81 Remove 5 bolts from housing and leave two

USE
in position shown.

Measure
82 Calculations
Measure the gap between the the retainer
plate and the housing adjacent to the bolts
on both sides record the measurements on
both sides add them together and divide by
2 and add 0.019 inches to give shim pack
required.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 25 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Remove
83 Remove the two remaining bolts and remove
the pinion assembly and lay it on the work
bench.
Place

DRAFT - NOT
Place shim pack on housing lining up the
dowel holes and oil ports.
Refit pinion assembly and secure retainer
plate to housing with 7 bolts as before.
Torque all the bolts evenly to 115lbs/ft using
torque tool RDFTW2.

FOR
Place
84 Attach a dial gauge and magnetic mount on
to the retainer plate as shown
Measure
To measure the axial end play of the pinion
gear.rest the tip of the gauge against the

PRODUCTION
spline shaft and zero the gauge.
Push the shaft side to side and record the
maximum dimensions.
The minimum and maximum dimensions are
0.001 to 0.003 inches
If the dimensions are out add or remove
shims from the pack as necessary to obtain
the correct dimensions.

85
USE Remove
Remove the guage and mount and store in a
safe location.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 26 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Remove
86 Remove the retaing bolts lift out the pinion
gears assembly and lay aside.

DRAFT - NOT
FOR
Remove
87 Remove the shim pack.

Apply
Apply a thin layer of loctite 5922 to the face
of the housing,as shown
Fit the first shim and repeat the process of

PRODUCTION
applying a thin layer of loctite and continue
doing it to all shims in pack, rembering to
line up the dowel holes and oil holes.

Insert
88 Insert the pinion assembly into housing

USE
Remove
Remove lifting tackle from assembly and
store.

PartCode PartDesc Qty

89 271567 BOLT 14

Wash
Prep the bolts by washing them with loctite
cleaner 7063 ,then allow them to dry, then
apply loctite 277 to the threads.
Torque
Torque 12 of the 14 bolts leaving 2 loose as
shown in photo.
Torque the 12 bolts to 115lbs/ft with torque
bar RDFTW2.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 27 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Apply
90 Apply sentre seal to the 12 bolts that were
torqued.

DRAFT - NOT
FOR
Hand Tools: Hex Keys
91 ½" Drive 5/16"

Assemble
Fit Three 139191 screws into housing and
tighten.

PRODUCTION
Hand Tools: Hammers
92 2Lb Ball pein Hammer

USE
Hand Tools: Miscellaneous
Centre punch

Mark
With a centre punch and hammer punch
edges of bores in two places on both plugs
fitted in retainer. see photo

Hand Tools: Screwdirvers

93 Flat 8mm

Insert
On tapped holes at top and bottom of
housing insert screw 139230 in both.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 28 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

94
:

DRAFT - NOT
Assemble
Assemble dummy yoke to pinion shaft assemble and tighten bolts to shaft.

Assemble
95 Assemble handel to dummy yoke as per
photo

FOR
96
PRODUCTION Place
Place bearing cup 9427249 on top of plane
and flange housing as shown.

USE
Insert
97 Insert short sling 3701 through the centre of
the housing as shown

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 29 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Assemble
98 Pull the sling all the way through the housing.
slide the second cup with the sling through
the middle of the cup and thread a large drift
through the loop in the sling.

DRAFT - NOT
as shown in photo.

FOR
Lift
99 Lift the sling up until the cup is against the
bearing
Remove
Remove the 4 clamps that hold the assembly
to the assembly stand.
now lift the assembly out of the stand and lay

PRODUCTION
it on the floor.

Remove
100 Remove the bar and short sling and store

USE
Lift
Attach the long sling 3702 through the
housing as shown in photo.
Lift the assembly as shown in photo.

Place
101 Place assembly on housing as shown.
Remove sling and store

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 30 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Assemble
102 Fit bearing caps to housing ensuring they
are lined up with the dots that was teeped in
an earlier task.
Fit the bolts that were removed with the caps

DRAFT - NOT
and tighten them.

FOR
Assemble
103 fit bearing adjuster into both sides of bearing
caps.
Screw 1 adjuster fully home until the bearing
is full seated.the back it off a 3 turns.
Screw the outer adjuster fully home until the
bearing is fully home.

PRODUCTION
Setup
Screw the adjusters shown in photo until the
crown wheel is full against the pinion gear
and no backlash is present.
Screw the other adjuster in until it goes tight.

Assemble
104 Attach dial gauge and mount to housing with

USE
dial gauge resting on crown wheel tooth as
shown

Measure
105 Lock the handle on the yoke against the
assembly stand.
Using a flat bar adjust the bearing adjusters
in or out to obtain a backlash of 0.016 to
0.022 inches By rocking the crownwheel
back and forth.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 31 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Assemble
106 When the backlash has been obtained trial fit
the bearing adjuster lock plates 9245142
x2 with bolts 9170517 x 4
Readjust the bearing adjusters if necessary

DRAFT - NOT
to fit the lock plates.
Recheck the backlash if adjustment was
made.

FOR
Torque
107 Torque the 4 bearing caps to 695lbs/ft with
torque tool RDFTW3

PRODUCTION
Remove
108 Remove both reatiner lock plates

USE
Measure
Measure the distance between the end caps
as shown,(pre-load)
Example
First reading taken in earler task =19.412
inches
Reading taken now = 19.415 inches
differance = 0.003 inches
maximum aloud = 0.005 inches
If it is over the max size contact team leader.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 32 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Rotate
109 Rotate the assembly 90 degrees

Assemble

DRAFT - NOT
Fit dial gauge and mag mount to assembly
with gauge resting on rear of crown wheel as
shown
Measure
Rotate the handle on the yoke and mearure
the maximum run out recorded,this should
not exceed 0.005 inches.
If the run out is not within spect contact team

FOR
leader.
If run out is ok remove mic and mount and
store.

Apply
110 Apply engineers blue onto the front and rear
of 2 teeth on the cronwheel as shown.

PRODUCTION
111
USE Visual Check
With assistance from another TM locate the
resistance shaft between the crownwheel
and the housing,push down on the shaft while
the other TM rotates the handel fixed to the
yoke 10 times in both directions.
Remove the shaft and store.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 33 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Visual Check
112 Check pattern on crown wheel teeth to
ensure the pattern is central as shown in
photo.
Should the pattern be out of spec the diff will

DRAFT - NOT
have to be stripped and pinion will have to
be reshimmed.

FOR
PartCode PartDesc Qty
113 9113457 LOCKWIRE (MULTIPLE ISSUES 25GR 1

Insert
Thread lock wire through the bolt head twist
wire with pliers then thread through the
second bolt and tie off.
Repeat process with the other side.

PRODUCTION
Assemble
114 Refit the lock plates with bolts that were

USE
removed in a previous task to both sides.

Torque
Torque the 4 bolts to 24lbs/ft with torque bar
RDATW4.
Then lock wire the bolts as shown.

Remove
115 Rotate assembly to position shown.
Remove the handel and bolts from the
dummy yoke.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 34 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Assemble
116 Assemble lifting tackle MLT420 to housing.

Remove

DRAFT - NOT
Remove the nuts and bolts that clamp the
housing to the stand.

FOR
Lift
117 Lift Assembly from stand and Secure it to the
test rig with the 4 bolts and nuts that are on
the rig.
Remove
Remove lifting tackle and store.

PRODUCTION
Rotate
118 Rotate test rig 180 degrees to position

USE
shown.
Connect
Connect the driveline to the yoke with the
bolts that are on the rig.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.
 Task Sheet Printed: 12/12/12 Page 35 of 35

Task TR100 Standard Diff sub assembly Task ID: 1524 Version: 1
Name: Task Ref: SRD

Validity: Applies to: TR100 OPLI783 & OPLI883.  Effectivity 2.2.12 to 5.3.12.  Author: Stephen Bradley

Warning
119 Before carring out the test the saftey
guard must be down.
Info

DRAFT - NOT
Test
Operate the test rig in forward for 5 minutes
then 5 minutes in reverse.
While it is operating listen for any strange
noises. Report any strange noises to the
team leader.
Visual Check
Check the input seal at the yoke for leaks.

120 FOR Disconnect

Disconnect the driveline.

Rotate
Rotate the rig into position shown and attach

PRODUCTION
lifting bracket MLT420.
Drain
Remove the bolts that hold the housing to the
rig.
Lift the housing clear of the oil and allow to
drain.

USE
121
:

Wait
Wait until the housing has drained,then remove from the rig and place it in the basket to be shipped to
the next area.

Remove
Remove the lifting tackle and store.

This document and its contents are Confidential and for Terex use only.
No part maybe copied or used without prior written authorization from Terex .
Terex operates a policy of continual improvement, this document is therefore subject to change without prior notification.