Carraro issued this 140-page repair manual under document number CA357358 as the factory book for its 20.19 front axle. The disassembly and assembly chapters take up the bulk of this Carraro 20.19 repair manual PDF, covering the sensor group, steering cylinder, epicyclic reduction gears, wheel hub, pinion and axle beam, plus separate ML and LS builds of the differential and its support. A troubleshooting chapter works from axle symptom to probable cause, and the special tools pages show the false pinion, false differential box and preload measurement tool your rebuild calls for. Set pinion to ring gear backlash at 0.15 to 0.20 mm, and heat bearings to 80 to 90°C before fitting them to their shafts. With the axle split on stands, nobody is around to ask. Bookmarked chapters take you straight to the right group, and the file goes wherever the machine is parked.
What's Inside This Carraro 20.19 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-11 | Manual Use, Information Property, Agreements and Definitions, Recommendations for Repair Operations |
| Safety Instructions | 12-16 | General Safety Recommendations, Safety Symbols, General Precautions |
| General Specifications | 17-37 | Intended Use, Product Identification, Technical Features, Oil Change and Checks, Grease in Assembly, Adhesive and Sealant, Tightening Torque |
| Sensor Group | 39-47 | Sensor Pin, Sensor Cover, Electrical Wires, Rubber Bush, Connector |
| Steering Cylinder Group | 48-53 | Pipe Fittings, Tie Rods, Steering Cylinder, Ball Joints, Cylinder Heads, Seal Rings |
| Epicyclic Reduction Gear Group | 54-57 | Planetary Carrier, Planetary Gears, Needle Bearings, Thrust Washers, Snap Rings, O-Ring |
| Wheel Hub Group | 58-67 | Wheel Carrier, Ring Gear, Bearing Cups, Bearing Cones, Seal Ring, King Pins, Belleville Washers |
| Flange Group | 68-70 | Flange, Pinion Shaft, Seal Ring, Lock Ring |
| Differential Support Group (ML) | 71-81 | Differential Carrier, Adjuster Ring Nuts, Ring Nut Retainers, Differential Housing, O-Rings, Bushes |
| Differential Support Group (LS) | 82-91 | Differential Carrier, Adjuster Ring Nuts, Ring Nut Retainers, Differential Housing, Bushes |
| Differential Group (ML) | 92-101 | Bevel Crown Gear, Differential Housing, Differential Cover, Piston, Disks, Counter Disks, Side Gear, Spider Gears |
| Differential Group (LS) | 102-105 | Disassembly, Assembly, Bevel Gear Marking Test, Inner Components, Planetary Gear, Spider Gears, Thrust Washers, Counter Disks |
| Pinion Group | 106-112 | Disassembly, Assembly, Pinion Components, Bearing Cups, Tapered Roller Bearing, Ring Nut, Preloading Measurement |
| Axle Beam Group | 113-117 | Disassembly, Assembly, Double U-Joints, Slinger, Seal Rings, King Pin Bush, Ball Bearing Cup, Pivot Bush |
| Toe-In/Steering Angle | 118-121 | Toe-In Adjustment, Steering Angle Adjustment, Mechanical Steering Stop, Linear Bars, Protractor |
| Testing After Assembly | 122 | Testing Methods, Axle Lifting, Gear Engagement, Wheel Rotation, Brake Regulation |
| Troubleshooting | 123-131 | Control and Examination of Faults, Axle Problems and Diagnosis |
| Special Tools | 132-135 | Drifts, Pads, Handles, Wrenches, False Differential Box, False Pinion, Puller, Preloading Measurement Tool |
| Service Operations Time | 136-140 | Service Operations Time Schedule |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Bevel gear set backlash | 0.15÷0.20 mm | p. 20 |
| Bearing assembly temperature | 80°C - 90°C | p. 10 |
| Pinion-ring gear backlash | 0.15÷0.20 mm | p. 76 |
| Tightening torque | 10 Nm | p. 36 |
| Bearing cup dimension A | 25.100 ÷ 25.300 mm | p. 64 |
| Differential locking engagement feed port pressure | 13÷15 bar | p. 79 |
| Dry weight (CA641391) | 362 kg | p. 20 |
| Dry weight (CA641392) | 357 kg | p. 22 |
| Differential feed pressure | 20 bar | p. 20 |
| New friction plate thickness (ML) | 2.5 ± 0.05 mm | p. 21 |
| Worn plate minimum thickness (ML) | 1.8 mm | p. 21 |
| New separator plate thickness (ML) | 1.5 ± 0.07 mm | p. 21 |
Carraro 20.19 Common Problems This Manual Covers
Carraro 20.19 front axle noise while steering, intermittent or constant noise while driving or in neutral
Check whether the noise changes when steering, driving or coasting in neutral, using the diagnosis section starting on page 123. Inspect the double U-joints and king pin bushes following the axle beam procedure on page 112. Measure pinion-ring gear backlash against 0.15 to 0.20 mm on page 76 before condemning gears.
Manual Section: Troubleshooting p. 123Front axle differential lock system selected with feed pressure applied but no differential action
Test the differential locking engagement feed port by applying oil at 13 to 15 bar for 3 minutes and check for leakage, following page 79. Remove the differential and measure the ML friction plates against the 1.8 mm worn minimum on page 21; new plates measure 2.5 ± 0.05 mm.
Manual Section: Differential Support Group (ML) p. 79Front wheel hub bearing cups and cones worn, wheel vibration felt during forward drive
Inspect the wheel hub bearing cups and cones following the wheel hub procedure on page 57 and replace any worn set. Heat new bearings to 80°C to 90°C before fitting them on their shafts, as stated on page 10. Verify bearing cup dimensions against the values listed on page 64.
Manual Section: Wheel Hub Group p. 57Toe-in or steering angle out of adjustment, steering difficulty and uneven tyre wear
Check toe-in with the linear bars and adjust following the procedure on page 117. Measure steering angle with a protractor and set the mechanical steering stop to match. Inspect tie rods, ball joints and steering cylinder seal rings following page 47, and replace worn ball joints before resetting toe-in.
Manual Section: Toe-In/Steering Angle p. 117Axle flange leaking oil past the seal ring and flange spline showing wear
Remove the lock ring and flange following page 67 and inspect the flange spline and pinion shaft for wear. Fit a new seal ring on reassembly, and replace the flange if the spline is worn. Refill the axle and keep to the 1500 hour oil change interval on page 32.
Manual Section: Flange Group p. 67Ring gear and pinion teeth pitted, overheated or broken, with excessive transmission noise
Replace the bevel gear set and set pinion preload with the preloading measurement tool following page 105. Check pinion-ring gear backlash against 0.15 to 0.20 mm using the adjuster ring nuts on page 76, then run the bevel gear marking test before closing up the differential.
Manual Section: Pinion Group p. 105Frequently Asked Questions
What are the replacement specifications for the axle pivot pin bush on the Carraro 20.19 front axle?
The axle beam group uses a pivot bush (D5) which has a replacement time of 30 minutes. When replacing the bush (11) in the axle beam (7), use the special tool CA715966 and a hammer. p. 117
What are the replacement specifications for the lower kingpin on the Carraro 20.19 front axle?
The replacement of the king pin (A11) takes 30 minutes. When reassembling the lower king pin (25), grease the housing with specific grease and position the belleville washers (33) and (35) on the king pin housings. p. 63
What is the differential oil capacity for the Carraro 20.19 axle?
The differential oil capacity for the Carraro 20.19 axle is 8.5 liters (8.5 litri/litres). p. 20
What oil specification is recommended for the Carraro 20.19 front axle?
The recommended oil specification for the axle is API GL4/GL5, respectively MIL-L-2105/2105 D. Always use recommended oil enriched with additives. p. 20
Is this Carraro 20.19 manual a download or a disc?
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