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GENERAL WORKSHOP MANUAL

RÁBA 360

SINGLE REDUCTION REAR AXLES

RÁBA FUTÓMŰ Kft. H - 9002 GYŐR P.O.B. 141 HUNGARY TEL.: 36/96/622-000, 36/96/624-654

FAX: 36/96/624-900 E-mail: [email protected]

D2.4.0103.C.2003-1

MR25135-5-0

1

SECTION 202. CONTENTS PAGE SECTION FOREWORD 5 203

DRAWINGS OF THE AXLES 6 204

TECHNICAL DATA 11 205

Data 11

Wheel brake 13

Rolling bearings 15

Seals 15

TORQUE RATINGS 16 206

Wheel hub 16

Wheel brake 16

Differential carrier head 17

ADJUSTMENT DATA 18 207

Wheel brake 18


MR25135-11-0

2

SPECIAL TOOLS 19 208

Wheel hub 19


Listed according to drw. no. in increasing ordrer 23

Puller and pilot bolts 25

GENERAL SERVICE INSTRUCTIONS 26 209

Wheel hub 26

Wheel brake 26


General instructions 27

Application of "LOCTITE" bolt securing materials 28

WHEEL HUB 29

SECTIONAL VIEWS OF THE WHEEL HUB AND 30 210

THE WHEEL BRAKE

PARTS OF THE WHEEL HUB AND THE WHEEL BRAKE 31 211

REMOVING AND REINSTALLING THE WHEEL DISK 31 212

MR25135-11-0

3

REMOVING AND REINSTALLING THE AXLE SHAFT 32 219 REMOVING AND REINSTALLING THE WHEEL HUB 33 223

DISASSEMBLING AND REASSEMBLING THE WHEEL HUB 34 224

REMOVING AND REINSTALLING THE BRAKE DISK 35 225

GENERATING RING GUID -PLATE REMOVING AND

REINSTALLING 35 228 INSTALLATION INSTRUCTIONS FOR PARTS 36 229

OF ANTIBLOCKING SYSTEM DISK WHEEL BRAKE 39 REMOVING AND REINSTALLING THE SLIDING

SADDLE-BACKED DISK BRAKE TYPE PERROT 40 262/1 REMOVING AND REINSTALLING THE HYDRAULIC

DISK BRAKE TYPE MERITOR 41 262/2

DIFFERENTIAL CARRIER ASSEMBLY 43

DIFFERENTIAL CARRIER ASSEMBLY SECTIONAL VIEWS 44 310

PARTS THE DIFFERENTIAL CARRIER ASSEMBLY 46 311

REMOVING AND REINSTALLING THE DIFFERENTIAL 47 312

CARRIER ASSEMBLY

REMOVING AND REINSTALLING THE 47 313 COMPANION FLANGE, REPLACING THE OIL SEAL

REMOVING AND REINSTALLING THE DIFFERENTIAL, 49 314

ADJUSTING THE BACKLASH AND THE CONTACT PATTERN MR25135-11-0

4

DISASSEMBLING AND 53 315 REASSEMBLING THE DIFFERENTIAL

REMOVING AND REINSTALLING THE BEARING CAGE, 55 316 ADJUSTING THE AXIS DISTANCE

DISASSEMBLING AND REASSEMBLING THE 57 317 BEARING CAGE

OIL FILL-UP, RUN, CHECK 66 395

MR25135-11-0

5

SECTION 203.

FOREWORD This production "GENERAL WORKSHOP MANUAL" was prepared for workshops and contains all the

necessary assembly instructions as well as data to be checked and adjusted during repair, with the knowledge of which repair and adjustment of the

RÁBA 360 type axles can properly be performed. For technical data on the specific type versions of the RÁBA 360 type axles refer to the publication "TECHNICAL DATA", while for the spare parts of that "PARTS CATALOG" grouped according to the Orderers. The " GENERAL WORKSHOP MANUAL " contain divided into sections the technical data and the service instructions of the axle. The sections of the service instructions contain the disassembly and reassembly operations of the individual assembly unit, stating the special tools to be used. The order of the sections is determining the oder of the mounting. The serial numbers of the figures are started from the beginning in each section. The item numbers of the figures for an assembly unit are referred to in each section dealing with the assembly procedures. For service operations it is recommended to use the tools shown in the figures in order to assure proper assembly of the individual units. The figures show each essential service operation stating the designation of the tool and its service position. The tools can be fabricated in the workshop according to the tool blueprint ordered on basis of tool number list supplemented to the " GENERAL WORKSHOP MANUAL " or can be ordered from RÁBA.

The manufacturer shall not be liable for warranty claims on damages resulting from negligence of the general service practice required for normal service operations but not contained in this Manual.

For replacing assembly units or individual parts use ONLY genuine RÁBA made products.

RIGHTS FOR ALTERATIONS RESERVED!

Gyõr, 02. 2003.

RÁBA - AXLE Ltd. H - 9002 GYŐR P.O. BOX 141 - HUNGARY

TEL.:36/96/622-000 36/96/624-654 FAX.: 36/96/624-900

E-mail: [email protected]

SECTION 204. DRAWINGS OF THE AXLES Example

Forward direction

360.05

6

204 Example

Forward direction

360.08

7

204 Example

Forward direction

360.20

8

204

Example

Forward direction

360.30

9

204 Example

360.65

Forward direction

10

11

SECTION 205. TECHNICAL DATA

TYPE DESIGNATION

UNITS 360

SYSTEM OF THE AXLES: Single reduction axle with welded steel plate axle housing, hypoid-toothing drive gear-pinion pair. DIMENSIONS Wheel track

mm 1800*

a., Rubber tire

inch

215/75 R17,5 *

b., Rolling radius

mm

370*

c., Applicable wheel disk

mm

6,00 x 17,5

Overall width (with rubber tire)

mm

2020* (2311)*

Spring center distance

mm

1080*

RATIOS

Drive gear / drive pinion tooth number

41 / 10*

Ratio

4,10

For detailed technical date marked by asterisk (∗) at the type versions required by one orderer refer to publication "TECHNICAL DATA" related to the type versions"

205 TECHNICAL DATA

TYPE DESIGNATION UNITS

360 GENERAL DATA

Permitted axle load

kg

6300 *

Permitted engine power

kW (LE) 114 (155) *

Max. permissible retarder torque (on 2 Wheel hubs)

Nm 4500 *

Permitted total rolling mass

kg

9500 *

Permitted output torque

Nm

17000 *

Max. input RPM.

1/sec

55 *

Axle mass without oil fill

kg

345 *

Constructional elements of ABS

Can be installed

Impulse ring

Installed

"A", "C" WHEEL HUB EXECUTION

"A" Bolt centering for installing wheel disk

mm

mm

160,8 Flange diameter: 24 Wheel nut hex. distance:

"C"

Hub centering for installing wheel disc mm

mm

160,8 Flange diameter: 27 Wheel nut hex. distance:

0 -0,2

0 -0,2

12

13

205 TECHNICAL DATA

TYPE DESIGNATION

UNITS 360

WHEEL BRAKE Depending on installation: PERROT PAN 17 or MERITOR 68032208 / 68032209 * WHEEL BRAKE PERROT PAN 17 -This axle is mounted for installation of disc brake with mechanical slip saddle, Model PAN 17 mode by

PERROT BREMSEN GMBH WABCO Automative Products Group. Mean theoretical value of brake torque on

2 wheel hubs at 7,2 (6,5)* bar pressure

Nm 14800

Min.brake lining thickness

mm 2

Min.brake disk thickness

mm

26

Brake chamber

"

12 / 16 * 14/16 *

16 / 16 * Further data refer to D5.9.0001.C.2003 (PERROT PAN 17) INSTALLATION AND MAINTANCE MANUAL.

14

TECHNICAL DATA TYPE

360 DESIGNATION UNITS WHEEL BRAKE MERITOR 68032208 / 68032209 -This axle is mounted for installation of disc brake with hidraulic, Model MERITOR 68032208 / 68032209

Mean theoretical value of brake torque on 2 wheel hubs at 100 bar pressure

Nm

11230

Min.brake lining thickness (Pad wear warning indicator is des, gned to operate when thickness of friction material is 2.4/1.9 mm.)

mm

1,9

Min.brake disk thickness

mm

26

Further data refer to D5.9.0019.C.2003 (MERITOR 68032208 / 68032209) INSTALLATION AND MAINTANCE MANUAL

15

205 TECHNICAL DATA

TYPE DESIGNATION SECTION / FIG.

ITEM No. 360

diameter of the drive pinion shaft is 45 mm


ANTIFRICTION BEARINGS In wheel hub

Double row tapered roller bearing

Assortment 803194 FAG

DU 78130-4CS26 KOYO

On drive pinion Assortment Outer: taper roller bearing Inner: taper roller bearing

31309 CL7C SKF 31309A F22 FAG

Inner side 55200 C TIM

4T-55200 C NTN 55200 CPW 3 BOW

Outer ring 55437 TIM

4T-55437 NTN 55437 PW2 BOW

Cylindric roller bearing

Assortment UC 1306 TM FAG

UC 1306 TAM FAG UC 1306 TAM-1 C3 KOYO

On differential

On flanged case half: taper roller bearing

Assortment 32015 X SKF 32015 X FAG

32015 JR KOYO

On half case: taper roller bearing

Assortment 32015 X SKF 32015 X FAG

32015 JR KOYO

OIL SEALS

In differential carrier CC.65x100x10.46 FPM STEFA

(BEIER TECHNIK)

GGA HH 109 CR INDUSTRIES

16

SECTION 206.

TORQUE RATINGS

The serial numbers are the item numbers of the figures in the " GENERAL WORKSHOP MANUAL ".

TYPE DESIGNATION

SECTION / FIG. ITEM No. 360

WHEEL HUB 210 / 1 Nm Wheel huts

" A" Wheel nut with lock washer (Hex distance: 24 mm)

12 225 - 247

"C" Sole nut (Hex distance 27 mm)

24 280 - 320

Threaded clamping ring

14 300 - 350

Mounted with thread locker

Axle shaft mounting bolts 21

190 - 210 Mounted with thread locker

Spindle nut 19

500 - 550

Guard-plate mounting bolts

228/2

40 - 45 * Mounted with thread adhesive

WHEEL BRAKE

260/1 260/2

Nm

Brake support disk hex. bolts

13

120 -130 Mounted with thread locker

Brake to axle housing mounting bolts

260/1/ 27 260/2/ 27

160 - 200 205 - 225

Mounted with thread locker Mounting nuts of brake diaphragm

260/1/ 28 260/2/ 28

180 - 210 90 - 110

Bolt for releasing the spring force of the spring brake chamber

Release torque of spring force

29

35

Prevailing torque of in operating position spring force

29

70 *

17

206 TORQUE RATINGS


ITEM No. 360



DIFFERENTIAL CARRIER HEAD

310 / 1, 2

Differential carrier housing to axle housing

mounting bolts

--

110 - 130


Drive pinion self-lock nut

1

630 - 730

1200 - 1600

70 - 80 110 - 130 Bearing cage mounting bolts

14


Adjuster lock plate mounting bolts

22

15 - 20 Mounted with thread locker

49 - 59

55 - 60

Differential case halves clamp bolts

25 Mounted with thread adhesive

260 - 290 Ring gear mounting nuts

38 Mounted with thread adhesive

Bearing caps mounting bolts 41

350 - 400 Mounted with thread adhesive

Oil baffle plate mounting hex. bolts

33

10 - 15


Screw for fixing the retarder clamping plate

--

110 - 130* Mounted with thread locker

Stud bolt Rocknut for clamping the inner rotor

--

18*

18

SECTION 207.


ITEM No. 360



WHEEL BRAKE: * Refer to PERROT PAN 17 D5.9.0001.C.2003 INSTALLATION AND MAINTANCE MANUAL Refer to MERITOR 68032208 / 68032209 D5.9.0019.C.2003 INSTALLATION AND MAINTANCE MANUAL DIFFERENTIAL CARRIER HEAD Drive pinion to drive gear backlash

GLEASON - toothing:

mm 0,15 - 0,22

Drive pinion rolling torque, after preloading the bearings (the seal is not installed, adjustment by the distance rings)

Nm

2,5 - 3,5*

3,5 - 5,5*

Size of distance rings

mm

- 25 distance rings from 13,950 to 14,550 mm in 0,025 mm steps *

- 28 distance rings from 17. 780 to 17.870 mm in 0.025 or 0.026 mm steps. *

Theoretical distance between the drive pinion face and the drive gear centerline ("AXIS DISTANCE")

mm

84,55

Shim thicknesses

mm 0,15; 0,20; 0,30; 0,50; 1,00

19

SECTION 208.

SPECIAL TOOLS

Note: The numbers -1, -2,... -15 etc. following the part number are the item numbers of the set. SECTION DESIGNATION DRW. NO. DESCRIPTION APPLICATION WHEEL HUB 212 --- 4771-00819

590842 Wheel nut wrench (Hex. distance: 24)

For wheel nuts

--- 4642-00471 342229

Wheel nut wrench (Hex. distance:27)

For wheel nuts

223 --- 8922-00003 345797

Claw wrench Spindle nut mounting

224, 315, 317

RA-1039 8928-00006 403294

Drive mandrel For step plates

224 --- 8922-00004 345796

Pinned wrench For clamping ring

RA-1087 8928-00012 403300

Step plate For compact taper roller

--- 8922-00015 402912

Step plate

bearing

DIFFERENTIAL CARRIER HEAD 313 --- 4745-01797

559770 HN-131 Wrench adapter

--- 4749-00071 681236

HN-162 Wrench adapter

--- 8839-00321 341911

∅130 x 70° Counter support


--- 8928-00063-1 475280

42,88x114,3 Counter support

--- 8889-00083 213840


313, 315,

642-1

4644-00642 -1

Backing plate with

317 642-8 -22,-25,-26,-27 414863

puller bolt

642-12 4644-00642-23 411383

Bolt Pulling down the companion

642-34 4644-00642-34 411382

Bolt flange, differential bearing cone

--- 8889-00653

Bolt

20

208 SECTION DESIGNATION DRW. NO. DESCRIPTION APPLICATION 313 --- 4746-00104

345300 Drive For drive pinion oil seal

CC.65x100x14.46 FPM --- 8889-00052

594769 Drive

For drive pinion oil seal GGA HH 109

--- 4746-00105 Companion flange drive 1,250-18 UNF 2A

--- 4695-00337 410732

Companion flange drive 1,750-12 UNF 2A

Companion flange mounting

314 --- 4746-00106 345308

Claw wrench Differential, bearing adjuster

--- 4750-00122 214273

Backlash checking device

For checking the backlash

--- 4746-00452 Leg dimension checking ring

For checking the leg dimension

315 --- 4746-00107 345305

Puller ring set

--- 4746-00108 345306

Drive sleeve

Differential bearing cone

316 --- 4746-00109 345303

Axial distance calibrator

Drive pinion mounting

317 --- 4746-00110 345304

Bearing puller set Drive pinion bearing cone 31309

--- 8889-00088 1....-9 475279

Bearing puller set Drive pinion bearing cone 55200

--- 4746-00111 345301

Bearing puller set Cylindric roller bearing mounting

--- 4746-00112

Bearing driver set

--- 4746-00113 345309

Driver set

Bearing cage, bearing cups 31309

21


213833 Bearing driver set

--- 8889-00091 213832

Driver set

Bearing cage, 55437 bearing cups,

--- 4746-00114 345310

Master shaft set ∅45

For adjusting bearing preload 31309

8937-00012 056223


For adjusting bearing preload 55200 / 55437

--- 4746-00115 345311

Thrust head

--- 4746-00116 345312

Securing thrust head

Cylindric roller bearing mounting

--- 4746-00117 345313

Drive sleeve ∅45

31309 Drive pinion, bearing cone

--- 4745-00794- -5 475274

Drive sleeve ∅50


22

208

SPEZIAL TOOLS LISTED ACCORDING TO DRW. NO. IN

INCREASING ORDRER

Note: The numbers -1, -2,... -15 etc. following the part number are the item numbers of the set. SECTION DESIGNATION DRW. NO. DESCRIPTION APPLICATION 212 --- 4642-00471

342229 Wheel nut wrench (Hex. distance:27)

For wheel nuts

313, 315,

642-1

4644-00642 -1

Backing plate with

317 642-8 -22,-25,-26,-27 414863

puller bolt

642-12 4644-00642 -23

Bolt Pulling down the companion flange, differential bearing

642-34 4644-00642 -34

Bolt cone

313 --- 4695-00337 410732

Companion flange drive 1,750-12 UNF 2A


317 --- 4745-00794- -5 475274

Drive sleeve ∅50


313 --- 4745-01797 559770

Wrench adapter

HN-131 Drive pinion self-lock nut

313 --- 4746-00104 345300

Drive disk For drive pinion oil seal

313 --- 4746-00105 Companion flange drive 1,250-18 UNF 2A


314 --- 4746-00106 345308

Claw wrench Differential, bearing adjuster

315 --- 4746-00107 345305

Puller ring set


315 --- 4746-00108 345306

Drive sleeve


316 --- 4746-00109 345303

Axial distance calibrator

Drive pinion mounting

317 --- 4746-00110 345304

Bearing puller set 31309 Drive pinion bearing cone

317 --- 4746-00111 345301

Bearing puller set Cylindric roller bearing mounting

23


Bearing driver set

31309

317 --- 4746-00113 345309

Driver set Bearing cage bearing cups

317 --- 4746-00114 345310

. Master shaft set ∅45

For adjusting bearing preload

317 --- 4746-00115 345311

Thrust head


317 --- 4746-00116 345312

Securing thrust head


317 --- 4746-00117 345313

Drive sleeve ∅45

Drive pinion, bearing cone

314 --- 4746-00452 Leg dimension checking ring

For checking the leg dimension

313 --- 4749-00071 681236

Wrench adapter HN-162 Drive pinion self-lock nut

314 --- 4750-00122 214273

Backlash checking device

For checking the backlash

212 --- 4771-00819 590842

Wheel nut wrench (Hex. distance:24)

For wheel nuts

313 --- 8839-00321 341911



313 --- 8889-00052 594769

Drive

GGA HH 109 For drive pinion oil seal

313 --- 8889-00083 213840



317 --- 8889-00088 1....-9 475279

Bearing puller set 55200 Drive pinion bearing cone

317 --- 8889-00090 213833

Bearing driver set 55437

317 --- 8889-00091 213832

Driver set Bearing cage, bearing cups,

313 --- 8889-00653

Bolt Pulling down the companion flange

223 --- 8922-00003 345797

Claw wrench Spindle nut mounting

24


345796 Pinned wrench For clamping ring

224 --- 8922-00015

402912 Step plate

For compact taper roller bearing

224, 315, 317

RA-1039 8928-00006 403294

Drive mandrel For step plates

224 RA-1087 8928-00012 403300

Step plate For compact taper roller bearing

313 --- 8928-00063 -1 475280

Counter support 42,88x114,3


317 --- 8937-00012 056023


55200 / 55437 For adjusting bearing preload

PULLER AND PILOT BOLTS

SECTION STOCK NO. DRW. NO. DESCRIPTION APPLICATION 313 910214 ISO 4017

M12x30 -10.9 Hex. full thrd. bolt, (4 off)

910200 ISO 4017

M10x30 -10.9 Hex. full thrd. bolt, (4 off) Companion flange

900969 ISO 4032 M10-8

Hex. nut (4 off)

312, 316

905483 ISO 4017 M10x65-10.9

Hex. full thrd. bolt, (2 off) Differential carrier housing, bearing cage

313, 317

900966 ISO 4032 M12-8

Hex. nut (2x4 off) Companion flange, drive pinion, differential

315 ISO 8676 M16x1,5x90-10.9

Hex. bolt (4 off)

820175 ISO 7091 M16

Washer (4 off) Drive gear mounting

500069 MSZ 8673 M16x1,5-8

Hex. nut (4 off)

316 923737 MSZ 2402 M12x30-10.9

Stud bolt 1.25d (2 off) Bearing cage mounting

SECTION 209. GENERAL SERVICE INSTRUCTIONS

25

This section summarizes the service operations and adjustment data considered by us to be most important and which should thoroughly be observed and followed during assembling the axle. WHEEL HUB Apply an oil proof (LOCTITE 510) surface sealant between the mating surfaces of the axle shaft and the wheel hub. Assemble the axle shaft to the wheel hub according to the match-mark. The M8 holes of the axle shaft and the turned parts of the wheel hub have to align at mounting.

WHEEL BRAKE Service refer to No PERROT PAN 17. D5.9.0001.C.2003 or MERITOR 68032208 /68032208 D5.9.0019.C.2003 "INSTALLATION AND MAINTANCE MANUAL".

DIFFERENTIAL CARRIER HEAD Install the taper roller bearings of the drive pinion with preload. Assure such a preload the bearings shall roll on torque of 2.5 - 3.5 Nm* or 3.5 - 5.5 Nm*. During check the sealing ring (4) is not equipped. For adjustment refer to Section 317. The differential gears should be rotatable without jamming. Install the taper roller bearings supporting the differential without clearance. For proper contact pattern and specified backlash refer to Section 314.

26

GENERAL INSTRUCTIONS

For purpose of labor safety during service operations performed on the axle removing the individual assembly units make sure to assure safe backing, fixing or suspension. Install only clean and sound parts free of burr and knock-outs. Before installation wipe the mating surfaces of the parts clean and apply thin coat of oil. For assembly operations use ONLY plastic or copper insert hammer. Before installing the oil seals make sure to check if the sealing lip is sound and apply specified grease to between the sealing lip and the dust protection edge. When installing the taper roller bearings take care of the pairing according to the original packing or to the manufacturer’s specification. The following thread cementing, locking and surface sealing material are used at the axle. e.g.: Thread adhesive High-strength: LOCTITE 277 Omni FIT 1550 HENKEL Thread locker Medium strength: LOCTITE 243 Omni FIT 230 M HENKEL Surface sealant: LOCTITE 510 LOCTITE 518 Omni FIT 58 H HENKEL

Clean and degrease the surfaces before applying the thread adhesive and thread locker. Clean and degrease the surfaces before applying the air-curing sealant. Apply a continuous strip of min. 3

mm diameter to the specified surface. The time between applying the sealant and assembling the parts together may not exceed 10 min. Instead of the above cementing, fixing and sealing material other equivalent grade ones may also be used.

APPLICATION OF "LOCTITE" BOLT LOCKING MATERIALS The LOCTITE 277 thread adhesive material needs min. 3 - 4 hrs on 22°C temperature, the LOCTITE

243 thread locking needs 1 - 2 hrs in the same conditions - to 75% solidification - based on the LOCTITE catalogue. The proper bonding strength does not develop on greasy, oily surfaces even after a longer period. Oil must not reach the surface even after the application of the LOCTITE 277 thread adhesive and 243 bolt locking materials and after the bolts are driven in, within the curing time. REPAIR OF THE PARTS ASSEMBLED WITH LOCTITE THREAD ADHESIVE AND THREAD LOCKING MATERIALS: In case of a defect during the operation and during a general overhaul, after the assembly unit had been previously washed, the first thing to do is to dismount the bonded joints. Clean carefully the matching surfaces and the hex bolts and the threaded bores of the dismounted units from the dirt and the remains of the adhesive. The remains of the adhesive shall be removed both by mechanical cleaning and with LOCTITE 806 solvent. The threaded bores can be considered to be cleaned, when the bolts can easily be driven upto the total thread length.

Prior to assembly, degrease carefully the bores of the parts to be assembled and the bolts. If oil/dirt is detected in the bores of the washed parts, drop the oil from bores then spray with LOCTITE 7061 cleaning spray then dry it in free air. (Blowing is permitted only with oil-free compressed air!) Spray the bores and the bolts with LOCTITE 7649 activator and stand to such a position that the surplus activator could flow down, then let them dry at least for 10 minutes

Before driving in, apply LOCTITE on the bolts around 4 - 5 threads from the end of the shank. (If steel is to be bonded to steel, the curing time is 1 - 3 hrs for achieving 50 - 80% strength which provides the loadability).

27

28

WHEEL HUB

210. SECTION SECTIONAL VIEWS WHEEL HUB AND WHEEL BRAKE

360.05-61/1

20

19

18

16

7 6

15

14

1 42

41

21

12

11

10

9

24

29

Fig. 1.: DISK BRAKE WHEEL HUB SECTIONAL VIEW

29

30

SECTION 211. PARTS OF THE WHEEL HUBS AND THE WHEEL BRAKE 1 - Axle housing with spindle

--- 6 - Compact taper roller bearing 7 - Wheel hub -- 9 - Wheel bolt

10 - Centering ring 11 - Lock washer 12 - Wheel nut (Hex. dist.: 24) -- 14 - Threaded clamping ring 15 - Snap ring 16 - Tab washer

--- 18 - Lock plate 19 - Shaft-end nut 20 - Axle shaft 21 - Hex. bolt --- -24 - Sole wheel nut (Hex. dist.: 27) --- 41 - Sensor 42 - Spring bushing

SECTION 212. REMOVING AND REINSTALLING THE WHEEL DISK

REMOVING THE WHEEL DISK

With wheels in loaded condition loosen the hex. distance 24 mm wheel nuts (12) by means of the wheel nut wrench 4771-00819, loosen the hex. distance 27 mm wheel nuts (24) by means of the wheel nut wrench 4642-00471, then jack up the axle, back out the wheel nuts and remove and the wheels. REINSTALLING THE WHEEL DISK Thoroughly clean the mating surfaces of the wheel disk and the wheel hub. After positioning the wheel disk diagonally tighten the 24 mm hex. wheel nuts (12) to 225 - 247 Nm torque, and the 27 mm hex. wheel nuts (24) to 280 - 320 Nm torque.

212

Fig. 1.: ASSEMBLING THE WHEEL NUTS SECTION 219. REMOVING AND REINSTALLING

THE AXLE SHAFT

REMOVING THE AXLE SHAFT After match-marking remove the hex. bolts (21) attaching the axle shaft. Pull out the axle shaft out of the axle housing.

REINSTALLING THE AXLE SHAFT

Clean the mating surface of the wheel hub and the axle shaft from the used sealant and as described in the "GENERAL SEVICE INSTRUCTIONS" apply oil proof sealant to the axle shaft mating flange, avoiding the bores from inside (LOCTITE 510). When installing the axle shafts make sure to install them to their original place. The M8 holes of the axle shaft and the turned parts of the wheel hub have to align at mounting. According to the match-marks push the axle shaft through the wheel hub matching the splines and the dowel pins until bottom out. Apply the thread locker to 4 - 5 threads of the hex. bolts and attach the axle shaft. Diagonally tighten the bolts to 190 - 210 Nm torque.

311.62-11 4642-00471 (Lt.: 27)

31

SECTION 223.

REMOVING AND REINSTALLING THE WHEEL HUB

REMOVING THE WHEEL HUB

After removing the axle shaft and the brake saddle unsecure the shaft-end nut (19). Assure safe suspension or backing for the wheel hub against fall down.

The shaft-end nut can be removed by means of the tools shown, then remove the lock plate and the tab washer (see Fig. 1.). Pull off the wheel hub, the compact taper roller bearing and the securing parts.

Fig.1.: ASSEMBLING THE SHAFT-END NUT

INSTALLING THE WHEEL HUB Push the wheel hub - preassembled according to section 224. Position the tab washer (16) and the lock plate (18), screw on the shaft-end nut (19), tighten to 500 - 550 Nm torque and secure by the lock plate.

305.64-11

8922-00003

32

SECTION 224.

DISASSEMBLING AND REASSEMBLING THE WHEEL HUB

DISASSEMBLING THE WHEEL HUB Screw out the threaded clamping ring (14) (Fig. 1.), removing the snap ring (15) and drive out the compact taper roller bearing (6) by means of step plate RA-1087 and RA-1039.

1. ábra: MENETES SZORÍTÓGYŰRŰ SZERELÉSE

Fig. 1.: ASSEMBLING THE THREADED CLAMPING RING

REASSEMBLING THE WHEEL HUB

Drive in the compact taper roller bearing by means of the tools shown (Fig.2.). Fig. 2.: DRIVING IN COMPACT TAPER ROLLER BEARING

8922-00004 305.64-12

305.64-13

8922-00015

RA-1039

33

224 Insert the snap ring (15), then screw in the threaded clamping ring (14) with thread locker and tighten it to 300

- 350 Nm torque and at four places of 90° punch secure. SECTION 225.

REMOVING AND REINSTALLING THE BRAKE DISK REMOVING THE BRAKE DISK After removing the wheel disk, the caliper and the wheel hub back out the hex. bolts (13) attaching the brake disk to the wheel hub and pull the brake disk off. REINSTALLING THE BRAKE DISK Aligning the bores position the brake disk to the wheel hub. Install the hex. bolts (13) with thread locker attaching the brake disk and tighten to the specified 120 - 130 Nm torque.

1 - Guard plate 2 - Hex. bolt 3 - Washer Fig. 1.: GUARD-PLATE

SECTION 228. GENERATING RING GUARD-PLATE REMOVING AND REIN-STALLING

When the guard plate is mounted, you have to adjust about 2 mm clearance between the brake disk and the guard plate, if necessary, by inserting a washer (3) between the brake support and the plate. Lock the guard plate with hexagon-head bolts (2) coated with thread retainer, tightened to 40 – 45 Nm torque.

360.65-1

34

SECTION 229.

INSTALLATION INSTRUCTIONS FOR PARTS OF ANTIBLOCKING

SYSTEM

This description contains the constructional elements of the anti-blocking and anti-skid systems (ABS and ASR), that can be installed by the customer into the axle as well as the installation instructions. The models given in "TECHNICAL DATA" contain the items (A), necessary at the installation of the anti-block and anti-skid systems (1).

1. Installable elements of the anti-block and anti-skid systems

1.1 Revolution sensor: Robert Bosch GmbH A 335 545 231 or KNORR-BREMSE ZB 9010-I/83315 or WABCO 441 032 808 0 or WABCO 441 032 578 0 or WABCO 441 032 001 0

1.2 Spring bushing:

Robert Bosch GmbH C 335 002 431 A or KNORR-BREMSE 4B 69698 or WABCO 899 760 510 4 or WABCO 899 759 815 4

Note: The revolution sensor and the spring bushing must be of the same make.

"A" Toothed pulse

generating ring Fig. 1.: INSTALLATION OF THE ANTIBLOCKING SYSTEM

35

36

229 2. Installation instruction

Before installing the spring bushing coat the ∅18H11 bore of the revolution sensor holder with copper paste or silicone grease (e.g. Molykote FP 186, NBU30 PTM, Univew N3) in order to prevent corrosion.

Insert the spring bushing from the middle of the axle into the ∅18H11 bore until stop (1.2). Put the revolution sensor (1.1) into the spring bushing and push it until it reaches the generating ring developed on brake disk. This setting has to be performed every time the hub will be disassembled. During operation maximum clearance between the revolution sensor and the generator ring may be 0,8 mm. When leading the wire of the revolution sensor out of the axle brake mechanism be sure not to bend it with a radius less than R50 mm. Fasten the wire at distances of 50 mm exposed to heat load inside the brake mechanism. Check the run out of the toothed pulse generating ring. Maximum permissible run out of toothing in direction of revolution sensor shaft is 0.2 mm.

Note: Tachometer to be built in only with spring bushing of the same manufacturing. Besides BOSCH, KNORR and WABCO tachometer, a tachometer of other production, interchangeable with the above is allowed to be built in. TOOTHING CAN NOT GET DAMAGED!

37

THE DISK WHEEL BRAKE

SECTION 262/1. REMOVING AND REINSTALLING THE SLIDING SADDLE-BACKED DISK BRAKE TYPE PERROT

Fig. 1.: SLIDING SADDLE-BACKED DISK BRAKE TYPE PERROT 8 - Brake disk

13 - Hex. flanged bolt 23 - Sliding saddle-backed disk brake 26 - Spring brake chamber 27 - Hex. flanged bolt 28 - Hex. nut with lock washer 29 - Bolt for releasing the spring force

REMOVING THE DISK BRAKE Remove the hex. flanged bolts (27) and the brake from the brake holder. For repair of the type PERROT PAN 17 sliding saddle-backed disk brake refer to No. D5.9.0001.C.2003 "SERVICE MANUAL".

REINSTALLING THE DISK BRAKE Fix the brake to the brake holder with hex. bolts (27) with thread locker. Tighten the bolts to 160 - 200 Nm torque. Fix the brake chamber to the brake with hex. nuts (28) with lock washer. Tighten the nuts to 180 - 210 Nm torque.

360.20-8/1

29

38

SECTION 262/2

REMOVING AND REINSTALLING THE SLIDING SADDLE-BACKED DISK BRAKE TYPE MERITOR 68032208/ 68032209

Fig. 2.: HYDRAULIC DISK BRAKE TYPE MERITOR

8 - Brake disk 9 – Pin 10 – Washer 11 - Splint 13 - Hex. flanged bolt 23 - Hydraulic disk brake 26 - Spring brake chamber 27 - Hex. flanged bolt 28 - Hex. nut with lock washer

REMOVING THE DISK BRAKE Remove the hex. flanged bolts (27) and the brake from the brake holder. For repair of the type MERITOR 68032208/ 68032209 hydraulic disk brake refer to No. D5.9.0019.C.2003 "SERVICE MANUAL".

REINSTALLING THE DISK BRAKE Fix the brake to the brake holder with hex. bolts (27) with thread locker. Tighten the bolts to 205 - 225 Nm torque. Fix the brake chamber to the brake with hex. nuts (28) with lock washer. Tighten the nuts to 90 - 110 Nm torque.

360-30-05

26289, 10,23 8 27

13

39

40

DIFFERENTIAL CARRIER ASSEMBLY

SECTION 310. DIFFERENTIAL CARRIER ASSEMBLY SECTIONAL VIEWS

Fig.1.: DIFFERENTIAL CARRIER ASSEMBLY SECTIONAL VIEW (diameter of the drive pinion shaft is 45 mm)

26 27 28 37 25 31 19 20 41 40

1

2

3

4 8

14

13

9

10

12

16

45

20

19

24

22

21

32 33

49

15

39

38

30

29

360.20-7

A

A

B

B

41

310

360.60-7

Fig. 2.: DIFFERENTIAL CARRIER ASSEMBLY SECTIONAL VIEW (diameter of the drive pinion shaft is 50 mm)

42

43

SECTION 311. PARTS THE DIFFERENTIAL CARRIER ASSEMBLY 1 - Self-lock nut

2 - Washer / ---- 3 - Companion flange 4 - Sealing ring --- 8 - Bearing cage 9 - Taper roller bearing 10 - Distance ring --- 12 - Taper roller bearing 13 - Shims 14 - Hex. flanged bolts 15 - Differential carrier 16 - Drive pinion --- 19 - Taper roller bearing 20 - Bearing adjuster 21 - Tab lock plate

22 - Hex. bolt --- 24 - Differential case half 25 - Clamp bolt 26 - Spacer 27 - Differential gear 28 - Spider 29 - Differential pinion 30 - Shim 31 - Differential case half (flanged) 32 - Oil baffle plate 33 - Hex. bolt -- 37 - Drive gear 38 - Self-lock nut 39 - Hex. bolt 40 - Bearing shackle 41 - Hex. bolt --- 45 - Cylindric roller bearing --- 49 - Disk / ---

. SECTION 312.

REMOVING AND REINSTALLING THE DIFFERENTIAL CARRIER ASSEMBLY REMOVING THE DIFFERENTIAL CARRIER Before removing the differential carrier assembly from the axle drain the oil. Remove the axle shaft as described in Section 219. Remove the hex. flanged bolts attaching the differential carrier assembly to the axle housing. By means of two M10 bolts driven into the threaded bores in the differential carrier flange remove the differential carrier from the axle housing.

REINSTALLING THE DIFFERENTIAL CARRIER

As described in the "GENERAL SERVICE INSTRUCTIONS" apply oil-proof surface sealant to flange of the axle body and to connecting flange of the differential carrier to between the inner edge and the bolt bores. Aligning the bores position the differential carrier into the axle housing. Secure the differential carrier with hex. flanged bolts applied with thread locker to axle housing. Tighten the bolts diagonally to 110 - 130 Nm torque. Reinstall the axle shaft according to Section 219.

SECTION 313. REMOVING AND REINSTALLING THE COMPANION FLANGE, REPLACING THE OIL SEAL REMOVING THE COMPANION FLANGE

By means of the tools shown Figure (1.) remove the self-lock nut (1) . Figure 1.: MOUNTING THE SELF-LOCK NUT

4745-01797HN-162

-1

360.60-11

4749-00071

44

313 Pull the companion flange by means of the tools as

shown (Fig. 2.)

Fig. 2.: PULLING OFF THE COMPANION FLANGE

REPLACING THE OIL SEAL By means of pry remove the old oil seal (4).

Drive in the new oil seal by means of the tools shown (Figure 3. and 4.) to bottom. Apply AMBLYGON TA 15/2 specified grease to between the sealing lip and the dust protection edge of the sealing ring.

Fig.3.: HAMMERING CC.65x100x10.46 SEAL RING IN

Fig.4.: HAMMERING GGA HH109 SEAL RING IN

642-8

642-1

642-12 (M10)

642-34 (M12)642-8

642-1M10 ISO 4032

8889-00653 (3/8-24UNF 28)

360.20-10

360.08-10

45

313 REINSTALLING THE COMPANION FLANGE

(Position the disk (49)∗ over the cone of the inner taper roller bearing (9)).∗

By means of the tool shown press the companion flange (3) to the drive pinion splines to bottom out (Fig. 5.). Fig. 5.: PRESSING ON THE COMPANION FLANGE

(Install the washer (2)∗), screw on self-lock nut (1) and tighten to a torque given in TECHNICAL DATA.

SECTION 314. REMOVING AND REINSTALLING THE DIFFERENTIAL, ADJUSTING THE BACKLASH AND THE CONTACT PATTERN REMOVING THE DIFFERENTIAL

Back out the hex. bolts (22) and remove the tab lock plates (21). Back out the hex. bolts (41) and remove the bearing shackles (40). Following this remove the differential from the differential carrier and remove the outer race of the taper roller bearing (19) and the bearing adjusters (20).

360.60-29

46

314 REINSTALLING THE DIFFERENTIAL Reinstall the differential only after installing the

bearing cage and adjusting the axis distance (see Section 316.)!

Fit the assembled differential together with cups of the taper roller bearings (19) into the differential carrier, then screw on the bearing shackles to the original place, adjust on the bearing adjusters and secure. Tighten the hex. bolts (41) applied with thread adhesive to 350 - 400 Nm torque (Fig. 1.). Fig. 1.: ASSEMBLING THE BEARING ADJUSTERS

ADJUSTING THE BACKLASH AND THE BEARING PRELOAD

Adjust backlash between the drive pinion and the gear to 0.15 - 0.22 mm (GLEASON toothing).

Measure the backlash at the drive gear diagonally at four places, by means of dial indicator with stand and perpendicularly to the tooth surface by means of the backlash checking device shown in figure (Fig. 2.). Fig. 2.: CHECKING THE BACKLASH

4746-00106

006.10-30

009.00-34/1

47

314 Maintaining the backlash install the differential taper roller bearings (19) with no

clearance. IT IS IMPORTANT that while the bearing is adjusted, the ring gear has to be kept revolving, this will assure seating of the taper rollers in the bearings. If setting is made in stationary position, the bearings can get stressed or the rolling bodies can get jammed. The bearings set in this way release during revolution. After adjusting the backlash and the 0,000 mm bearing clearance check the contact pattern as follows.

ADJUSTING THE CONTACT PATTERN Apply indicator paint to 2 opposite teeth pairs of the drive gear at four places of 90°

pitch and one tooth of the drive pinion. Rotate the drive pinion to both directions for approx. 15 sec, while braking the drive gear by a piece of wood.

PROPER CONTACT PATTERN If a contact pattern shown in detail 1 of Fig. 3. is obtained, the drive gear-pinion pair is installed properly.

D = Large diameter 1 = Proper contact pattern 2 = Too deep contact 3 = Too high contact Fig. 3.: THE CONTACT PATTERN

Practically the perfect contact pattern shown in the figure cannot be obtained, but it is important that the pattern shall nowhere reach the edge of the tooth surface.

118.00-20

48

In case of GLEASON toothing the contact pattern along the tooth is shifted toward the small diameter of the

drive gear.

TOO DEEP CONTACT If the contact pattern is shifted to the dedendum as shown in detail 2 of Fig. 3. increase the "AXIS DISTANCE" by increasing the thickness of the shim pack (13) and simultaneously reduce the increased backlash by shifting the drive gear so, to obtain the contact pattern shown in detail 1 of Fig. 3.

TOO HIGH CONTACT If the contact pattern is shifted to the addendum as shown in detail 3 of Fig. 3. reduce the "AXIS DISTANCE" by reducing the thickness of the shim pack (13) and simultaneously increase the reduced backlash by shifting the drive gear so, to obtain the contact pattern shown in detail 1 of Fig. 3.

Durning drive the rotation should be smooth and noiseless. After each contact pattern adjustment measure the backlash, readjust the bearing preload and check the dimension ∅316 mm on the supporting flange. Perform assembly by the check ring No. 4746-00452. The checking ring of "GO SIDE" are placed on the bearing cap legs, then both bearing adjusters are tightened by equal angular displacement until the check ring fits the bearing cap legs free of clearance. If the bearing adjusters can not be locked, they must be kept revolving until all of them can be locked. Before locking the bearing adjusters you must make sure that the backlash has remained with in the specified range. Size of the diagonal legs of the bearing cap must be checked separately with the "NO GO SIDE" of the check ring. Maintining the previously adjusted ∅316 mm leg dimension secure the adjuster lock plates (21) by the countersonk hex. bolts (22) applied with thread locker. Tighten with 15-20 Nm torque.

+0,35 +0,25

49

SECTION 315.

DISASSEMBLING AND REASSEMBLING THE DIFFERENTIAL

Pull the inner of the taper roller bearings (19) from the removed differential (see Fig. 1.). Fig. 1. PULING OFF THE TAPER ROLLER BEARINGS CONE

For disassembling the differential case remove the hex. bolts (25) clamping the case halves (24 and 31) together and separate the case halves.

Remove the spider (28) together with the differential pinions (29) and shims (30) as well as the differential gears (27) and the spacer (26).

Replace the drive gear only together with the matched drive pinion. The match-marks are stamped to one face of the drive pinion and to one tooth end on the outer taper surface of the drive gear. The match-marks indicate the identification number of the matched drive gear-pinion pair and the deviation - true to sense - from the theoretical "AXIS DISTANCE" measured between the drive pinion face and the drive gear centerline. For example: 1225 +0.032.

4746-00107

642-34

642-8

642-1

006.10-31

50

315 REASSEMBLING THE DIFFERENTIAL Insert the spacer (26) and the differential gear (27) as well as the spider (28) subassembled with shims

(30) and differential pinions (29) to the flanged differential case half (31). Following this insert the other differential gear and the spacer.

According to the match-marks and aligning the bores fit the differential case halves together, then install the clamp bolts (25). Tighten the clamp bolts to a torque given in TECHNICAL DATA. Rotate the differential, no jamming or jerk is permitted, the differential should roll freely and smoothly.

Fit the drive gear to the subassembled differential and by means of four M16x1,5 small-headed bolts of at least 90 mm length and nuts with washer pull the drive gear to the differential to bottom out (Fig. 3.). Fig 3.: PULLING ON THE DRIVE GEARS

M16 x1,5 ISO 8673-8

16 ISO 7091

M16x1,5x90 ISO 8676-10.9

006.10-33/1

After this remove the small-headed bolts, install the original hex. bolts (39)applied with thread adhesive and tighten the self-lock nuts (38) attaching the drive gear to the differential to 260 - 290 Nm torque.

51

315 Drive on the taper roller bearing cone by means of the tool shown (Fig. 4.). Fig. 4.: DRIVING ON THE TAPER ROLLER BEARING CONE

Fix the oil baffle plate (32) to the differential half case (24) with hex. bolts (33). Tighten the bolts to 10 - 15 Nm torque.

RA-1039

4746-00108

006.10-34

SECTION 316.

REMOVING AND REINSTALLING THE BEARING CAGE, ADJUSTING THE AXIS DISTANCE By means of M10 bolts of at least 50 mm thread length driven into the two threaded bores in flange of the bearing cage out of the differential carrier and remove the shims from flange of the differential carrier. REINSTALLING THE BEARING CAGE TO THE DIFFERENTIAL CARRIER Finally install the bearing cage after adjusting the rolling torque - bearing preload (section 317.), as well as the axis distance and the contact pattern (section 314.).

52

316 ADJUSTING THE AXIS DISTANCE

For purpose of piloting screw M12 guide stud bolts to two opposite bores in the differential carrier, position the shims necessary for adjusting the drive pinion and gear contact pattern over these studs so, the extreme ones shall be the thicker. Aligning the bores push the bearing cage subassembled with drive pinion into the differential carrier and provisionally secure by hex. flanged bolts (14) driven into two opposite bores. On the relevant measuring pin of the accessory "A" belonging to the measuring device shown in Fig. 1. adjust the theoretical "AXIS DISTANCE" B = 84.55 mm minus 10 mm (master gage thickness) , by setting the dial indicator to zero. By means of a thrust plate attached to the differential carrier flange secure the master gage to the drive pinion face. Insert the measuring device set to B = 74.55 mm to the differential carrier as shown in Fig. 1. and measure the "AXIS DISTANCE" deviation. Check if the reading is identical to the "AXIS DISTANCE" deviation stated on end of the drive pinion.

Fig: 1.: CALIBRATING THE AXIS DISTANCE

4746-00109

B(84,55)-10=74,55

+-

B=84,55

10

360.20-11

53

316 In case of identity the adjustment is proper, otherwise obtain the specified value by selecting the proper shim

pack (13). The permitted deviation is ±0.025 mm. Eg.: If axis distance stated on the drive pinion is +0.04, the value "B" to be adjusted is 84.55±0.025 mm. REINSTALLING THE BEARING CAGE In case of proper contact pattern adjustment and operation remove the bearing cage subassembled with drive pinion and according to the "GENERAL SERVICE INSTRUCTIONS" apply oil-proof surface sealant to the inner flange, then reinstall the bearing cage by means of hex. flanged bolts (14) coated with thread locker. Diagonally tighten the bolts to a torque given in TECHNICAL DATA.

SECTION 317.

DISASSEMBLING AND REASSEMBLING THE BEARING CAGE

By means of the device shown in the figure press the drive pinion (16) out of the bearing cage (see Fig. 1.). Fig. 1.: PRESSING OUT THE DRIVE PINION

M12 ISO 4032

642-34

642-8

642-1

360.20-12

54

317 By means of the device shown (Fig. 2.) press out the cone of the inner taper roller bearing (12)

remained on the drive pinion (16).

Fig. 2.: PRESSING OFF THE INNER TAPER ROLLER BEARING CONE

By means of the device shown (Fig. 3.) pull the cylindric roller bearing (45) off the drive pinion.

4746-00111

360.20-14

Fig. 3.: PULLING OFF CYLINDRIC ROLLER BEARING

When replacement of the bearing cage (8) is reqiured the new bearing cage is available subassembled with cups of the taper roller bearings (9 and 12) and furnished with bearing cones. When assembling use care of original pairing of the bearings. If replacement only the taper roller bearings is required, install the taper roller bearing cones shown inFig. 4., 5., 6.

55

317 The cone and the cup of the taper roller bearings

should be replaced together according to the factory pairing.

By means of the tools shown (see Fig. 4.) drive the cup of the taper roller bearing (9) out of the bearing cage. Fig. 4.: DRIVNG OUT THE CUP OF THE TAPER ROLLER BEARING

Turn the bearing cage over and by means of tools shown drive out the cup of the other taper roller bearing (see Fig. 5.). Fig. 5.: DRIVING OUT THE TAPER ROLLER BEARING CUP

REASSEMBLING THE BEARING CAGE When reassembling the bearing cage select the thickness of the distance ring (10) to be installed to between the taper roller bearing cups so, after tightening the nut to the specified torque, the rolling

56

torque of the bearing cage - without installing the sealing ring - shall be between the specified limits.

317 Drive the cup of the taper roller bearing (9) to both sides by means of the tools shown, to bottom out (Fig. 6.). Fig. 6.: DRIVING IN THE TAPER ROLLER BEARING CUP

Before assembling by means of caliper determine the expected thickness of the distance ring.

Before pressing to the drive pinion, subassembled the bearing cage on a loose-fit master shaft as per Fig. 7. or 8. to be able to determine the installation thickness of the distance rings after tightening the flanged nut to the specified torque.

Fig. 7.: ADJUSTING THE BEARING PRELOAD (diameter of the shaft is 45 mm) Install the parts to the master shaft and tighten the flanged nut of the device to 630 - 730 Nm torque.

57

317 Measure the rolling torque by means of a cord attached to mantle of the bearing cage and by a fish-scale.

With new bearing installed the force obtained from the fish-scale at approx. 50 rpm should be 41.3 - 57.8 N, which corresponds to 2.5 - 3.5 Nm torque. Installing reused bearings adjust the rolling torque to 1.25 - 1.75 Nm (approx. half to the new bearing). In case of deviation perform correction by replacing the distance ring. With higher rolling torque use higher distance ring, while at lower torque use lower one. In case of proper adjustment relocate the parts from the master shaft to the drive pinion. Make sure to install only the parts used for the previous adjustment.

Fig. 8.: ADJUSTING THE BEARING PRELOAD (diameter of the shaft is 50 mm) Install the parts to the master shaft and tighten the flanged nut of the device to 1200 - 1600 Nm torque.

Measure the rolling torque by means of a cord attached to mantle of the bearing cage and by a fish-scale. With new bearing installed the force obtained from the fish-scale at approx. 50 rpm should be 51.5 - 80.8 N, which corresponds to 3.5 - 5.5 Nm torque.

317 Installing reused bearings adjust the rolling torque to 1,75 - 2,25 Nm (approx. half to the new bearing).

58

In case of deviation perform correction by replacing the distance ring. With higher rolling torque use higher distance ring, while at lower torque use lower one. In case of proper adjustment relocate the parts from the master shaft to the drive pinion. Make sure to install only the parts used for the previous adjustment.

Press on the cylindric roller bearing (45) by means of the press head shown (Fig. 9.). Fig. 9.: PRESSING ON THE CYLINDRIC ROLLER BEARING

4746-00115

4746-00116-1

360.20-19

59

317 By means of the shown securing press head the cylindric roller bearing by indenting the journal end of the drive pinion (Fig. 10.). Fig. 10.: SECURING THE CYLINDRIC ROLLER BEARING

4746-00116 1±0,1

2.3±0,1

60°

1±0,1

∅27,8±0,1

360.20-20 By means of the tools shown drive the cone of the inner taper roller bearing (12) onto the drive pinion (Fig. 11.). Fig: 11.: DRIVING ON THE INNER TAPER ROLLER BEARING CONE

60

61

317 Position the previously selected distance ring (10) and the bearing cage subassembled with bearing cups

to the drive pinion stem, them by means of press sleeve 4746-00117-1 (31309)∗ or 4745-00794-5 (55200)∗ drive on the outer taper roller bearing cone to bottom out, while assuring proper connection of the bearings. Position the disk (49)∗ and press the companion flange (3) onto the drive pinion. Screw on the flanged castle nut of the adjusting device and tighten to a torque given in TECHNICAL DATA. Do not install the sealing ring yet. Check the rolling torque as described earlier. If deviation is experienced repeat the adjustment until obtaining the specified value. After adjusting the proper rolling torque remove the companion flange. Install the sealing ring and the companion flange a described in Section 313. Tighten the self-lock nut (1) to the specified a torque given in TECHNICAL DATA.

62

SECTION 395. OIL FILL-UP, RUN, CHECK According to the Operator′s Manual fill up the finish assembled axle with oil to lower edge of the filler

bores in the end-cover of the wheel hubs, in the axle housing and the differentials. Fill only completely clean oil fill-up into the axle. After oil fill-up install the screw plugs and tighten to be leak-tight. Following this it is recommended to run the axle to both directions at varying. DURING RUNNING CHECK THE FOLLOWING: THE AXLE FOR LEAKS:

No leaks are permitted. THE AXLE FOR OPERATION:

No unusual noise or excessive friction may be experienced at the rotary mechanisms in the differentials and the wheel hubs. The meshing gears should roll on one freely with out unusual noise.

THE AXLE FOR WARMING: At the end of running the temperature of the wheel hub parts may not exceed approx. 60°C and at the input section approx. 80 C°

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