MOXY Drive Line

DRIVE LINE Ch 3 page 1
Chapter 3
Drive line
SHOP MANUAL MT41 - 01.2005

Ch 3 page 2 DRIVE LINE
Drive line
Index
Introduction ............................................................................................. 4
General ..................................................................................................... 5
Structure of the Repair Manual .....................................................................................................6
Important information on industrial safety .....................................................................................6
Denomination of standard dimensions ..........................................................................................7
Conversion table ...........................................................................................................................7
Torque limits for screws. ........................................................................ 8
Table ..............................................................................................................................................8
View of the drive line components ........................................................ 9
Front reduction gear ............................................................................. 11
View of the reduction gear and parts list .....................................................................................11
Front reduction gear cross section .............................................................................................13
Tool for RP17. ............................................................................................................................14
Disassembly the front wheel hub ........................................................ 15
Safety precautions. ......................................................................................................................15
Prepare Disassembly front wheel hub, RP-17 .............................................................................15
Disassembly ................................................................................................................................18
Assembly .....................................................................................................................................23
Drive shafts ............................................................................................ 36
Front frame ..................................................................................................................................36
Rear frame...................................................................................................................................37
The intermediate shaft.................................................................................................................38
Front differential and transmission ..................................................... 39
Brakes .................................................................................................... 40
Service brakes .............................................................................................................................40
Service brake description ............................................................................................................41
Testing of parking brake ..............................................................................................................42
Remove the Linings .....................................................................................................................43
Disassembly the park brake unit .................................................................................................45
Assembly the park brake unit. .....................................................................................................46
Adjust the Initial Caliper Clearance ............................................................................................47
Park brake Maintenance ..............................................................................................................48
Disc .............................................................................................................................................50
Troubleshooting Park brake .........................................................................................................52
Rear differential ..................................................................................... 53
General function ..........................................................................................................................54
Illustrated tables - Special tools ...................................................................................................57
Disassemble the TK-differential ...................................................................................................58
Safety precautions. ......................................................................................................................58
Disassemble the differentilal from the axle housing ....................................................................59
Disassemble the boggi unit from frame .......................................................................................62
Dismantle Differential ..................................................................................................................66
Disassemble Drive pinion ............................................................................................................67
ASSEMBLY..................................................................................................................................70
Adjust Backlash ...........................................................................................................................84
Examples of gear-tooth-contact...................................................................................................85
Assemble the TK-diff in the axle housing ........................................... 87
Assemble the tandem housing unit to the rear frame. .................................................................91

Wet disc brake ....................................................................................... 95

Front hub ............................................................................................... 96
Outer view and section drawing ..................................................................................................96
Tools for WDB ..............................................................................................................................98
Disassembly the front wheel hub...............................................................................................100
Disassemble the WDB-brake housing .......................................................................................105
Reassemble ..............................................................................................................................110
Adjust the rolling resistance of the wheel bearing .....................................................................113
Installation of the wet multi-disc brake .......................................................................................115
Pre-assemble the return mecanism ..........................................................................................116
Installation of the wheel head ....................................................................................................121
Check the brake chamber/wheel head for leak tightness ..........................................................129
Leakage test of the brake hydraulics ........................................................................................130
WDB cirquit front brake ...................................................................... 131
Rear hub, ............................................................................................. 132
Outer view and section drawing ................................................................................................132
Disassembly the rear hub................................................................... 134
Assemble the WDB rear hub .....................................................................................................140
Cooling cirquit rear brake................................................................... 158
Axle and Tandem housing Bearing .................................................... 162
Cross section .............................................................................................................................162
Checking clearance in the Tandem bearing...............................................................................163
View of the Tandem bearing ......................................................................................................164
Calculation of the Tandem bearing ............................................................................................165
Disassemble Tandem housing unit.................................................... 166
Safety precautions. ....................................................................................................................166
Disassemble the tandem unit from the rear frame ....................................................................167
Disassembly the axle housing from the tandemhousing ..........................................................169
Disassemble the tandem bearings ...........................................................................................170
Assemble the tandem housing to the axle ................................................................................171
housing. .....................................................................................................................................171
Wheel hub, rear ................................................................................... 173
Safety precautions. ....................................................................................................................173
Sectional drawing of the wheel hub. ..........................................................................................174
Disassembly the wheel hub .......................................................................................................175
Assemble the wheel hub ...........................................................................................................181
Assemble the brake disc to the carrier .....................................................................................181
Pre-assembly the wheel hub axle..............................................................................................183
Pre-assembly the wheel hub .....................................................................................................185
Assembly the wheel hub to the axle ..........................................................................................187
Assemble the gear wheel to the hub .........................................................................................188
Assembly the hub to tandem huousing .....................................................................................189
Disassemble the tandem housing’s innside parts .....................................................................190
Assembly piniong in the tandem house .....................................................................................199
Tyres ..................................................................................................... 201

Introduction
The Drive Line consists of the components transferring the power from the engine to the transmission, and
from the transmission to each wheel, and also wheels, and brakes.
Right Tandem
Housing
Rear Axle
Hub
Rear Axle
Parking Differential
Brake
Transmission
(Chapter 2)
Right Front
Axle Drive
Assembly
Left
Intermediate Tandem
Drive Shaft Housing
Engine
(Chapter 1)
Left Front Axle
Drive Assembly
Fig 3.1 Drive Line Overview

General
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-like
manner.
The Drive line parts should only be disassembled for renewing damaged parts. Covers and housing parts
installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been re-
moved. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and
similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools developed
for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from
the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and
locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn
down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust wash-
ers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies
remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFERENCE: For heating up parts such as bearings, housings etc, only a heating
furnace, oil or an electric drier is permitted to be used!
CAUTION When assembling the transmission, absolutely observe the indicated

torque limits and adjustment data. Screws and nuts must be tightened
according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of
liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a

leather cloth.
DANGER When using detergents, observe the instructions given by the

manufacturer regarding handling of the respective detergent.

Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled drive line. Dismantling and installing as well as the disassembly and assembly of a main group
are always summarized in one chapter.
Special tools required for performing the respective repair works are
listed under „Special tools“ See this chapter, 3.0
Important information on industrial safety
Generally, the persons repairing MOXY product-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to
persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these MOXY-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods, information,

the use of auxiliaries etc..
CAUTION Is used, if a deviating and improper working procedure can damage the product.
DANGER: Is used, if lacking care can lead to personal injury or danger to life.
REFERENCE: Prior to starting the checks and repair works, thoroughly

study the present instructions.
CAUTION: Illustrations, drawings and parts do not always represent the original;
the working procedure is shown. The illustrations, drawings, and
parts are not drawn to scale; conclusions regarding size and weight
must not be drawn (not even within one representation).
The works must be performed according to the description.
REFE-RENCE: After the repair works and the checks, the expert staff must
convince itself that the product is properly functioning again.

Denomination of standard dimensions
Note: linear density in kg/m; areal density in t/m2

Unit New Old Conversion Note
Mass m kg (Kilogramm) kg
Force F N (Newton) kp 1 kp = 9,81 N
Work A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
1 PS = 0,7355 KW 1
Power P KW (Kilowatt) PS (DIN)
KW = 1,36 PS
T (Nm) = F
Torque T Nm (Newtonmeter) kpm 1 kpm = 9,81 Nm
(N) . r (m)
M (Nm) = F
Moment(Force) M Nm (Newtonmeter) kpm 1 kpm = 9,81 Nm
(N) . r (m)
Pressure 1,02 atü = 1,02 kp/cm2
pü bar atü
(Overpress) = 1 bar = 750 torr
Speed n min -1
Conversion table
=
25,40 mm 1 in (inch)
1 kg (Kilogramm) = 2,205 lb (pounds)
9,81 Nm (1 kpm) = 7,233 lbf x ft ( pound force foot)
1,356 Nm (0,138 kpm) = 1 lbf x ft (pound force foot)
1 kg / cm = 5,560 lb / in (pound per inch)
1 bar (1,02 kp/cm 2 ) = 2

14,233 psi (pound force per squar inch lbf/in )
2 =
0,070 bar ( 0,071 kp/cm ) 1 psi (lbf/in2)
1 Liter = 0,264 Gallon (Imp.)
4,456 Liter = 1 Gallon (Imp.)
1 Liter = 0,220 Gallon (US)
3,785 Liter = 1 Gallon (US)
1609,344 m = 1 Mile (Landmeile)
0° C (Celsius) = + 32° F (Fahrenheit)

= 273,15 Kelvin
0 ° C (Celsius)

Torque limits for screws.
Table
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF - STANDARDS 148

- treatment as well as phosphatized
Friction value: µ total= 0,12 for screws and nuts without after
nuts. Tightening by hand! Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO Standard thread Metric ISO Fine thread

Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2,8 4,1 4,8 M8x1 24 36 43
M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M 10 x 1 52 76 89
M7 15 23 28 M 10 x 1,25 49 72 84
M8 23 34 40 M 12 x 1,25 87 125 150
M10 46 68 79 M 12 x 1,5 83 120 145
M12 79 115 135 M 14 x 1,5 135 200 235
M14 125 185 215 M 16 x 1,5 205 300 360
M16 195 280 330 M 18 x 1,5 310 440 520
M18 280 390 460 M 18 x 2 290 420 490
M20 390 560 650 M 20 x 1,5 430 620 720
M22 530 750 880 M 22 x 1,5 580 820 960
M24 670 960 1100 M 24 x 1,5 760 1100 1250
M27 1000 1400 1650 M 24 x 2 730 1050 1200
M30 1350 1900 2250 M 27 x 1,5 1100 1600 1850
M33 1850 2600 3000 M 27 x 2 1050 1500 1800
M36 2350 3300 3900 M 30 x 1,5 1550 2200 2550
M39 3000 4300 5100 M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300

View of the drive line components
DRIVELINE
From the inter axle differential, the torque is distributed to the front and the rear differential.
The front differential, in front of the transmission, is equipped with limited slip that allows
torquedistribution depending on what is the friction between tyres and ground. Drive shafts
will then transmit the torque to the front reduction gears and to the wheels.
The torque is distributed, via 3 propeller shafts, (MT40B CH is 4 shafts) to the rear axle
differential. The rear differential is equipped with limited slip and drive shafts will then transmit the torque to the
tandem housing reduction gears and to the wheels, this is to avoid wheel spin.
BRAKES
The Moxy dump truck have 4 independent brake systems.
* Service brake
* Parking brake
* Engine brake (see chapter 1)
* Retarder (see chapter 2)
WHEELS
All 6 wheels are driven on the dump truck.


Front reduction gear
View of the reduction gear and parts list
10 1 •Hub carrier cpl. 300 3 •Planet gear

16 1 •Shim 310 3 •Retaining ring
20 1 •Shaft seal 320 1 •Shim
30 1 •Roller bearing 330 31 •Hexagon screw
50 1 •Roller bearing 334 1 •Cap screw
70 1 •Hub 350 1 •Screw plug
122 1 •Ring gear carr. 510 19 •Wheel bolt
124 1 •Ring gear 530 19 •Wheel nut
126 1 •Snap ring 570 1 •Flange shaft
162 1 •Tab washer 630 1 •Support shim
164 2 •Locking screw 640 1 •Ball bearing
250 1 •Sun gear shaft 644 1 •Retaining ring
260 1 •Driver 654 1 •Cover
280 1 •Planet carrier 660 1 •Shaft seal
282 1 •Screw plug 670 7 •Hexagon screw
290 1 •O-ring 682 1 •Slot. pin

NOTE:
To ensure the correct lubrication of the wheel bearings, pay attention to the radial installation
location of the wheel head!
The slot. pin (pinning of bearing bush and hub carrier Pos.1)
must be installed facing the road level (6-o’clock position).
See also the following draft.
3
4
5
6
1
1 8 7
2 1 = Roll pin
2 = Road level (ground)
3 = Hub
4 = Hub carrier
5 = Bearing bush
6 = Flange shaft
7 = Lubricating hole
8 = Wheel bearing

Front reduction gear cross section
The planetary reduction gear reduces the differential speed and transmits the rotation power to the wheels,
which provides a large driving force.
The reduction gear half shafts drives the sun gear, the sun gear drives the planetary gears, which rolls inside
the hub fixed ring gear . The wheel hub then turns as a consequence.
Wheel hub RP-17 i= 6.353- MT41

Tool for RP17.
504232 8344 504213 505766 505766 505760

Tool for RP17
From machine 513050 -
504185 505755 504256 505755 504256 504231 505770 504210 504182 504198
505754 505771 504210 504196
Tool for RP 17
From machine 513050
505768 505764 505769 505757 504256 505765 504175 504173 504170

Disassembly the front wheel hub
Safety precautions.
Connect the framelink lock to front frame
Secure the machine with to block the rear wheel
Prepare Disassembly front wheel hub, RP-17
Disassembly front wheel
Place safety the front frame bar, 2 car ramps.
On each car ramp = 5 ton

Disassembly the brake pipes
Disassembly the brake calliper
M20x65 ISO4014-10.9
For assembly:
Apply Locking liquid: Loctite 245

Assembly torque 649 Nm
Disassembly the propeller shaft from the front differential
Screw M12x60 ISO4014-12.9
For assembly:
Apply Locking liquid: Tree Bond 1374

Disassembly bolts for hub inside the axlearm
Machine 810001 - 810052

M18x100 DIN912-12.9
For assembly:
Machine 810053 -
Screw M18x1.5x100 ISO4014-10.9
Washer 19x30x3 NS-ISO 7091 300HV
For assembly:

Separate wheel hub from the suspension arm.
Disassembly propeller shaft from the hub
M12x60 ISO4014-12.9
For assembly:
Apply Locking liquid: Tree Bond 1374


Disassembly
Wheel hub RP-17 i=6,353 WDB
MT41 512624
Fasten wheel head on the assembly car.
(S) Assembly car 504213

(S) Support 8344
Figure 26
Loosen screw plug, bring drain hole in lowermost position and

drain oil.
Figure 27
Tilt wheel head 90° and loosen screw connection.
Mark radial installation location (see Arrows) !
Figure 28
Lift planet carrier out of the hub.
(S) Crow bar (2x) 504210
Figure 29
Squeeze circlip out.
(S) Set of external pliers 504231
Figure 30
Pull planetary gear from planetary shaft.
(S) Two-leg puller 505770
Figure 31
Loosen both hex. head screws and remove lock plate.
Figure 32
Tilt wheel head 90° and loosen slotted nut.
(S) Pin-type wrench 505768 or

(S) Hook spanner 505764
(S) Centering bracket 505769
Figure 33
Remove released shim from the hub carrier end face.
Remove sun-gear shaft. Figure 34
Pull internal gear from the hub carrier splines. Figure 35
(S) Crow bar (2x) 504210
Separate hub from hub carrier, using lifting device. Figure 36
(S) Lifting chain 504198

(S) Eye bolts (2x) 505751
Figure 37
Version „C“:
Pry both shaft seals out of the seal retainer and remove released
bearing inner race.
If necessary, drive both bearing outer races out of the bores.
Version „D“:
Pry shaft seal out of the hub and remove released bearing inner
race.
If necessary, drive both bearing outer races out of the bores.
(S) Crow bar 504210 Figure 38
Locate hub by means of press and loosen socket head screws.
Figure 39
Version „C“:
Separate brake disk by tapping from the hub.
If necessary, remove seal retainer (see Arrow).
Version „D“:
Tap brake disk loose and separate it from the hub.
(S) Plastic mallet 504196
Figure 40
Separate hub carrier from assembly car and pull driver from the
flange shaft splines.
Figure 41

Loosen hex. head screws and drive flange shaft by tapping out of
the hub carrier.
Squeeze circlip out and remove support shim.
Figure 42
Squeeze circlip out and remove support shim.
Figure 43
Pull cover by means of two-leg puller from the flange shaft.
Now, separate ball bearing and shaft seal from cover.
Figure 44

Assembly
Pre-assemble and install Flange shaft
Install shaft seal with the sealing lip showing downward (facing the
ball bearing).
At application of the prescribed driver (S), the exact instal-lation

position is obtained !
Wet outer diameter of the shaft seal with spirit, and grease sealing
lip !
(S) Driver 505754
Figure 44
Line up cover upon flange shaft.
Figure 45
Mount ball bearing upon the flange shaft and press it against
shoulder.
Figure 46
Fix ball bearing by means of support shim and circlip.
Figure 47
Cover mounting face of the hub carrier with sealing compound

Loctite (Type-No. 574).
Figure 48
Insert hex. head screws into the flange shaft bores and fix pro-vi-
sionally.
Screw in two adjusting screws and introduce flange shaft until

contact is obtained.
Pay attention to the radial installation location (hole for roll pin)!
(S) Adjusting screws 504185

Figure 49
Position cover by means of hex. head screws and spring washers

against shoulder (do not tighten).
Drive roll pin in (see Arrow) flush-mounted to the cover.
Install roll pin with the slot in circumferential direction !
Figure 50
Fasten cover finally, using hex. head screws.
Torque limit (M8/8.8) . . . . . . . . . . . . . . . . . 23 Nm
Figure 51
Introduce driver.
Figure 52
Fasten pre-assembled hub carrier on the assembly car.

(S) Support 8344
Figure 53
2.2.2 Pre-assemble Hub Version „C“:
Mount all wheel studs.
(S) Wheel-stud puller – Basic tool 505767

(S) Insert (M 22x1,5) 505766
Figure 54
Drive both bearing outer races into the hub bores until contact is
obtained.
(S) Driver 505755

(S) Handle 504256
Figure 55
Press seal retainer into the hub until contact is obtained.
Wet sealing surface with Loctite (Type-No. 574) !
Figure 56
Insert bearing inner race and disk.
Figure 57
Insert lower shaft seal, with the sealing lip facing the bearing until
contact on the disk is obtained.
Insert upper shaft seal until contact on the lower shaft seal is ob-
tained (see following Draft).
Wet outer diameter of the shaft seals with spirit and grease sealing
lip !
(S) Driver 505756

(S) Handle 504256
Figure 58
Ref. Draft:
1 = Hub 3 4
2 = Roller bearing 5
2
3 = Seal retainer
4 = Shaft seals 1
5 = Disk
Figure 59
Mount brake disk, align it radially and locate it provisionally with

socket head screws and disks (do not tighten the socket head
screws).
Now, fix brake disk by means of roll pins (2 pieces each bore).
Pay attention to the installation position of the roll pins, install roll
pin slots always in circumferential direction and 180° displaced !
Figure 60
Fix hub by means of press and tighten socket head screws.
Torque limit (M18/10.9) . . . . . . . . . . . . . . . 390 Nm
Figure 61
2.2.3 Pre-assemble Hub Version „D“:
Mount brake disk, align it radially and locate it provisionally with

socket head screws and washers (do not tighten socket head
screws).
Now, fix brake disk by means of roll pins (2 pieces each bore).
Pay attention to the installation position of the roll pins, install slots
of roll pins always in circumferential direction and 180° displaced !
Figure 62
Locate hub by means of press and tighten socket head screws.
Torque limit (M18/10.9) . . . . . . . . . . . . . . . . 390 Nm
Figure 63
Mount all wheel studs.
(S) Wheel-stud puller – Basic tool 505767

(S) Insert (M22x1,5) 505766
Figure 64
Press both bearing outer races into the hub bores until contact is
obtained.
(S) Driver 505755

(S) Handle 504256
Figure 65
Insert bearing inner race.
Figure 66
Insert shaft seal into the hub, with the sealing lip facing the bear-
ing.
Wet outer diameter of the shaft seal with spirit and grease sealing
lip !
At application of the prescribed driver (S), the exact instal-lation
position is obtained !
(S) Driver 505757

(S) Pressing ring 505765
(S) Handle 504256
Figure 67
Assemble Hub
Line up pre-assembled hub carefully upon the hub carrier, using

lifting device.

(S) Eye bolts (2x) 505751
Figure 68
Install bearing inner race.
Figure 69
Guide internal gear over the hub carrier splines and insert it until
(S) Crow bar 504210
Figure 70

Adjust Total rolling moment of the Wheel bearing

Version „C“: 14,5 – 20,5 Nm
Version „D“: 30,0 – 40,0 Nm:
The following adjustment of the wheel bearing refers to the

installation of new wheel bearings !
At already run bearings, aim at the lower value of the pres-cribed
bearing rolling moment !
Screw on the slotted nut, with the chamfer showing upward.
Figure 71
Tilt wheel head 90° and tighten slotted nut.
Torque limit . . . . . . . . . . . . . . . . . . . . . . . . 500 Nm
By the tightening of the slotted nut with 500 Nm, the settling of the
bearing, resp. the exact centering of the bearing rollers is
obtained !
During the tightening, rotate the hub several times in both direc-
tions and relax additionally the bearing by tapping onto the hub
(use plastic mallet) !
Figure 72
Tilt wheel head 90° and loosen slotted nut again.
(S) Hook spanner 505764 or

(S) Pin-type wrench 505768
Figure 73
Determine Dimension I from the plane face of the internal gear to

the end face of the hub carrier.
Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . 1,70 mm
We know from experience that by installation of a shim which is

about 0,25 mm thinner, the required bearing rolling moment is
obtained !
Figure 74
EXAMPLE:
Dimension I . . . . . . . . . . . . . . . . . . . . . . . . . .1,70 mm
Empirical value . . . . . . . . . . . . . . . . . . . . . . - 0,25 mm
Difference = Thickness of the shim s = 1,45 mm
Lay shim e.g. 1,45 mm over the end face of the hub carrier.
Figure 75
Mount slotted nut with the chamfer showing upward.
Torque limit . . . . . . . . . . . . . . . . . . . 2000+200 Nm
(S) Hook spanner 505764 or

(S) Pin-type wrench 505768
During the tigthening, rotate the hub several times in both Figure 76
directions and relax additionally the bearing by tapping onto
the hub (use plastic mallet) !

Check Rolling moment T = F . r.
T = Rolling moment in Nm (Newtonmeter)

F = Traction force in N (Newton)
r = Radius (½ Hub ø) in m (meter)
Record Traction force F by means of spring scale on the

hub diameter 444 mm (r = 0,222 m).
(S) Spring scale 100N 505760

(S) Spring scale 200N 505761
Figure 77
Traction force in the actual case e.g. F = 175 N.

From the Formula T = F . r results the
Rolling moment T = 175 N . 0,222 m = 38,9
Nm.
If the rolling moment is too low, a thinner shim (see Figure 75)
must be installed !
If the rolling moment is too high, a thicker shim
(see Figure 75) must be installed !
If necessary, repeat steps, starting from Figure 75 !
Fix slotted nut by means of lock plate (see Arrow) and locking
screws (2x).
Torque limit . . . . . . . . . . . . . . . . . . . 90 Nm
Figure 78

Pre-assemble and install Planet carrier
Press planetary gears against shoulder.
Pay attention to the installation location, install large radius of the

bearing inner race showing downward !
Fix planetary gears by means of circlip.

Figure 79
Adjust axial play of the sun-gear shaft 0,3 ... 0,6 mm Figure 80
(Figure 81 ... 83):
Measure Dimension I from the mounting face to the locating face

of the thrust washer.
Dimension I e.g. . . . . . . . . . . . . . . . 4,00 mm
(S) Straightedge 504170

(S) Digital Depth gauge 504175
(S) Gauge blocks 504173
Introduce sun-gear shaft into the driver until contact is obtained. Figure 81
Determine Dimension II from the mounting face of the hub to the

end face of the sun-gear shaft.
Dimension II e.g. . . . . . . . . . . . . . . . 9,40 mm
Figure 82
EXAMPLE:
Dimension II . . . . . . . . . . . . . . . . . . . . . . . 9,40 mm
Dimension I . . . . . . . . . . . . . . . . . . . . . . . . - 4,00 mm
Difference . . . . . . . . . . . . . . . . . . . . . . . . 5,40 mm
required Axial play e.g. . . . . . . . . . . . . . - 0,40 mm
Result = Thrust washer e.g. s = 5,00 mm
Introduce determined shim e.g. s = 5,0 mm.
Grease contact face !
Figure 83
Mount two adjusting screws, introduce planet carrier by means of

lifting device into the hub and position it against shoulder.
Wet mounting face with sealing compound Loctite (Type-No. 574) !
Pay attention to the radial installation location, see marking!

Oil drain hole must be brought to overlap with the recess in the
hub.
Figure 84
Fasten planet carrier by means of hex. head screws.
Torque limit (M16/10.9) . . . . . . . . . . . . . . . . 280 Nm
Prior to the commissioning of the unit, fill in oil according to the

Lubrication Instructions, Page 0.5 !
Figure 85

FRONT REDUCTION GEAR
1. Park on level ground.

2. Turn hub so that oil level indicator is horizontal.
3. Apply the parking brake.
4. Remove the oil filler plug and check that oil level is near
bottom edge of plug hole.
Note!
The oil level changes considerably if the machine is angled dur-
ing checking.

Drive shafts
Front frame
Pos Qt‘y Description

A Shaft Engine -Transmission
1 2 •U. joint as’y
2 1 •Tube ass’y
3 8 •Screw
4 4 Screw
5 4 Screw
Rubber coupling
11 1 •Housing
12 1 •Friction ring
13 1 •Hub
14 1 •Friction ring
15 1 •Rubber element
16 8 •Screw
17 12 •Screw
18 8 Screw
19 8 Washer
F Shaft left side

1 2 •U. joint ass’y
2 1 •Tube ass’y
3 8 •Screw
4 8 Screw
H Shaft right side

2 1 •Tube ass’y
3 8 •Screw
4 8 Screw

Rear frame
Pos Qt‘y Description

B Shaft in articulation hinge
2 1 •Tube ass’y
3 8 •Screw
4 8 Screw
C Intermediate shaft
1 1 •Flange
3 1 •Flange
4 1 •Nut lock set
5 1 •Screw
6 1 Brake disc
7 1 •Bearing housing ass’y
8 1 •Bearing housing ass’y
9 12 Screw
10 2 Screw
11 2 Washer
12 2 Screw
13 2 Washer
D Intermediate shaft for

Coal Hauler
1 2 •U.joint ass’y
2 1 •Tube ass’y
3 4 •Screw
4 8 Screw
5 4 •Screw
E Shaft rear
1 2 •U.joint ass’y
2 1 •Tube ass’y
3 8 •Screw
4 4 Screw
5 4 •Screw

The intermediate shaft
The bearing housing to the end of shaft to the parking brake disc, are have the bearing without adjuster ring
inside.
When reassemblying check that the axial clearance are same at both sides of the dust cap.

Front differential and transmission
Also see chapter 2.
View from the left side
FRONT DIFFERENTIAL
This differential has limited slip with 45%

locking ratio. It automatically compensates for
1:2,64 grip difference between left and right
front wheels. When the differential brake is
activated, the drive wheel is forced to give a
torque decided by the locking value.
Axle insert "LK"
The differential is viewed 6WG-310

from the top of the transmis-
sion

Brakes
Service brakes
MEASURING PAD AND DISC
1. Stop the machine on a level ground and apply the parking brake.
2. Stop the engine.
3. Place safety blocks under the wheels.
4. Dismantle one wheel.
* STANDARD VALUE: Min. shoe thickness: 3,5 mm
Min. disc thickness: 9,5 mm
MEASURING BRAKE FLUID PRESSURE
1. Stop the machine on level ground and apply the parking brake.
2. Connect a pressure gauge to the test point rear frame. (See figure below)
4. Depress brake pedal fully down.
* STANDARD VALUE: 185 ±5 bar
WARNING
Failure to replace lining when worn to limits will result in
loss of braking and possible
catastrophic failure

Service brake description
The service brake consist of:

Hydraulic pump, Accumulators, Accumulator valve, Brake pedal, Control valve, and calippers.
See the Shop Manual: Chapter 5
Fan and Accumulator pump
WDB = 1 x Accumulators WDB = 1 x

gon
R ea
r wa
rw
R ea
ago
Left
n
Right
e
hand
brak
hand side
ing
side
Park
gon
Fro
t wa
nt w
Fron
ago
Brake pedal Accumulator valve

n
Brake system sketch

Calipper

Testing of parking brake
1. Stop the machine on a level ground.
2. Charge brakes to specified pressure.
3. Warm up engine to 70°C, transmission

oil to 80 - 95°C and hydraulic oil to 40 - 70°C.
4. Apply parking brake.
5. Place gear shift lever in the 1st gear.
6. Slowly increase engine speed to 1500 rpm.

If the truck starts to move at 1500 rpm. or
below, adjust the parking brake.
The park brake is able to keep a fully loaded truck

parked at a inclination 32% (19°) when correctly
adjusted.
Note!
Over-adjustment may result in dragging of the
brake.

Remove the Linings
WARNING
To prevent serious eye injury, always wear safe eye

protection when you perform vehicle maintenance
or service.
Do not work under a vehicle supported only by
jacks. Jacks can slip or fall over and cause
serious personal injury. Support the vehicle with
safety stands.
1.
Block the wheels of the vehicle to prevent the vehicle from
moving.
2.
Figure 3.1
If necessary, raise the vehicle.
Support the vehicle with safety stands.
3.
Remove the adjuster plug and washer from the chamber
bracket.
Figure 3.1.
CAUTION
Use an Allen wrench to manually adjust and

de-adjust the brakes. Do not use an air gun to
adjust or de-adjust the brakes. Damage to
components can result.
Stop turning the Allen wrench when you feel
resistance. Do not continue to turn the Allen
wrench beyond the resistance point. Damage to
components can result.
NOTE:
When you de-adjust the brake (increase disc clearance),
you will hear a “’clicking” sound and feel a “pulsing”
sensation during the adjustment.
4.
ALLEN
Use a 6 mm Allen wrench to de-adjust the brake as
WRENCH
specified on the brake caliper and in Table A below. Stop
turning the Allen wrench when you feel resistance, which
indicates that the adjuster pistons are fully retracted.
Figure 3.2.
• To ensure that the automatic adjustment will occur: Figure 3.2

Adjust the brake an additional ¼-turn after
you reach the resistance point.
Increasing and Decreasing Disc Clearance
Increase Disc Clearance Decrease Disc Clearance
Counterclockwise Clockwise

5.
Remove the stabilizer bar cotter pin and retainer pin.
Hinge the stabilizer bar so it is out of the way.
Figure 3.3.
6.
Lift the inner lining out of the caliper
assembly. If you plan to reuse the lining,
mark the lining INBOARD.
7.
Slide the caliper OUTWARD and remove the
outboard lining. If you plan to reuse the
lining, mark the lining OUTBOARD.
NOTE:
If the caliper moves past its working
position and jams on the slide pins, use a rubber
mallet to move the caliper back to its working
range.
8.
Verify that the caliper slides freely on the
slide pins.
9.
Remove dirt and dust from the lining contact
surfaces of the saddle.
10.
Inspect the caliper boots. If the boots are
damaged, replace the caliper/saddle
assembly. Figure 3.3
11.
Inspect the disc for wear and damage.
Refer to Section 5.

Disassembly the park brake unit
Block the wheels to prevent the machine from moving.
Set the park brake in position OFF, (Hydraulik press on the

cylinder is no ON)
Remove the adjuster plug.
Figure 3.1
Use a 6 mm Allen wrench, turn the adjuster screw 3 turns

backwards, (out).
Set the park brake in ON position.
The brake linings are now unfasten from the disc.
With engine NO running, release ON and OFF the park brake to

the accumulator is empty.
Disassemble the oil hose connector. from the cylinder.
Protect the oil inlet with plastic cap or similar.

Secure the brake unit with lifting device.
Do not use the stabilizer bar to lift the caliper on

or off of the vehicle. Damage to the stabilizer
bar can result.
Unfasten the bracket f/parking brake.
Screw M16x50 ISO4017-10.9 EL

Lock washer M16 (Nord-lock)
Assembly torqe: 280 Nm
Place the brake unit in an vice or similar.
Disassemble the screw between the calipper and the

bracket.
Screw M20x1.5x60 DIN961-10.9 fzb

Lock washer M20 (Nord-lock)
Assembly torqe: 560 Nm
Assembly the park brake unit.
Assemble new or overhaul calipper in revesing order.

Adjust the Initial Caliper Clearance
1. Adjust the caliper by reducing the caliper-to-disc Figure 4.1.

clearance to ZERO.
Refer to Table A for the adjusting direction.
2. Check that the load plate fully contacts
the lining backing plate.
3. Use a 6 mm Allen wrench to increase the disc
clearance SEVEN CLICKS, which sets the initial
clearance.
Figure 4.1.
4. Install the adjuster plug and washer.

Tighten the adjuster plug to 8-12 lb-ft Figure 4.2
(11-17N•m).
Figure 4.2.
5. Unhinge the stabilizer bar and return it to position.

Install the stabilizer bar pin and cotter pin. Figure 4.3
Figure 4.3.
6. Apply and release the brake assembly 15-20

times to allow the adjuster to set the final
caliper clearance.
7. Check the adjusted chamber stroke length.
Refer to the next pages
Table A: Increasing and Decreasing Disc Clearance
Caliper Identification Increase Disc Clearance Decrease Disc Clearance
LH Hydraulic Release Brake Assembly Counterclockwise Clockwise
RH Hydraulic Release Brake Assembly Clockwise Counterclockwise

Park brake Maintenance
Hydraulic Fluid
WARNING
Use only the type of hydraulic fluid specified In the MOXY Operating & Maintenance Manual.
Do not use different types of hydraulic fluid.
Using incorrect hydraulic fluid will damage the rubber parts of the caliper. Component damage,
loss of braking and serious personal injury can result.
Do not reuse hydraulic fluid. Used fluid can be contaminated and cause incorrect operation.
Serious personal injury can result.
The brake system uses a petroleum based hydraulic fluid (mineral oil) and includes fluids
that meet MIL-H-5606 specifications.
For fluid type and specifications, refer to the MOXY Operating & Maintenance Manual
recommendations.
Inspection Schedule
Inspect the brake according to one of the following schedules. Choose the schedule that
provides the most frequent inspection and lubrication interval.
• The chassis lubrication schedule used by your fleet

• The chassis lubrication schedule recommended by the OEM
• A minimum of four times during the life of the linings
• At tire replacement.
Check the Adjusted Chamber Stroke Length
WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle
maintenance or service.
Do not work under a vehicle supported only by jacks. Jacks can slip or fall over and cause
serious personal injury.
Support the vehicle with safety stands. Block the wheels to prevent the vehicle from moving.
Use the following procedures to check in-service push rod travel.
1. Park the vehicle on a level surface.

2. Place blocks under the wheels.
3. Turn the engine OFF.
4. Check the gauges in the cab. Ensure the tanks contain the correct amount of pressure.
Refer to Table below.
Pressure Specifications
Brake Type Pressure
Hydraulic Release Brake 1700-3000 psi (117.3-207 bar)

5. Measure the distance from the bottom of the chamber to the

MEASURE ADJUSTED
center of the clevis pin while the brakes are applied.
Figure 5.1. CHAMBER STROKE
6. Have another person release and hold the brakes.
7. Measure the distance from the bottom of the chamber MEASURE

to the center of the clevis pin while the brakes are THIS
released. DISTANCE
• To determine push rod travel (adjusted chamber

stroke): Subtract the measurement you recorded
in Step 5 from the measurement recorded in Step 7.
The difference is the push rod travel (adjusted
chamber stroke).
Push rod travel (adjusted chamber stroke)
must not exceed 2.0-inches (50.8 mm).
Figure 5.1.
• If push rod travel (adjusted chamber stroke)
exceeds specification, Refer to Section,
Troubleshooting Park brake
Inspect the Brake Components
WARNING
Use MOXY parts only. Do not use parts manufactured by other suppliers.
Use of non-MOXY parts can cause damage, loss of braking and serious personal injury.
Lining Thickness
Lining material thickness must not be less than 0.200-inch (5.1 mm). Replace the linings before
the lining material thickness reaches this specification.
Anti-Rattle Springs
1. Anti-rattle springs are attached to the linings.
Inspect for bent, cracked or broken springs.
2. If you find damaged springs, replace both springs.
Seals
Replace the caliper if you find cracked, torn or damaged seals.
CAUTION
Install only the specified components when you service the caliper.
Do mix components from other calipers. Installing non-specified components
can cause the caliper to operate incorrectly and can cause equipment damage.
Caliper
1. The caliper should slide freely on the slide pins. Slide the caliper back and forth to check for
clearance between the disc and pad.
2. Check that the linings slide freely in the caliper.
3. If components are worn enough to restrict free movement of the caliper or linings,
replace the caliper.

Disc
CAUTION
You must always replace a damaged disc.
1.
When you inspect the brakes, inspect both sides and the outer
diameter of the disc for the following conditions:
• Cracks
• Heat checking
• Grooves or scoring
• Blue marks or bands
2.
When you reline the brakes, you must measure the thickness
of the disc. Figure 5.2
Cracks
When a crack extends deep into a section of the
disc, replace the disc.
Figure 5.2.
Heat Checking
Heat checks are cracks in the surface of the disc caused by heat.
Heat checking can be light or heavy.
Light Heat Checking

Light heat checking is very fine, tight, small cracks. Light heat
checking is normal.
You can continue to use a disc with light heat checking.
Figure 5.3
Heavy Heat Checking
Heavy heat checking is surface cracks with width and depth.
Figure 5.3.
If you find heavy heat checking,
always replace the disc.
Deep Grooves or Scores

Check both sides of the disc for deep grooves or scores. If the
grooves or scores are not too
deep, you can continue to use the disc.
Figure 5.4.
Blue Marks or Bands
Blue marks or bands indicate that the disc was very hot. Figure 5.4
If blue marks or bands are present, refer to Section 6 to find and
correct the cause of the problem.
Figure 5.5.
Figure 5.5.
Measure Disc Thickness

Measure the thickness of the disc when you reline the brakes.
The disc must be at least 0.866-inches (22.0 mm).
Figure 5.6.
If the disc thickness is outside specification, replace the disc.
Caliper Assembly
The caliper and saddle assembly are not serviceable.
Replace the brake assembly when a caliper is worn or damaged.
O R IG IN A L D IS C M A X IM U M D IS C M IN IM U M D IS C
T H IC K N E S S WEA R T H IC K N E S S
Cleaning 1. 0 0 -i n c h 0 . 0 6 7 -in c h 0 . 8 6 6 -in c h
(2 5 . 4 m m ) (1 . 7 m m ) (2 2 . 0 m m )
WARNING
Figure 5.6.
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance or service.
Solvent cleaners can be flammable, poisonous and cause burns.

Examples of solvent cleaners are carbon tetrachloride,
emulsion-type cleaners and petroleum-based cleaners.
To avoid serious personal injury when you use solvent cleaners,
you must carefully follow the manufacturer’s product instructions
and these procedures:
• Wear safe eye protection.

• Wear clothing that protects your skin.
• Work in a well-ventilated area.
• Do not use gasoline or solvents that contain gasoline. Gasoline can explode.
• You must use hot solution tanks or alkaline solutions correctly.
Follow the instructions carefully.
Cleaning Ground or Polished Metal Parts

• Use a cleaning solvent to clean ground or polished parts or surfaces.
Kerosene or diesel fuel oil can be used for this purpose.
NEVER USE GASOLINE.
• Be careful not to damage ground surfaces.
• DO NOT clean ground or polished parts in a hot solution tank, water, steam or alkaline solution.
Cleaning Metal Parts With Rough Finishes

• Parts with a rough finish can be cleaned with cleaning solvent or in a hot solution tank
with a weak alkaline solution.
• Parts must remain in hot solution tanks until completely cleaned and heated.
• Parts must be washed with water until the alkaline solution is removed
• Use a wire brush to clean the threads of fasteners and fittings.
Cleaning Non-Metal Parts

• Use soap and water to clean non-metal parts.
• Scrape away build-ups of mud and dirt on the linings. Replace all linings contaminated with oil or grease.
Drying Cleaned Parts

• Dry the parts immediately after cleaning and washing.
• Dry the parts with soft clean paper or rags.
Corrosion Protection
Apply rust inhibiting fluid to the cleaned and dried parts that are not damaged and are to be
immediately assembled. Do NOT apply fluid to the brake linings or the disc.
If you plan to store the brake parts, apply a special corrosion preventative material to all
surfaces. Do NOT apply this material to brake linings or the disc.
Store the parts inside special paper or other material that prevents corrosion.

Hydraulic Release
Troubleshooting Parking
Park brake Disc Brake
Conditions : Possible Cause(s): What to Check : Corrections :
À Chamber exceeds Incorrect initia l Check the chamber stroke If the air chamber stil l
two-inch maximum adjustment or after 20 brake overstrokes, replace th e
stroke requirement inoperative automatic applications . caliper/saddle assembly.
adjuster Refer to Sections 3 and 4 .
Á Brake drag Incorrect lining-to - Minimum stroke Replace the caliper/saddl e

rotor clearance 7/8-inch (22 mm ) assembly.
Incorrect initial Adjust the rotor to pad
adjustment clearance. Refer to Section 4.
Vehicle brake release Correct operation of the Repair or replace parts as
pressure malfunction quick release valve required.
Â Short outboard Caliper seized or Damaged slide-pin seals Replace the caliper/saddle
brake pad lining lif e sticking on slide pins assembly.
Caliper should move
back and forth by hand
with linings removed
Ã Short lining lif e Refer to conditions Á Refer to conditions Á Refer to conditions Á and Â .
and Â . and Â .
Rotor surface Cracks or heavy hea t Refer to Section 5 for disc
checking. Refer to inspection .
Section 5 .
Ä Brake smokin g High brak e Refer to conditions Á , Â Refer to conditions Á , Â

temperature and Ã . and Ã .
Grease, oil, etc., on Grease, oil, etc., on the Check for oil leaks in the
the linings linings brake area. Repair as
required. Clean the rotor
and caliper assembly.
Replace the linings.
Refer to Sections 3 and 4 .
Å Poor stopping Vehicle brake releas e Correct operation of the Have the system evaluated
powe r pressure malfunction quick-release valve by a qualified brake syste m
specialist .
•• Long stoppin g Brakes out of Stroke exceeds Refer to condition À .
distance s adjustmen t two-inch requiremen t
•• Poor driver fee l Vehicle overload Refer to the GAWR Observe the vehicle
•• Lack of normal limitations on the vehicle manufacturer 's load
response I.D. plate . recommendations .
Lining contamination Grease, oil, etc., on the Inspect for oil leaks in the
linings brake area. Repair as
required. Clean the rotor and
caliper assembly. Replace the
linings. Refer to Sections 3
and 4 .
Torque Specification
Component Torque
Mounting Bolt s 400-500 lb-ft (544-680 N •m)
Chamber Nut s
• Air Release Brakes 135-155 lb-ft (180-210 N •m)
• Hydraulic Release Brakes 30-40 lb-ft (41-54 N •m)
Adjustment Plu g 8-12 lb-ft (11-17 N •m)

Rear differential

General function
The differentials transmit the torque of the transmission

output propeller shafts to the wheels.
The differential contains one crownwheel and one pinion,
as well as a differential gear.
The teeth of the crownwheel and pinion are cut in
a special way to provide proper mesh and high strength.
As heavy torque has to be transmitted, the fit between
crown wheel and pinion has to be accurate and therefore
the parts are lapped together as a pair in manufacturing.
When changing crownwheel or pinion, both parts have to
be changed.
Under heavy load the gearwheel set is exposed to

forces which both tend to push the pinion forward
(front diff.) / backward (rear diff.), as well as pressing
the crownwheel and pinion apart.
To prevent this, the pinion runs in robust roller
bearings.
The rear diff. has a support bearing which is cylindrical
and seated in the gear housing inside the crownwheel circum-
ference.
The other two bearings are taper roller bearings and
absorb the axial and radial forces in the pinion.
The crownwheel is attached to the differential casing,
which runs in two robust taper roller bearings in the
differential housing.
With a hypoid crownwheel and pinion arrangement the

pinion centre is below the centre of the crownwheel,
which provides the teeth with increased strength by
extended sliding mesh and more tooth overlap.
Distance “a” is known as offset

Although the wheels have different distances to roll when ne-

gotiating bend and thereby different rotation speed, exactly the
same drive torque has to be transmitted to both sides.
This torque distribution takes place in the differential gear.
The differential gear consists of four taper gear wheels, star
wheels, that run on a differential spider.
The star wheels are in constant mesh with two opposed differ-
ential gear wheels, each attached to a half shaft.
The differential gear sits in the differential casing to which the
crown wheel is attached.
When the truck travels straight ahead and the rotation speed
of the drive wheels is the same, the star wheels on the differ-
ential spider do not turn, and only function as a driver between
crownwheel and half shafts.
When the dump truck travels round a bend, the inner drive
wheels will roll a shorter distance than the outer ones. Because
of the drive wheels then having different rotation speeds, this
also applies to the differential gear wheels on the half shafts.
The star wheels will then turn.
Because of the compound speed of the drive wheels being
constant, the outer drive wheel will turn much faster in relation
to the crown wheel, as the inner drive wheel will turn slower.
In extreme cases, when one drive wheel side is stationary and
the other one spins, the spinning wheels turns twice as fast as
the crown wheel.
If a drive wheel side does not have sufficient grip and starts
spinning, the dump truck comes to standstill. The grip of the
spinning wheels determine the amount of torque.
This torque becomes decisive in regards to the drive power of
both sides because the differential gear will always distribut the
torque equally to both sides.

To avoid wheel spin, the two differentials each have a differential brake with a locking value of 45%. When the
differential brake is activated, the drive wheel is forced to roll at the rotation speed decided by the locking value.
Torque flow diagram when driving in a straight line equal

grip on both driven wheels.
Torque flow diagram when turning to the left or when grip dif-
ference between the left and right driven wheels.
Multi-disc brakes are mounted at the left

and right on the side gears, and react to
relative movement between them and
the differential cage by generating a
braking force dependent on torque. This
braking movement has the effect of par-
tially locking the output side concerned,
and increasing the torque on the side
with good wheel grip. The braking mo-
ment in other words, acts as a substitute
for the torque reaction on the side with
poor grip.

Illustrated tables - Special tools
509157 504198 504731 509109 504195

DIFF.CARRIER.
153441
Page: 1/2
509110
504173
504185
504170
505759 150
140
130
120
110
100
90
80
70
60
50
29.31
0
504175
504171
0
90 10
80 20
70 30
60 40
50
509111
504172
150
140
130
120
110
100
90
80
70
60
50
29.31
0
230 V 115 V
504209 504193 504194 509112 505158 504175 505155 504231 505770 504196
DIFF.CARRIER. 8344 504213
153441
Page: 2/2
DISASSEMBLY WITH MECHANIC UNITS
509113 504243 509115 509114 504243

Disassemble the TK-differential
Safety precautions.
Differensial “TK new” i=4,375 (UNF)
Connect the articulation lock to front frame.
Be aware of personal injury.
Secure the machine with wheel chocks on the

front wheel.
Drain the oil from axle housing.
Note:
Draining of oil from tandem housing is not necessary if removal
takes place just for work on the tandem bearing.

Disassemble the differentilal from the axle hous-

ing
NOTE:
To disassemble the differential is the safely way to do when the

bogie unit is separated from the rear frame.
It’s also possible when using these next pages description:
On both side of the boggi unit, disassemble screws

from the cover for the shaft and pinion
Remove the cover.
Use chisel and hammer.
Be aware not to damage the cover
Remove the snap ring for the thrust washer

Pull out the thrust washer
Use screw M16x220 060583
Pull out the shaft.

Now the differential is free from the axle and can be lifted out.
Use screw M16x220 060583
When repair or assembly, follow the descriptions for the assembly when the boggi unit is separated from the
frame.

Lift the body in safe position and welding a bracket under the body bottom.
The bracket is not Moxy part.
Note:
When welding on machine, place the welding ground cable to
the same object and close the welding point as possible.
Be sure the contact to the ground is optional.
Othervise it’s safe to disconnect cables from:
Battery, - Engine controller and the
Transmission controller.
Moxy Engineering is not responsible for
damage of the machinary equipment when
welding on the machine.
Unfasten the rear propeller shaft from the differential flange
M12x60 DIN912-12.9
Secure the rear propeller shaft for damage with a strop
Disassemble 15 of the lovering screws from axle housing

flange. The last one of the screws must be taken out when
the lifting device is place.
Place in the “free” hole (M20, arrow) 2 pcs. screw M20 x 75

or eye bolt and fasten the lifting device.
Secure with the lifting device and take out the upper screw.
Carefully move the differential out of the axle housing.
Lower the differential to a pallet or to the

floor

Disassemble the boggi unit from frame
1 Disassemble 2 brake hoses from Tandem housing

LHS and RHS
1
2 Disassemble 2 lubrication hose from Tandem housing
LHS and RHS
2
3 Disassemble axle housing screws (4 in each side).
Screw M24x380 DIN931-10.9
By crane:
lift the rear frame up and move the tandem
unit backwards
Place safety supports under the rear frame.

Aware of the propeller shaft.

By crane, turn the axle housing 90°
Assemble 2 pcs. M16 eye bolt to the M16 threaded hole in the
bearing housing
Disassemble screws from the differential flange
By crane, carefully lift the differential out from

the axle housing

Fasten differential carrier on the assembly car.

(S) Support 509253
Figure 1
Loosen hex. head screws and remove both lock plates
Figure 2
Loosen both adjusting nuts.
(S) Pry bar 504209
Figure 3

Mark installation position of the bearing brackets with the axle

drive housing, see Arrows !
Figure 4
Loosen hex. head screws and remove both bearing brackets,
adjusting nuts and bearing outer races.
Hex. head screws are secured with Loctite !

Heat axle drive housing in the area of the tapped holes !
(S) Hot-air blower 230 V 504193

Figure 5
Separate the differential from the axle drive housing, using lifting
device.
(S) Gripper tongs 505155
Figure 6
Loosen lock nuts and remove set screws.
Pay attention to the released sliding pad !
Figure 7
Dismantle Differential
Pull off both bearing inner races (differential bearing).
(S) Quick-acting grip 509254

(S) Quick-acting grip 509255
(S) Basic tool 504243
Figure 8
Loosen hex. head screws, remove housing, cover and

disasssemble components.
Figure 9
If necessary, loosen screw connection (Figure 10), resp.

bore off the rivet joint (according to the version), and
separate crown wheel from differential case.
Figure 10

Disassemble Drive pinion
Unlock and loosen castle nut.
Do not remove the castle nut !
(S) Clamping yoke 509110
Pipe KM 509157
Figure 11
Mark the radial installation location of sealing cap and bearing

bush with the axle drive housing, see Arrows !
Loosen hex. head screws.
Figure 12
Separate the drive pinion (compl.) from the axle drive housing,
using lifting device.
Pay attention to the released shim !
(S) Lifting device 504198

Figure 13
Remove castle nut and disc.
Pull off input flange.
Figure 14
Demount sealing cap and disassemble shaft seal.
Figure 15
Press drive pinion out of the bearing bush.
Pay attention to the released components !
Figure 16
Remove adjusting ring.
Figure 17
Pull off bearing inner race from the drive pinion.
(S) Grab sleeve Bearing 78 238 509256

(S) Reducer 509114
(S) Quick-acting grip

Bearing HM 813 841 509254
Figure 18
Squeeze circlip out.
Figure 19
Pull off roller bearing.
Figure 20

ASSEMBLY
If the crown wheel or drive pinion are damaged, both parts must
be changed together !
Pay attention to equal mating numbers !
Clean tapped holes of the bearing bracket screw connection from

Loctite residues !
Figure 21
DRIVE PINION
Adjust Contact pattern - Bevel gear set, see Figure 22 (Draft) to

Example A3:
Carry out the following measuring operations with outmost accu-

racy !
Inaccurate measurements are causing a faulty contact pattern !
Ref. Draft: 1 = Axle drive housing

2 = Measuring shaft 505158
3 = Fitting piece 509257
4 = Digital Depth gauge 504175
Figure 22

Locate both bearing brackets provisionally by means of hex. head

screws.
Insert fitting pieces into the bearing bores and introduce meas-ur-
ing shaft, see also Figure 22/Page 1.7 !
(S) Fitting pieces 509257

(S) Measuring shaft 505158
Figure 23
Tilt axle drive housing 180°.
Determine Dimension a, from the mounting face to the measur-

ing shaft.
Dimension a e.g. ...................................... 235,10 mm
Example: „A1„:
Dimension a e.g.. ...................................... 235,10 mm
Dimension b (1/2 Æ measuring shaft) .. + 15,00 mm
gives Dimension X (housing dimension) = 250,10 mm
Figure 24
Press both bearing outer races into the bearing bush until con-tact
is obtained.
At the version with compl. bearing bush, the two

bearing outer races are already installed !
Figure 25
Insert bearing inner race, press it uniformly on, and measure

Dimension c, from the end face/bearing inner race to the mount-
ing face.
Dimension c e.g. .................................... 53,55 mm

(S) Gauge blocks 504173
Figure 26
Read Dimension d (pinion dimension). 197+0,1
Dimension d e.g. (197 + 0,1 mm) ............... 197,10 mm
Example „A2„:
Dimension c (Figure 26)................................. 53,60 mm
Dimension d ....................................... + 197,10 mm
gives Dimension Y (install. Dimension) 250,70 mm
Figure 27
Example „A3„:
Dimension Y ............................................. 250,70 mm
Dimension X ............................................. - 250,10 mm
gives Shim e.g. s = 0,60 mm
The assembly of the shim is realized at Figure 39 !
Press bearing inner race over the drive pinion stem until contact is
obtained.
Figure 28
Adjust Rolling moment of Drive pinion bearing 1 ... 2 Nm (without

shaft seal), see Figure 29 ... 35 !
We know from experience that at application of the

adjusting ring (e.g. s = 15,28 mm) found at the
disassembly, the required rolling moment is
obtained !
However, the later checking of the rolling moment
is necessary !
Line up the adjusting ring e.g. s = 15,28 mm, with the small col-
lar showing upward.
Figure 29
Line up the bearing bush.
Figure 30
Press bearing inner race against shoulder.
Figure 31
Press dust cap over the input flange until contact is obtained.
Figure32
Heat input flange and line it up until contact is obtained.
Use protective gloves !
Figure33
Line up the disc and tighten castle nut.
Torque limit ............................... 1300 Nm
During the tightening, rotate the drive pinion several

times in both directions !
Figure 34
Check Bearing rolling moment 1 ... 2 Nm !

In case of deviations from the required rolling
moment, correct with corresponding adjusting ring
(Figure 29), according to the following specification:
Rolling moment too low - install thinner ring,

Rolling moment too high - install thicker ring.
Now, loosen the castle nut again and pull off the input flange.
Figure 35
Press shaft seal, with the sealing lip facing the oil chamber, into
the sealing cap until contact is obtained.
Grease sealing lip !
According to the version different shaft seals can be

applied:
Outer diameter rubber-coated - wet with spirit;

Outer diameter metallic - wet with sealing compound
(Loctite, No. 574) !
(S) Driver (rubber-coated) 509109

(S) Handle 504195
Figure 36
(S) Driver steel cage) 509259

(S) Handle 504195
Press roller bearing against shoulder.
Figure 37
Fix roller bearing by means of circlip.
Figure 38
Install two adjusting screws and line up the shim e.g. s = 0,60 mm
(see Example A3 / Page Figure 27B).
Pay attention to the overlapping of the oil ducts, see

Arrows!
Wet the shim(s) on both sides with the sealing
compound
(Loctite, Type-No. 574) !
Figure 39
Introduce pre-assembled bearing bush until contact is obtained.
Pay attention to the radial installation location, see

markings (Arrows) !
Figure 40
Wet mounting face with sealing compound (Loctite, Type-No.

574) and position pre-assembled sealing cap against shoulder.
Pay attention to the radial installation location, see

markings (Arrows) !
Figure 41
L- diff
Figure 42
Assemble bearing housing
Torque limit (M16/10.9) ... 280Nm
TK- diff
Figure 42
Assemble the Sealing cap
Torque limit (M8/8.8)..................................23Nm
TK- diff
Figure 42
Heat input flange and line it up.
Figure 43
Screw sealing cap and bearing bush together with

the axle drive housing.
Tilt differential carrier 90°.
Wet contact face of the disc with sealing compound (Loctite,

Type-No.574).
Torque limit .............................. » 1300 Nm

Pipe, slotted nut 509157
Figure 44
Secure castle nut by means of cotter pin, see Arrow !
Figure 45
Wet contact face of the disk with sealing compound

(Loctite,Type-No.574).
Torque limit .............................. » 1300 Nm


1. 2.2 DIFFERENTIAL DL-1600, Interlock value 45%
The following Perspective Illustration shows the components of the Differential and its installation location.
41 = Strain bolts 38 = Thrust ring

43 = Housing cover 37 = Side gear
42 = Thrust washer 35 = Differential bevel gear
40 = Outer plate (optional) 36 = Differential axle
39 = Inner plate 44 = Differential housing
Figure 47
For the adjustment of the assembly play of the inner parts (see Figure 57 ... Example B), outer
plates (4) of different thickness are available (s = 2,9 ... 3,1 mm).
With that, the outer plates must be selected in such a way that the height of the plate packs A
and B is identical on both sides of the differential !
Fasten crown wheel on the differential case, using socket head

screws and castle nuts.
M20x1,5/10
Loctite No. 262
Torque limit .................................. » 620 Nm
Now, secure castle nuts by means of cotter pins !
Figure 48
Pre-assemble Differential (Figure 49 ... 61)
Lubricate the differential components according to

ZF-List of lubricants TE-ML 05
(with LS-Additive) !
Insert thrust washer, with the chamfer on the outer diameter show-
ing downward, into the differential housing.
Figure 49
Install plate pack A, starting with one outer plate.
Pay attention to the Note,

Figure 47 Previous Page !
Figure 50
Introduce thrust ring.
Figure 51
Introduce side gear until both inner plates are accommodated.
Figure 52
Insert complete differential spider.
Figure 53
Figure 54
Figure 55
Install plate pack B, starting with one inner plate.
Pay attention to the Note, Figure 47
Figure 56
Check the Assembly play of the internal components =

0,2 ... 0,6 mm (Figure 57 ... Example B):
Differential housing
Measure Dimension I from the mounting face to the outer plate.
Dimension I e.g. ........................................ 6,50 mm
Figure 57
Housing cover
Measure Dimension II from the contact face to the mounting face.
Dimension II e.g. ...................................... 6,20 mm
Figure 58
Example B:
Dimension I .............................................. 6,50 mm
Dimension II ............................................. - 6,20 mm
Difference ^ Assembly play = 0,30 mm
At the assembly of new plates, aim at the lower value

of the assembly play !
Corrections have to be carried out with
corresponding outer plates !
Pay attention to the Note, Figure 47
Make thrust washer, with the chamfer on the outer

diameter showing downward, adhere in the housing cover.
Use assembly grease !
Figure 59
Mount housing cover and fasten it with strain bolts.
Torque limit .................................. 105 Nm
Wet thread of strain bolts with Loctite

(Type-No. 262) !
Only use of new strain bolts permitted !
Figure 60
Press bearing inner race against shoulder.
Install crown wheel-side bearing inner race accordingly.
Figure 61
Install set screw and hex. nut, see Arrow !
Wet thread of set screw with

Loctite (Type-No. 574) !
Screw in the set screw only far enough until the
sliding pad can be installed (Figure 63) !
Figure 62
Make sliding pad adhere with assembly grease on the end face of
the set screw.
The adjustment of the sliding pad is realized after

the installation of the complete differential !
Figure 63
Position differential by means of lifting device in the axle drive

housing and install both bearing outer races.
Pay attention to the position of the sliding pad !
(S) Gripper tongs 505155
Figure 64
Install both adjusting nuts.
Figure 65
Mount both bearing brackets and locate them provisionally by

means of hex. head screws (mount flat washers).
Pay attention to the installation position of the

bearing brackets, see markings (Arrows) !
Wet thread of hex. head screws with
Loctite (Type- No. 262)!
Pay attention to the exact overlapping of the
threaded parts (axle drive housing, adjusting nuts
and bearing brackets !
Free movement of the adjusting nut must be
ensured !
Figure 66
Tilt axle drive housing 90° and tighten hex. head screws.
Hex head screw M22/10.9

Loctite No. 262
Torque limit ................. ....................... 750 Nm
Hex head screw M16/10.9

Loctite No. 262
Torque limit ..........................................280 Nm
Figure 67
Adjust Backlash
Adjust Backlash - Bevel gear set = 0,27 ... 0,33 mm

Bearing rolling moment - Differential bearing T = 3 ... 4 Nm
and
Yoke width = 472 - 0,2 mm (Figure 68 ... 69):
Determine the backlash by the alternating adjustment of the two
adjusting nuts (Figure 68).
Adjust the adjusting nuts without greater force -

differential bearing must not yet be preloaded,
however must be absolutely playfree ! To ensure
this, rotate the differential during the adjustment
procedure several times as well as relax the bearing by tap
ping onto both bearing brackets (use plastic mallet) !
Figure 68

(S) Crow bar 504209
(S) Magnetic stand 504171
(S) Dial indicator 504172
(S) Precision micrometer 509260
Now, adjust both adjusting nuts further for about 1 notch.
We know from experience that by adjustment of the

two adjusting nuts for about 1 notch each, the
required bearing rolling moment of the differential
bearing as well as the bearing bracket dimension is
obtained !
Check bracket dimension and backlash once more and correct if
necessary Figure 69
Check Contact pattern (Figure 70 ... 71) !
Cover some driven and driving flanks of the crown wheel with
marking ink.
Figure 70
Roll crown wheel several times in both directions over the drive
pinion.
Compare the obtained contact pattern with the Examples of Con-

tact patterns, (See next pages, examples of
gear-tooth-contact patterns
In case of a contact pattern deviation, a measuring

error has been made at the determination of the
shim (Figure 39), which must be absolutely
corrected !
Figure 71
Examples of gear-tooth-contact.
Examples of gear-tooth-contact patterns for the

gleason gear-tooth system Coast side (concave)
Ideal tooth-contact pattern i.e.
pinion distance is correct
Figure 71-1
Drive side (convex)
Ideal tooth-contact pattern i.e.
pinion distance is correct
Figure 71-2
Pinion distance
must be increased Figure 71-3
Figure 71- 4
Pinion distance must

be decreased
Figure 71-5
Figure 71-6
Fix both adjusting nuts by means of lock plate (Arrow).
Wet thread of hex. head screws with

Loctite (Type-No. 262) !
Torque limit (M8/8.8) ............................... 23 Nm
Figure 72
Adjust Sliding pad without play and pressure:
Wet some threads of the set screw in the area of the housing
screw-in surface with Loctite (Type-No.574).
Position sliding pad by means of set screw on the crown wheel
back until contact is obtained.
Now, turn back the set screw only far enough until the crown wheel
can be rotated freely.
Lock the set screw by means of hex. nut.
Figure 73
Assemble the TK-diff in the axle housing
Apply sealing compound: Loctite 574.
Apply around the threaded holes.
Assemble the differential into the axle housing.
Check that the differential is in correct position
Assemble the screws
Screw: M20x90 ISO4014-10.9 2 pcs (arrow)

Screw: M20x65 ISO4014-10.9 14 pcs
Washer: 30,8x21x4 (Nord-lock)
Apply locking liquid: Loctite 245

Torque limit 560 Nm
Assemble the shafts on both tandemhousing.
Turn the input flange on the differential to line up the shaft

and the spline in the differential .
Assemble the thrust washer with new O-ring.
Assemble the snap ring.

Apply sealing compound: Loctite 574.
Apply on both sides of the holes.
Assemble the cover.
Screw: M10x40 ISO4017-8.8 fzb
Locking liquid: Loctite 245
Torque limit 46 Nm

Turn the axle housing back to normal position.
Assemble the wheels.
Lubricate the wheel bolts, and assemble the wheels
Torque limit: 450 Nm

Assemble the tandem housing unit to the rear
Assemble the tandem housing to the rear frame.

Lift the rear wagon with the crane.
Move the tandemhousing unit under the rear frame and connect
the frame and axle housing.
Make sure that the guide pin meet the hole in the frame.
Assemble screws for the axle housing to the frame.
Screw dimension: M24 x 380mm
Apply locking liquid: Tree Bond 1374
Torque limit: 935 Nm.
Assemble the propeller shaft to the flange

of the differential.

Fasten the brake

hose to the frame.
Fill oil to the axle housing,
the machine should be placed on a horizontal ground.
Check the oil level on the tandem housing.

Note:

Note:

Wet disc brake
NOTE: From machine 810053
Figure 1

Front hub
Outer view and section drawing
Figure 1

2
5
1= Connection external cooling from pump
4
2= Connection external cooling to pump
1
3= Oil drain - Cooling brake
4= Brake chamber 3
5= Bleeder
Figure A
4,3
\W1.00;B
00;67390 00;48685
00;67322 00;48620

Tools for WDB
504210
5870 345 071 505755
5870 050 008 514653
5870 260 004 505760
5870 230 006 505766
5870 610 002 505767
5870 610 010
2x
0 - 100 N M22x1,5
505756
5870 051 004 504175
5870 200 072
150
140
130
120
110
100
90
80
70
60
50
0
29. 35
5870 260 004

514653 504170
5870 200 022
5870 221 501

504194 5870 200 067
504174
115V
230V
504193
5870 211 500
514666
5870 651 092
115V
504194
5870 211 501
230V
514656
5870 281 043 5870 281 047
504198 505764
5870 401 141 5870 912 012
505769 504231
5870 900 015 504193
5870 211 500 504731
5870 970 003 505759
5870 204 023 514658
5870 281 058 504198
5870 281 047
514650
5870 204 026 514655
5870 281 026 5870 280 004
514654 514659
5870 286 072
M22x1,5 0 - 1,0bar M16x1,5

514671
5870 950 156 5870514660
286 079 514670
5870 950 103 5870 287 007
514661

504210
5870 345 071 5870 345 106
514662 514668
5870 705 011 5870 900 016
504232 5870 900 051
514669
2x
504182
5870 204 002 504198
5870 281 047 5870 654 047
514667 514644
5870 080 055 514673
5870 970 029 514663
5870 510 041

Disassembly the front wheel hub
Note:
Look in the section; Safety precautions
before starting disassembly of the hub.
When disassembly the WDB-hub it is from starting 2 ways for this:

To disassemble the unit complete, use descripotion 1
To disassemble inside parts use discription 2
1 Disassemble the propeller shaft from the transmission

flange shaft connection.
Assembly:
Screw: 1/2UNFx57 - 10.9
Locking liuid: Loctite 245
Tightening torque: 141 Nm
Fit the lifting device to the hub
Disassemble the screw inside the hub.

Machine 810001 - 810052
M18x100 DIN912-12.9
For assembly:
Machine 810053 -
Screw M18x1.5x100 ISO4014-10.9
Washer 19x30x3 NS-ISO 7091 300HV
For assembly:
Lift the hub away from the suspension arm
Disassemble the propeller shaft from the hub
2 Follow the description on the next pages

Figure 1
Brake (see Fig. 1)
Loosen the screw plug (1) and drain the oil.

4
Wheel head
Loosen the screw plug (2) and the cap screw (3) and drain the oil. 2
Remove the screw plug (4).
Also drain the oil in the axle insert. 3
Figure 2
Loosen the bolt connection (1) planet carrier/hub.

Mark the radial installation position of the
planet carrier to the hub (see arrows).
Install two adjusting screws.

1
Figure 3

By means of the lifting device separate the planet carrier (1)

from the hub.
Pay attention to the released sun gear shaft (2)!

(S) Lifting tackle 514658
2
1
Figure 4
Remove the O-Ring (1).

(S) Two-armed puller 504731
1
Figure 5
Unsnap the retaining rings (1) and by means of the extractor

separate the planetary gears from the planet carrier.
1
The roller bearing in the planetary gear is fixed with a

circlip and these components are destroyed at the
separation !
Both the planetary gear and the roller bearing have to be
replaced together at the reassembly.
Figure 6
Remove the driver (1).
Figure 7

Pull the stub shaft (1).
Left and right stub shaft are of a different length! 1
Figure 8
Loosen both hexagon screws (1) and remove the lock plate.
Figure 9
Loosen the slotted nut.

Loosening torque of the slotted nut is over 2000 Nm.
(S) Slotted nut wrench 505764

Figure 10
By means of the lifting tackle and the pry bar set separate the
hub from the hub carrier.
Pay attention to the released bearing inner ring and the

ring gear!

(S) Pry bar set 505762

Remove the hub.
Figure 12
Remove the ring gear (1) from the hub (2).

1
Figure 13
Unsnap the circlip (1) and separate the ring gear carrier (2) from
the ring gear (3). 1
Figure 14
By means of lever action press the shaft seal (1) out of the hub
bore (3) and remove the ring (2). 1
Expel both bearing outer rings (4) from the bearing 4

bores of the hub (3), if required. 2
(S) Pry bar set 505762

3
Figure 15

By means of lever action press the slide ring seal (1) out of the
hub (2). 1
(S) Resetting device 504210
Figure 16
Disassemble the WDB-brake housing
3
Loosen the hexagon screws (3) and separate the sealing
holder (2) from the brake housing (1).
Install the adjusting screws.
1
Figure 17
By means of lever action press the slide ring seal (1) out of the
sealing holder (2). 1 2
Figure 18
Remove the O-Ring (1) from the sealing holder (2). 1
Figure 19

Remove the disc set (1) from the brake housing (2).
Figure 20
By means of the lifting tackle separate the brake housing (1) 2

from the brake carrier (2).
(S) Eyebolts assortment 504182

Figure 21
Drive back the slotted pins (3) 2

to be flush and unsnap the circlip (1)
from the piston (2). 3
Figure 22
Press out the support shim by means of the automatic piston

adjusting from the piston.
Figure 23

Expel the slotted pins (1) from the support shim.

1
Figure 24
Preload the cup springs by means of the press and

unsnap the circlips.
(S) Clamping pliers 514669

(S) Assembly fixture 514662
Figure 25
Pull the pin (1) out of the support shim and

remove the released cup springs (2).
Figure 26
Press the gripping rings (1)

with sleeve (2)
from the pin (3).
2
1
Figure 27

By means of compressed air press the piston out of the brake

housing (1). 2 1 2
By means of the lifting tackle rotate the brake carrier by

180°!
See the sketch for connections (2)!
Cover the bore (1) with the hand (pressure build-up)!
Figure 28
Remove the guide ring, the support rings and U-rings from the
annular grooves of the brake housing.
See below sketch for installation position of

the single parts!
Figure 29
Legend to the sketch: 1

2
1 = Brake housing
2 = Guide ring 3
3 = Backup ring
4 = U-Ring 4
5 = U-Ring
6 = Backup ring
7 = Pressure connection 5
6 7
Figure 30
Loosen the bolt connection hub carrier (2), brake carrier (1) and
axle casing (3).
Install the adjusting screws. 1
2
3
Figure 31

By means of the lifting tackle separate t

he hub carrier (1) from the axle casing.
(S) Lifting strap 514655
1
By means of the lifting tackle separate the
brake carrier (1) from the axle casing.
Figure 32
Figure 33

Reassemble
Assemble of the complete hub unit .
Clean the connection surface (1)
Install the slots of slotted pins in direction

of force and by 180° turned to each other.
2 1
1 = Slotted pin S 25x70
2 = Slotted pin S 15x70 1 2
Clean the connection surface on the axlePower

arm. bearing
Wet the mounting face of brake carrier (2) with sealing

compound Figure 5
(Loctite Type No. 574).
Fix the hub to the axlearm,
Wet thread of hexagon screws with Loctite type no. 262.
Tighten the bolt connection with hexagon screws (1).
Screw: M18x1.5x100 -10.9


Assemble of the separated parts
Preassemble the slotted pins in the hub carrier and the brake
anchor plate before assembling to the axle arm 2 1
1 2
Clean the connection surface (1)

Power bearing
Install the slots of slotted pins in
direction of force and by 180°
turned to each other.
Figure 5
Wet the mounting face of the axle casing with

sealing compound.
(Loctite Type No. 574).
Clean connection surfaces and oil the slotted pins.
Observe the radial installation position

of the brake carrier!

Mount the hub carrier by means of the

lifting tackle.
Observe the radial installation position of the

hub carrier!
(S) Lifting strap 514655
Wet thread of hexagon screws with Loctite type no. 262.
Tighten the bolt connection with hexagon screws (1).
Screw: M18x1.5x100 -10.9

1
Press the wheel bolts into the output shaft until contact.
(S) Wheel bolt puller – basic device 505767

(S) Insert (M22x1.5) 505766
Special tool (S) can only be used for

repair solution when replacing single
wheel bolts!
Figure 7

Adjust the rolling resistance of the wheel bearing
Press both bearing outer rings into the hub until contact.
(S) Mounting tool 505755
(S) Handle 504256
Figure 8
Mount the bearing inner ring (1) onto the hub carrier.
By means of the lifting tackle locate the hub (2) cautiously until
Figure 9
Heat inner diameter of the bearing inner ring (approx. 120 ° C).
Figure 10
Mount ring (1) and bearing inner ring (2) onto the hub carrier
until contact is obtained.
Use the ring removed at disassembly to adjust the rolling

moment of the wheel bearing!
Empirical value s = 5.45 mm

1
Wear safety gloves!
Figure 11

Insert the ring gear carrier (1) 3

into the ring gear (2)
and fasten it by means of the retaining ring (3). 1
Figure 12
Insert the cpl. ring gear (1)

and screw on the slotted nut (2).
Mount the chamfer showing to the outside!
Figure 13
Tighten the slotted nut.

Tightening torque ………………................ MA = 2 000 Nm
When tightening rotate the hub in both directions

several times!
Check the rolling resistance by means of the spring balance.

Figure 14
Rolling moment T = 8 - 14 Nm
Hub Ø 444 mm r = 0.222 m
Tensile force F min = T: r = 8 Nm : 0.222 m = 36 N

Tensile force F max = T: r = 14 Nm : 0.222 m = 63 N
(S) Spring balance 505760
If the rolling moment is not achieved, it has to be corrected by

means of the ring (see Fig. 11).
In this case the steps of Fig. 11 - 15 are to be repeated!
Rolling moment too low: install a thinner ring

Rolling moment too high: install a thicker ring
Figure 15

NOTE !
In case of reusing bearings which had already been
running, reduce the rolling moment by 50%:
Rolling moment T = 4 - 7 Nm
Tensile force F min = T: r = 4 Nm : 0.222 m = 18 N

Tensile force F max = T: r = 7 Nm : 0.222 m = 31 N
Figure 16
Loosen the slotted nut.

Figure 17
By means of the lifting tackle and the crow bar set remove the
hub again from the hub carrier.
Pay attention to the released bearing inner ring and

the ring gear !
Installation of the wet multi-disc brake Figure 18
Clean the annular grooves of the brake housing with spirit.

Install the backup rings, U-rings and guide ring (see Sketch
Fig. 20).
Fix the guide ring with Loctite (Type No. 415) at its
extremities.
Guide ring must have contact on the whole circumference!
Upon installation the orifice of the guide ring

must show
upwards (12 o‘clock)!
Figure 19

Legend to the sketch:

1 = Brake housing 2 1
2 = Guide ring
3 = Backup ring
4 = U-ring 3
5 = U-ring
6 = Backup ring 4
7 = Pressure connection
5
6 7
Figure 20
Insert the piston (1) into the brake housing (2).

1
Apply sufficiently oil onto the sliding surfaces of the
piston or backup rings, U-rings and guide ring
(use W-10 oils)!
Figure21
Mount the piston by means of the back-off fixture (S) until

contact cautiously.
(S) Sliding pads 514644 2

(S) Two-armed puller 514673
(S) Support shim 514667
Figure 22
Pre-assemble the return mecanism
Insert the pins (1) into the assembly fixture (S) until contact. 1
(S) Assembly fixture 514662

S
Figure 23

Press 4 gripping rings (1) onto the pins until contact on the
assembly fixture (S). 1
The exact installation dimension (see Sketch, Fig. 26)

of the gripping rings is obtained when using the speci
fied assembly fixture!
Observe the installation position, install gripping rings

with the orifice offset by 180° to each other!
Figure 24
Mount 7 cup springs (1) onto the pin.
Pay attention to the installation position of the cup

springs, see below sketch (see Sketch, Fig. 26)!
1
Figure 25
Legend to the sketch: 5 4

1 = Pin
2 = Gripping rings
3 = Cup springs
4 = Support shim 3
5 = Circlip
X
X = Installation dimension Gripping rings 8.2 +0.3mm

2
1
Figure 26
Insert the preassembled pins into the support shim and fix it by

means of the circlip.
(S) Clamping pliers 514669
Pay attention to the clearance of the cup springs!
Figure 27

Insert the preassembled support shim (1) into the piston and
fasten it by means of the circlip (2).
2
1
Figure28
Drive 6 slotted pins (1) for locking of the circlip into the bore
holes of the support shim.
1
(S) Drift mandrel 514668
Wett the slotted pin at ist extremities with grease!

2
The circlip opening (2) must be located between two
slotted pins!
Always use new slotted pins!
See Sketch Fig. 30 for installation position and installa

tion dimension of the slotted pins 30!
Figure 29
Legend to the sketch: 2 X

4
1 = Brake housing
2 = Piston
3 = Resetting
4 = Circlip
5 = Support shim
6 = Slotted pin
X = Installation dimension 4.0 +0.5mm
1 3 5 6
Grease the O-Rings (1) and insert it into the pressure oil
supply bore. 1
Grease the O-Ring (2) and insert it into the annular groove. 2
Install the screw plug (3) with a new O-Ring
Tightening torque ....................................... MA = 60 Nm
3
Figure 31

By means of the lifting tackle locate the brake carrier (1) 1

Observe the radial installation position of the hub

carrier!
Figure 32
Fasten the brake carrier by means of three hexagon screws (1)

provisionally to the brake carrier.
Mount (2) the fixture onto the hub carrier.
2
(S) Spline mandrel 514663
1
Figure 33
Install the outer and inner discs alternately,

starting with an outer disc.
Disc arrangement (see Sketch, Fig. 35) and clearance

(see Fig. 35 and 36)!
Oil the disc to ZF Lists of Lubricants TE-ML 05!
Figure 34
Determination of the clearance for new lined discs

(inner discs): 1
4
Legend to the sketch Figure 35 and 36:
2
1 = Brake housing
2 = Piston
3 = Brake carrier 3
4 = Outer discs
5 = Inner discs
6 = Sealing holder
X = Size to determine the clearance 5
Y = Size to determine the clearance X
Figure 35

Determination of the clearance for new lined discs (inner discs):

Example: Y
X ……………………….. = 28.00 mm
Y ……………………….. = 26.60 mm 6
Clearance = - 1.40 mm
If required, correct the clearance with an adequate outer disc.
Max. clearance for new lined discs: 1.3 + 0.3 mm
Max. clearance (wear): 4.1 mm
Figure 36
Grease the O-Ring (1) and insert it into the annular groove of the 1
sealing holder.
Figure 37
Wet O-ring (1) of slide ring seal with spirit and insert into slide
ring guide.
Also wet locating hole of sealing holder (see figure 39) with 1
spirit.
Any opening of the seal kit necessary for repair work
requires the installation of a new seal kit (slide seal
rings), even if wear limit has not yet been achieved.
Figure 38
Thereupon snap new slide ring seal (1) into sealing ring holder.
Pay attention that sealing surface is in parallel to the

housing surface! The O-rings must be mounted evenly
in the locating hole and must not bulge out of the hole.
1
The surface of the slide ring seal must not show any
profiled grooves, scratches and other damages!
Also see sketch, Fig. 45 for installation position of the

slide ring seal.
The surface of the slide ring seal must not show any
profiled grooves, scratches and other damages!
Figure 39

Mount the sealing holder (1) onto the brake housing until contact
is obtained and fasten it with hexagon screws (2).
Tightening torque ....................................... MA = 390 Nm

2
Figure40
Install the bleeder valve (1).

1
Tightening torque/Screw neck….............. MA = 45 Nm
Tightening torque/Bleeder……................. MA = 5 Nm
2
Install the screw plug (2) with a new O-Ring.
Tightening torque………...……................. MA = 60 Nm
Install the adapter (3) and pressurize the piston with air
(approx. 4 bar) to fasten the disc set.
Figure 41
Remove the device for aligning of the disc set.
(S) Spline mandrel 514663
Figure 42
Installation of the wheel head
Wet O-ring (1) of slide ring seal with spirit and insert into slide
ring guide. 1
Also wet locating hole of sealing holder (see figure 39) with
spirit.
Any opening of the seal kit necessary for repair work

requires the installation of a new seal kit (slide seal
rings), even if wear limit has not yet been achieved.
Figure 43

Thereupon snap new slide ring seal (1) into sealing ring holder.
Pay attention that sealing surface is in parallel to the

1
housing surface! The O-rings must be mounted evenly in
the locating hole and must not bulge out of the hole.
The surface of the slide ring seal may not have any
grooves, scratches or other kind of damage!
For the installation position of the slide ring seal please

also refer to the sketch of figure 45!
Caution: the slide ring seal is sharp edged (use protec

tive gloves)!
Figure 44
1 2
3
1 = Slide ring seal for hub/sealing holder
2 = Brake housing
3 = Sealing holder
4 = Hub
Figure 45
Roller bearing cpl. (1), ring (2) and shaft seal (3) into the hub. 2
3
Figure 46
Insert the shaft seal by means of the mounting tool into the hub.
(S) Mounting tool 505756

(S) Handle 504256
Wet the outer diameter with spirit.
Grease the sealing lips!
Figure 47

Mount inner installer (S) on hub carrier
(S) Inner installer 514666
Figure 48
Mount hub by means of a lifting tackle.
Careless handling might damage the shaft seal (1) of the

inner installer (see arrow). 1
Carefully instal the wheel head on the inner installer.
Before clamping the seal rings to installation dimension,

clean sliding surfaces and then apply an oil film (most
suitably by means of a suede cloth)!
Figure 49
Use centering bracket to center the hub (1) on the inner installer.
Mount hub in the disc pack.
While mounting the hub rotate it in both directions

several times!

Figure 50
Push hub until contact is obtained, remove centering bracket and

inner installer.
Figure 51

Heat the inner diameter of the bearing inner ring (approx.

120 ° C).

Figure 52
Mount the ring (1) and bearing inner ring (2) onto the hub carrier
Use the ring determined for adjustment of the rolling

moment! 1
2
Wear safety gloves!
Figure 53
Insert the cpl. ring gear (1) and screw on the slotted nut (2).
Mount the chamfer (see arrow) showing to the outside!
1
FASE
Figure 54
Tighten the slotted nut.
Tightening torque ........................................ MA = 2 000 Nm

Release the compressed air-actuated brake!

When tightening rotate the hub in both directions
several times!
If necessary, increase the tightening torque until the

slotted nut can be locked, see Fig. 53.
Tightening torque ...............................MA = 2 000 - 2200 Nm
Figure 55

Install the lock plate (1) and fasten it by means of

locking bolts (2).
Tightening torque ........................................ MA = 86 Nm
Always use new locking bolts!

1
Prior to install the locking bolts, the leakage test of the
brake chamber/wheel head (see 1.2.5) and of the brake
hydraulics (see 1.2.6) can already be carried out!
2
Figure 56
Insert the stub shaft (1) into the differential until contact.
Left and right stub shaft are of a different length!

1
Figure 57
Mount the driver (1) until contact is obtained.
Figure 58
Press the roller bearing (1) into the planetary gear (2) until the
circlip (see arrow) has snapped into the recess of the planetary
gear.
1
Roller bearing and planetary gear are damaged at the
disassembly!
Figure 59

Heat the inner diameter of the roller bearing at the preassembled

planetary gear (approx. 120 ° C).

Figure 60
Mount the planetary gears (1) until contact and fasten them by
means of the retaining ring (2).
2
Observe the installation position! Big radius of the
bearing inner ring must show to the shoulder of the
planetary gear pin (downwards).
1
Wear safety gloves!
Figure 61
Adjust the axial play of the sun gear shaft 0.3 ... 0.8 mm
(Fig. 62 ... 64)
Insert the sun gear shaft (1) until contact.

1
Determine Dim. I, from the mounting face of the hub to the face
of the sun gear shaft.
Dim. I e.g. ............................................................ 9.40 mm

(S) Digital depth gauge 504175
Figure 62
Measure Dim. II, from the mounting face to the contact surface
of the thrust washer.
Dim. II e.g. .......................................................... 4.00 mm
(S) Digital depth gauge 504175

(S) Block gauges 504174
Figure 63

Example:
Dim. I e.g..…..................................... 9.40 mm 1
Dim. II e.g. ........................................ - 4.00 mm
Difference ........................................ = 5.40 mm
required axial clearance .............e.g. - 0.40 mm
Result = Thrust washer s = 5.00 mm
Fix the thrust washer (1) with grease into the

planet carrier.
Figure 64
Insert the sun gear shaft (1). 1
Insert the O-Ring (2) into the annular ring and grease it.
Figure 65
With the lifting tackle insert the preassembled planet carrier into
the ring gear and locate it at the hub until contact.

Figure 66
Observe the radial installation position of the planet car

rier (see Fig. 67 and 68)!
The through hole (1) in the hub (existing only 1x) must
be aligned to the filler and drain hole (2) respectively of
the planet carrier.
Also observe the markings made (3) at the
disassembly ! 3
4
Figure 67

Attach the cap screw (5) in the through hole.

4
Wet the thread of the cap screw with sealing compound
(Loctite, Type No. 574)!
Then fasten the planet carrier by means of hexagon screws (4).
Tightening torque (M16/10.9) .................... MA = 280 Nm
Figure 68
Mount screw plugs (1) and (2) with new O-ring. 1
Tightening torque (M16x1.5) ………. MA = 40 Nm
Tightening torque (M42x1.5) ………. MA = 150 Nm
Figure 69

Check the brake chamber/wheel head for leak

tightness
The brake chamber is to be pressure tested with 0,4 – 0,5 bar

compressed air for approx. 5 min. No pressure loss is allowed.
(S) Air connection with pressure

gauge and pressure release valve 514660
(S) Reducing tool 514671
Air pre
Air pressure in
Figure 70
Install the screw plugs (1) with new O-Rings.
Tightening torque (M22x1,5) ........................…... MA = 60 Nm
Figure 71

Leakage test of the brake hydraulics
Prior to start the test, ventilate the brake hydraulics

completely!
1. Open the bleeder.
2. Actuate the HP-pump slowly until oil gets out of the bleeder.
3. Close the bleeder again.
4. Pressurize the HP-Pump slowly with p > 10 bar and
keep the pressure for some seconds.
NOTE:
The brake piston extends and the cylinder chamber fills
up with oil. The air accumulates in the upper section of the
cyl. chamber.
5. Loosen the shut-off valve on the HP-pump.
NOTE:
The retracting piston presses the air out of the upper
section of the cylinder into the brake line.
6. Open the bleeder again.

7. Actuate the HP-pump slowly until oil gets out of the bleeder.
ATTENTION:
Repeat the procedure (Point 3 ... 7) until (at Point 7)
from starting of the actuation no more air comes out of
the bleeder.
Then pressurize the brake temporarily

(5x) with p = 100 bar max.!
High-pressure test:
Increase test pressure up to p = 100 –10 bar and close the
connection to the HP-pump by means the of shut-off valve.
During a 5 min. testing time a pressure drop of max. 2 %
(2 bar) is allowed!
If the maximum pressure of 100 bar is exceeded,

here will be an excessive piston adjustment and a
repeated disassembly of the brake or of the
adjusting is required to reset the gripping rings to the
adjusting dimension.
Low-pressure test:
Reduce test pressure to p = 5 bar and close the shut-off valve
again.
During a 5 min. testing time a pressure drop is not allowed!
Test media
Motor oils SAE 10-W corresponding with,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-Oils Type A, Suffic A Dexron
of II D.
(S) HP-Pump 514661

(S) Mini measuring hub 514670
(S) Bleeding equipment 514659
Prior to putting the axle into operation, fill in the oil

acc. to the lubrication instructions!
Figure 72b

WDB cirquit front brake
Front brake cirquit

Brake valve
Hub Rhs
WDB CAN monitor unit
6040 Oil reservoir
Front
service Rear service brake 6140 Circulation pump
brake 6220 Filter
valve Hub
Rhs 6300 Temp sensor block
6660 Oil cooler unit
6660 6780 Test connector
6800 Non return valve
(Open at 1 bar)
Inside cab rear. left side

WDB CAN monitor unit
6780
6040
6300
6220 6800
1 bar
6140
IVC4
To the
hub Lhs

Rear hub,
Outer view and section drawing
Pos Description Qty Pos Description Qty Pos Description Qty

1 Wheel axle 1 16 Shim 1 31 Brake disc 0
2 O-ring 1 17 Shim 1 32 Brake disc 5
3 Ring 1 18 Screw 4 33 Brake disc 0
4 Wheel bolt 20 19 Plug 1 34 Flange 1
5 Wheel nut 20 20 Seal ring 1 35 O-ring 1
6 Roller bearing 1 21 Support 1 36 Screw 20
7 Hub housing 1 22 Seal ring 1 37 Washer 20
8 Roller bearing 1 23 Support 1 38 Set screw 2
9 Gear wheel 1 24 Guide 1
10 Carrier 1 25 Seal ring 1
11 Screw 16 26 Piston 1
12 Washer 16 27 Return mech- pi 1
13 Ring 1 28 Slot. pin 6
14 Screw 8 29 Lock 1
15 End plate 1 30 Brake disc 4
9 8 10 35 31 30 29 19 26 28 7 6
11
12
4
38
15 1
18 3
16
17
(2) B ( 2,2 )
13
14
+0,4
36 37 34 1,7 0 24 21 20 27 22 23 25

Note Important !
When assembly:
Become aware of the direction of the (deflector) Scoop ring (pos 13)
Rhs Lhs
c t io n
Di r e

Disassembly the rear hub
NOTE:
Before disassembly see the chapter 3 section:
Safety precautions
B
Drain the oil (A).

2 C
Loosen the drain screw plug on the tandem housing.
Disconnect the brake hose from hub (C)
Disconnect screws (B)

20 x M16x70 ISO4014-10.9
20 x Washer 17x30x3 NS-ISO
Tightening torque 280 Nm. A
Insert M16 screw in top and bottom threaded hole (D) to lossen D
the hub from the tandem housing.
Inserrt lifting eye (M16) in the upper threaded hole (D).
Fasten the strap and carefylly move the hub from the tandem
housing.
Be aware of personal injury D
Disassemble the end plate (15) from the wheel axle

4 x Screw (18) M16x50 ISO4017-10.9
Tightening torque 280 Nm. 2 15

NOTE:
Take care of the shims

9 13
Carefully lift the gear wheel (9), scoop ring (13) and
the disc carrier (10) from the hub. 10
Note:
Heavy objects, use lifting device.
Separate the disc carrier (10) from the gear wheel

(If the part have to be changed)
16 x Screw M16x50 ISO4017-10.9
Tightening torque 280 Nm.
Separate the axle and the hub by pressing the axle out
of the hub
Disassemble the disc flange.

36-37 34
Unscrew 20 x Screw M16x50 ISO4017-10.9
(36 - 37)
Remove the disk flange (34)
Tightening torque 280 Nm.

Remove the disc plate (9 pcs)
When remove the return mechanism, knock down the slot

pin and remove the lock ring.
Lift out the return mechanism
Remove the piston, use compressed air into the oil line to lift
the piston up.
Use hook or similar to take the piston from the hub.
Remove the old and worn packing ring
Clean the hub and reusable parts.
30
32
29
22
28
26

Pre-assemble the wheel axle
Assembly the wheel bolts.
Use hydraulic press or sledgehammer.
Be aware of personal injury

Use safety glasses and be
aware of flying objects
Preassemble the distance ring (3):
Insert the O-ring (2) and oil the surface.
Apply sealing compound and Insert the hexagon screw plug

(Set screw M12x10 ISO 4029)
into the distance ring.
NOTE:
Check up that the screw plug not is
coming out of the threaded hole

Clean the wheel axle and apply oil the surface
Assemble the preassembled distance ring
With plastic mallet knock carefully on the ring
Clean the surfaces
Assemble the outer bearing.

Clean the axle and apply oil before assemble the
bearing.
Heat the inner diameter of the bearing v\with elec-
trical heater, Hot oil or Hot air blower
Temp 75 - 120°C
(167 - 248°F)

Figure 10
Clean the axle and apply oil before assemble

the bearing.
Use tube to press the bearing in position. 500 KG
Hold press on the tube to the bearing temperature is cool down
Clean and oil the surfaces on the distance ring
Assemble the slide seal ring into the wheel axle distance ring

Finaly check on the movement, by hand check about the ring can
be moving springy, approx 2 mm by hand.
Protect bearing and connection surfaces before the next step.
Assemble the WDB rear hub
Clean surfaces and assemble the outer bearing cup

drive line Ch 3 page 141
Assemble the slide ring seal
When assembly the slide ring seal it is important to clean the

surface of the connection well.
Assemble the guide ring between the flange and O-ring.
Note.
The rings are make together, dont mix the ring from others
ring set.
Also the ring is make of very hard iron (cast iron)

and can easy be broken.
O-ring support assembly tool 520361
Oil the surfaces on the hub housing
Press together the guide ring and press by hand

the slide ring into the hub.
Part 1
Assemble to the
wheel axle
By hand press the slide ring seal into the hub.
Part 2
Assemble to
the hub
Finaly check on the movement, by hand check on that the ring can
be moving springy, approx 2 mm.

Place the hub in assembly rack after assemble

of the bearing cup and the seal ring.
Clean the bearing surface and
assemble the bearing cup
Assemble the guide ring

Pos 23-24
Assemble the guide ring Pos. 23 and 24
Turn the hub housing

180 ° while assembly
the bearing cup and
the seal
Insert the plug
NOTE:
Assemble the seal ring
Be aware dont bend th
Handle with ca
Dont mix the ri
Ass
Clean the surfa
Che
wit
Be careful with the seal ring

surface and
assemble the bearing
seal ringcup Preassemble the distance ring
Insert 2 pcs. screws plug and O-ring
Lubricate the O-ring and use
locking compound (tread lock)
Place the hub in assembly rack after assemble Tree Bond 5111to lock the
of the bearing cup and the seal ring. screw plug.

Pos 23-24

the bearing cup and
the seal the piston ring
Assemble
Pos 21 - 22
Insert the plug
NOTE:
Be aware dont bend the
Handle with care
Dont mix the ring
Asse
Clean the surface
Chec
withA
w
U
s

surface and
seal ringcup
assemble the bearing Preassemble the distance ring
Tree Bond 5111to lock the
screw plug.


Use glue: Loctite
Assemble no.406
the guide ring
at
Posboth ends.
23-24
Assemble the guide ring (pos Turn the hub housing

24) 180 ° while assembly
the bearing cup and
Fasten both of the ends, use the seal the piston ring
Assemble
clue, Loctite 406 Pos 21 - 22
Insert the plug
NOTE:
Assemble
Be aware d
Ha
Do
Cle

surface and
seal ringcup
assemble the bearing Preassemble the distan
Insert 2 pcs. screws plu
Lubricate the O-ring an
locking compound (tre
Tree Bond 5111to lock
screw plug.
Lubricate seal area
before inserting the
piston.
Lubricate seal area before in- Assemble the guide ring
serting the piston. Use glue: Loctite
Assemble
Assemble the no.406
the guide
pistonring
ring
at
Pos
Posboth
21 -ends.
23-2422
Use plastic hammer to knock
the piston evenly into the bottom
position. Turn the hub housing
the bearing cup and
the seal
Insert the plug
NOTE:
Assembl
Be aware
H
D
C

surface and
seal ringcup
assemble the bearing Preassemble the dist
Insert 2 pcs. screws p
Lubricate the O-ring
locking compound (t
Tree Bond 5111to loc
screw plug.

Assemble the return mechanism (pre-assembled)
NOTE:
For details about pre-assembling of the return mechanism,
see in this chapter, front WDB hub assembly.
Section:
Pre-assembly of the return mechanism (Figure 23 - 27)
Preassemble the Return mechanism- piston
5 4
For more details about assem
Legend to the sketch: of the return mechanism, see
1 = Pin
3 2 = Gripping rings
description in the Shop Manu
3 = Cup springs front axle, hub assembly.
X
4 = Support shim
2 5 = Circlip
1
Figure 26
Lubricate seal area
piston.
Use glue: Loctite
Assemble
Assemble the no.406
the guide
pistonring
ring
at
Pos
Posboth
21 -ends.
23-2422

the bearing cup and
the seal
Insert the plug As

Cle
NOTE: be
He
Be aware dont bend the ring
ele
Handle with care, rep
Dont mix the rings Te
(O
Assemb (16
Clean the surfaces be
CheckHo th
withAsse
the
un
whe
Use
sledg

surface and
seal ringcup
SHOP MANUAL MT41 - 01.2005 Tree Bond 5111to lock the
screw plug.
2 5 = Circlip
DRIVE LINE X = Installation dimension
Ch 3 page 145 Grippin
1
Figure 26
of thethe
Place bearing
returncup and the lock
mechanism seal ring
ring.
Lubricate seal area
piston.
Assemble the guide rin
Use glue: Loctite
Assemble
Assemble the no.406
the guide
pistonrin
rin
at
Posboth ends.
23-24
Pospiston
21 - 22
Preassemble the Return mechanism-
Assemble the lock ring Pos 29,
5 4
Fo
Secure with 6 pcs. slot pin Pos 28 Turn the hub housing
Legend to the sketch: of
See figure below. 180 ° while assembly
1 = Pin
3the bearing cup and
2 = Gripping rings
de
the seal 3 = Cup springs fro
X
4 = Support shim
2 5 = Circlip Insert the pl
X = Installation dimension Grippin
1
Figure 26
of thethe
Place bearing
mechanism seal ring
ring.
Lubricate seal area
assemble the bearing cup Assemble 6 p
piston.
Assemble the guide rin
Use glue:
Assemble
the retur
intoLoctite
the no.40
Assemble the guide
pistonrir
at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20

the bearing
Be careful with thecupseal
and ring
the seal
surface and
seal ringcup Insert thePre
p
Ins
Lu
loc
Tre
scr

Pos 23-24

the bearing cup and
the seal the piston ring
Assemble
Pos 21 - 22
Be careful
Insert the plugwith the seal ring
Clean the bearing

surface and
surface and
seal ringcup P
In
Lu
lo
Tr
Be careful with the seal ring sc
surface and
seal ringcup

Brake disc- rotating (Qty 4)

Assembly the disc package in Available 4,7 mm
the hub housing.
See the calculation example

below
unit
1
iscs 2
D
Brake disc- stationary (Qty 5)

Available3,8 mm, 4,0 mm, or 4,2 mm.
Y Calculation example:
X Measure x.................................. 8,00
Measure Y.................................. - 6,50
Clearance.................................. = 1,50
Clearance:
Min: 1,3+0,3 mm (New discs) Preassemble the Return mechanism- piston
Max: 4,3 mm (Used
B discs) Calculation example: For more details about ass
5 4
Measure A.................................. 47,10
Measure B.................................- 6,40
of the return mechanism, s
A 1 = Pin
3
Gives:..........................................=
2 = unit..................................
Gripping rings - 38,60
40,70 description in the Shop Ma
Discs
Clearance..................................
3 = Cup springs = 2,10 front axle, hub assembly.
X
4 = Support shim
2 Allowed clearanse 1,7 - 2,1 mm
5 = Circlip
1 Place the "line up tool"
Before placing of the discs, place
Figure 26 Moxy part No. 514663
Place the returncup
of the bearing and the lock
mechanism seal ring
ring.
the tool, Spline mandre to the hub. Lubricate seal area
assemble the bearing cup Assemble 6 pcs. of the slot pin
piston.
Tool, Moxy part No. 514663 Assemble the guide ring
the return
intoLoctite mechanism
Use glue:
Assemble
Assemble the no.406
the guide
piston ring
ring
at
Pos Slot
both pin
ends.
23-24
Pos 21 - 22
6x20 DIN 1481

the bearing cup and
the seal
Insert the plug
NOTE:
Handle with care,
Dont mix the ring
Assem
Clean the surface
Chec
withA
w
U
sl

surface and
seal ringcup
screw plug.
4.0 3
A
p le
1 = Pin
Measure B.................................-
Gives:..........................................=
2 = unit..................................
6,40
40,70 description in th
of the return mec
m Ch 32,10page to 147
Discs
DRIVE LINE Apply front
oil theaxle,
partshub
and as
pl
a
Clearance..................................
3 = Cup springs =
3.8
X
Ex
4 = Support shim brake disc, one by one.
5 = Circlip Start assembly with outer di
4.0 1 Place the "lineX =up
Installation dimension
tool" 1 The Gripping rings 8.2
outer disc +0.3mm
(5 pcs, diffe
Place the hub in assembly rack after assemble 2 The inner disc (4 pcs. thick
Figure 26
Place
4.0
of thethe
bearing
Moxy part No. 514663
mechanism seal ring ring.
Lubricate seal area
Apply oil to the parts and place the piston. Assemble 6 pcs. of the slot pin
brake discs, one by one. Use
Assemble
Assemble
the return
intoLoctite
glue: the no.406
the guide
pistonring
ring
mechanism
Start assembly with outer disc. at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20 DIN 1481
1 The outer discs

(5 pcs . different thickness available) Turn the hub housing
2 The inner discs the bearing cup and
the seal
(4 pcs thickness 4,7 mm)
Insert the plug
NOTE:
Assemble
Be aware d
Han
Do
Cle

B For more details
4.05 4Clean the bearing Calculation example:
e
surface and
surface
Measure and
l
A.................................. 47,10
seal ring
assemble the bearing cup B.................................- 6,40 of
Legend
Measure
to the sketch: the return mec
Preassemble the distan
A 4.0
p
1 = Pin 40,70 description
3
Gives:..........................................=
2 = unit..................................
in the
m
Discs
Apply front
oil to theaxle,
parts hub
and as
pl
a
Clearance..................................
3 = Cup springs = 2,10
3.8 locking compound (tre
X
x
E
5 = Circlip Start assembly with outer di
screw plug.
4.0 1 Place the "lineX =up Installation dimension 1 TheGripping rings 8.2
outer disc +0.3mm
(5 pcs, diffe
Place the hub in assembly racktool" after assemble 2 The inner disc (4 pcs. thick
Figure 26
Place
4.0
of thethe
bearing
mechanism seal ring ring.
Lubricate seal area
Clean surface and place the O-ring Clean the bearing surface and
piston.
Assemble
Clean the surface
guide ring
(Pos 35) Use glue:
Assemble the
return
theguide
intoLoctite no.406
and
ring
mechanism
place
Assemble the
theO-ring
piston ring
at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20 DIN 1481

the bearing cup and
the seal
Insert the plug
NOTE:
Assemble
Be aware d
Han
Don
Cle

surface and
seal ringcup Preassemble the distan
locking compound (tre
screw plug.

4.0 3
A
pl 1 = Pin
Gives:..........................................=
2 = unit..................................
40,70 description in the Shop M
m
Discs
=Apply front
2,10 oil to theaxle,
partshub
and assembly.
place the
a
Clearance..................................
3 = Cup springs
Ch 3 page 148 3.8 DRIVE LINE
X
Ex
5 = Circlip Start assembly with outer disc.
Place the flange
4.0 X = Installation dimension
1 Place the "line up tool" 1 TheGripping rings 8.2
outer disc +0.3mm
(5 pcs, different thickne
20 pcs . screw Place the hub
M16x50 ISO4017-10.9 ELin assembly rack after assemble 2 The inner disc (4 pcs. thickness 4,7 mm
Figure 26
of the
Apply locking liquid: 4.0
Treebearing
bond
1374 cup and the
Place the return mechanism lock ring seal ring.
Washer 17x30x3 NS-ISO 7089 300HV Lubricate seal area
Tightening torque: 280 Nm. before inserting the
piston.
Assemble guide ring
Clean the surface and
Place the flange. Use glue:
Assemble the
return
theguide
intoLoctite no.406
ring
mechanism
place
Assemble the
theO-ring
piston ring
at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20 DIN 1481
20pcs. screw M16x50 ISO4017 - 10.9
Apply locking liquid: Turn the hub housing

TreeBond 1374 180 ° while assembly
the bearing cup and
the seal
Washer:
17x30x3 NS-ISO 7089 300HV Insert the plug
Tighetening torque: 280 Nm. NOTE:

Handle with care
Dont mix the rin
Asse
Clean the surface
Chec
withA
w
U
s

surface and
seal ringcup
Preassemble the Return mechanism- piston locking compound (tread lock)
B For more details about assembling
4.05 4 Calculation example: screw plug.
Pressure test:
Increase test pressure up to p=50 bar and
A 4.0
3
1 = Pin
le
Measure A.................................. 47,10
Measure B.................................- 6,40
p
Gives:..........................................=
Testing equipment
of the return mechanism, see
40,70 description in the Shop Manual,
rings - 38,60for the front and rear hub:
2 = unit..................................
Gripping
m
Discs
close the connection to the HP-pump by 3.8 =Apply front
partshub
and assembly.
place the
a
3 = Cup springs
Clearance..................................
X
x
means of the shut off valve. 2 Moxy No. XXXXXX
Allowed clearanse 1,7 - 2,1 mm
E
During a 5 min. testing time
Placeathepressure
flange
4.0
drop 1
X = Installation dimension
Place the "line up tool" Pressure 1 TheGripping rings 8.2
outer disc +0.3mm
(5 pcs, different thickness available)
of max. 2% (1 bar.) is allowed!
20 pcs . screw Place
M16x50 the hub
ISO4017-10.9 in
EL assembly rack after assemble 2 The inner
test: disc (4 pcs. thickness 4,7 mm)
Figure 26
of the
Apply locking liquid:
Place Tree4.0
bearing
bond
the
1374 cup
return and the lock
mechanism seal ring ring. Increase test pressure up to p = 50 bar and close the
Washer 17x30x3 NS-ISO 7089 300HV Lubricate seal area connection to the HP-pump by means the of shut-off valve.
Clean the bearing surface and During a 5 min. testing time a pressure drop of max. 2 %
(1 bar) is allowed!
piston.
Assemble guide ring
Clean the surface and
Use into
glue:
Assemble Loctite return
theguide
no.406
mechanism
Assemble the pistonring
place the
the O-ring ring
at
Pos Slot
both pin
ends.
23-24
Pos 21 - 22
6x20 DIN 1481

the bearing cup and 0 bar
the seal
Insert the plug Assemble

50 bar the outer bearing.
Clean the axle and apply oil
NOTE: before assemble the bearing.
Shut of valve
Heat the bearing with
electrical
Handle with care, replace worn heater
ringsorwith
hot new
oil
Dont mix the rings Temp
(Only 75 - 90°C
as set)
Assemble
Clean the surfaces before
the distance
Clean
(167 - 194°F)
assembly
the axlering.
CheckHold andisapply
the press
ring oil
in contact
to the bearing
Assemble
with the axle flange
until cool the
down
wheel bolt.
Use hydraulic press or
sledgehammer.

surface and
seal ringcup
Tree Bond 5111to lock the Prepare sta
screw plug.

4.0 3
A
p l 1 = Pin
Gives:..........................................=
2 = unit..................................
40,70 description in the Shop Manual,
m
Discs
=Apply front
partshub
and assembly.
place the
a
Clearance..................................
3 = Cup springs
DRIVE LINE 3.8 brake disc, one by one. Ch 3 page 149
X
Ex
4 = Support shim
Place the flange
4.0 1
Place the "line up tool" Pressure
Remove the tool 1 TheGripping rings 8.2
outer disc +0.3mm
20 pcs . screw Place the hub in
M16x50 ISO4017-10.9 EL assembly rack after assemble 2 The inner
Figure 26
of the
Place
4.0
Treebearing
thebond
1374 cup
return and the lock
Washer 17x30x3 NS-ISO 7089 300HVLubricate theseal
Lubricate parts
areaand connection to the HP-pump by means the of shut-off valve.
Clean the bearing
assemble surface and
the carrier. During a 5 min. testing time a pressure drop of max. 2 %
(1 bar) is allowed!
piston.
Assemble
Clean the surface
guide ringand
Use into
glue:
Assemble
the
Loctite
the
return
no.406
guide
mechanism
While the pressure place the
Assemble pistonring
theO-ring ring
at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20 DIN 1481
is on:
Remove the “Line
up tool”, lubricate Turn the hub housing The press is stay on !
the parts and as- 180 ° while assembly
semble the carrier. the bearing cup and
the seal
0 bar
Insert the plug Assemble

50 bar the outer b
Clean the axle and ap
NOTE: before assemble the b
Shut of valve
electrical
Handle with care, replace worn heater
ringsorwith
ho
(Only 75 - 90°C
as set)
Assemble the
(167 - 194°F)
Clean the surfaces before
distance
Clean
assembly
the axle
the press
ring oil
in con
to the bea
withAssemble
the
untilaxle the
coolflange
down
wheel bolt.
Use hydraulic press
sledgehammer.

surface and
seal ringcup
Tree Bond 5111to lock the P
screw plug.

B For more details about assem
4.05 4 Calculation example:
le
Measure A.................................. 47,10
Measure B.................................- 6,40
of the return mechanism, see
A 4.0
p
1 = Pin
Gives:..........................................= 40,70 description in the Shop Man
3 2 = unit..................................
m
Discs
=Apply front
partshub
and assembly.
place the
a
Clearance..................................
3 = Cup springs
3.8
X
Ex
Place the flange
4.0 1
Place the "line up tool" Pressure
Remove the tool 1 TheGripping rings 8.2
outer disc +0.3mm
(5 pcs, different thickness
Connect the lifting device. 20 pcs . screw Place the hub in
M16x50 ISO4017-10.9 EL assembly rack after assemble 2 The inner
Figure 26
of the
Place
4.0
Treebearing
thebond
1374 cup
return and the lock
Lubricate parts
areaand connection to the HP-pump by means the Now, rem
of shut-of
Remove the pressure tool and Tightening torque: 280 Nm.
Clean the bearing
assemble surface and
the carrier.
before inserting the During a 5 min. testing time a pressure drop of max.
pressure
assemble plug in the oil line. piston. Assemble
Assemble
Clean the surface
6 pcs. of the slot pin
(1 bar) is allowed!
guide ringand connect
Use into
glue:
Assemble
the
Loctite
the
return
no.406
guide
mechanism
place the
Assemble pistonring
theO-ring ring
at
Pos Slot
both ends.
Pos 23-24
21 - 22
pin 6x20 DIN 1481
Turn the hub housing The press is

the seal
Insert the plug A

C
NOTE: b
Shut of
Be aware dont bend the rinH
e
Handle with care, rep
Dont mix the rings Te
(O
Assemb
Clean the surfaces b(1
CheckHt
withAsse
thu
whe
Use
sled

surface and
seal ringcup
screw plug.

With attention and carefully assemble the hub on the axle.
NOTE:
The seal ring is made of specially material and
while assemblying the ring have to be handle
very carefully and surfaces have to be cleaning
well.
m- piston
Forsealing
Lubricate surfaces.
more details about assembling
ample:
le
.......................... 47,10
the sketch: 6,40 of the return mechanism, see
........................-Be aware and careful of the
40,70 ring on lower end of
.........................=seal
description in the Shop Manual,
g rings -the
........................ 38,60hub while assembly the
front axle, hub assembly.
2,10tooil
Apply
........................ =hub
rings to axle.
the the parts and place the
t shim brake disc, one by one.
nse 1,7 - 2,1 mm
Remove liftingwith
Start assembly device
outer disc.
tion dimension
1 TheGripping rings 8.2
outer disc +0.3mm
ol" Pressure test:
after assemble
2 The inner disc (4 pcs. thickness 4,7 mm)
63 Increase test pressure up to p = 50 bar and close the
ring.
ing connection to the HP-pump by means the Now, remove
of shut-off valve. the
During a 5 min. testing time a pressure drop of max. 2 %
Assemble 6 pcs. of the slot pin
(1 bar) is allowed!
pressure tester,
Assemble guide ring
Clean the surface
return
theguide
intoLoctite and
mechanism connect lifting device
Use glue:
Assemble
place
Assemble the no.406
theO-ring
the piston ring
ring
at
Pos
Pos
Slot
21 -ends.
both
23-2422
pin 6x20 DIN 1481
The press is stay on !
0 bar
Lubricate sealring Assemble

Insert the plug 50 bar the outer bearing.
surfaces. Clean the axle and apply oil
Be aware and careful
Shut of valve
Beof
aware seal
thedont ring
bend onHeat the bearing with
the ring
electrical
Handle with care, replace ringsorwith
heater oil
hot new
lower end of the hubasworn
(Only 75
Dont mix the rings Temp - 90°C
set)
while
Clean
Assemble (167 -the
the surfaces the
assembly before 194°F)distance
Clean
assembly
the axlering.
ring
the press oil
to thecontact
in bearing
hub to the axle.withAssemble the
coolflange
untilaxle
the down
wheel bolt.
Remove the Use hydraulic press or
lifting device. sledgehammer.
Preassemble the distance ring

Tree Bond 5111to lock the SHOP MANUAL MT41 - 01.2005
Prepare stand for the hub work over
screw plug.
4.05 4 Calculation example: For more details about assembling
le Ch 3 page 151
DRIVEMeasureLINE
Legend
A.................................. 47,10
to the sketch: of the return mechanism, see
Measure B.................................- 6,40
A 4.0
p
1 = Pin
Gives:..........................................= 40,70 description in the Shop Manual,
3 2 = unit..................................
m
Discs
=Apply front
partshub
and assembly.
place the
a
Clearance..................................
3 = Cup springs
3.8 Prepare to assemble the roller bearing:
x
E
5 = Circlip Start assembly with outer disc. Clean the hub axle and bearing cup.
4.0 1 PlaceRemove
the "line
up tool" Pressure test:
the tool 1 TheGripping
outer rings 8.2
disc (5 +0.3mm
pcs, different thickness available)
Apply lubricant.
the hub ELin assembly rack after assemble

SO4017-10.9 2 The inner disc (4 pcs. thickness 4,7 mm)
4.0
eeebearing
thebond
1374 cup
return and the lock
O 7089 300HVLubricate theseal
Lubricate parts
areaand connection to the HP-pump by means the Now, remove
Clean Prepare
the bearing
the to assemble
surface and Duringthe roller
a 5 min. bearing:
testing time a pressure drop of max. 2 %
Nm. assemble the carrier.
before inserting pressure tester,
piston. Clean the hub and bearing 6 pcs.cup.
assemble the bearing cup Assemble
(1 bar) is allowed! of the slot pin
Apply lubricant Assemble
into the
guide ring
Clean the surface
return and
Use glue:
Assemble
place Loctite
the
the no.406
guide
O-ring
Assemble the piston ring ring
at
Pos
Pos
Slot
both pin 6x20 DIN 1481
21 -ends.
23-2422
Turn the hub housing The press is stay on !

the seal
Shut of valve
Beof thedont
aware seal ring
the ring
electrical
Handle with care, replace heater
ringsorwith
hot new
oil
(Only 75 - 90°C
set)
while assembly
Clean
Assemble (167 -the
the surfaces the
before 194°F)distance ring.
Clean
assembly
the axle
the press
ring oil
in contact
to the bearing
hub to the axle.withAssemble
the
untilaxle the
coolflange
down
wheel bolt.
Be careful with the seal ring the inner bearing.
Assemble
ssemble the Return mechanism- piston
Clean
surface
Clean the bearing and the
surface andaxle and apply oil before assem-
05 4 assemble theble thecup
seal ring
bearing
Calculation bearing.
example: For Preassemble
more details about
the distance ringassembling
le
Heat
Legend the to the inner
Measure A..................................
sketch: diameter
47,10
of ofInsert
the the bearing
return
2 pcs. mechanism,
screws seeAssemble the inner bearing.
plug and O-ring
Measure B.................................- 6,40
p
0 3 v\with
1 = Pin electrical heater, Hot oil
Lubricate ortheHot
O-ring
Gives:..........................................= 40,70 description in the Shop Manual,air
and use Clean the axle and apply oil
blower
2 = unit..................................
Gripping rings - 38,60 locking compound (tread lock) before assemble the bearing.
m
Discs
=Apply front
2,10 oil toTree
theaxle,
partshub
Bond and assembly.
5111to lock the
place the Prepare stand for the hub work over
a
Clearance..................................
3 = Cup springs
8 brake disc, screw plug. Heat the bearing with
Prepare to assemble the roller bearing:
Ex
Temp
4 = Support 75 -shim120°C one by one.
2 Allowed clearanse 1,7 - 2,1 mm electrical heater
Cleanorthe
hothub
oil axle and bearing cup.
5 = Circlip
(167 - 248°F) StartGripping assembly with outer disc.
0 1 PlaceRemove
the "line
up tool" Pressure
the tool
rings 8.2 +0.3mm
1 The outer disc (5 pcs, different thickness (167
Temp 75 - 90°C
available)
- 194°F)
Apply lubricant.
hub ELin assembly

17-10.9 (S)rackHot-air after blower assemble 230
2 The V disc 504193
inner
test: (4 pcs. thickness 4,7 mm)
0ndreturn
aring
Moxy
1374 cup
part No.
and the lock
mechanism
514663
seal ring ring. Increase test pressure up to p = 50 bar and close the
9 300HVLubricate theseal
Lubricate parts(S)
areaandHot-air blower connection to the HP-pump by means the
115 V 504194 Now, remove
assemble the carrier.
(1 bar) is allowed!
pressure tester,
piston.
Assemble
into the
guide ring
Clean the surface
return and
Use glue: Loctite
Assemble
place
Assemble the
the no.406
guide
theO-ring
piston ring
ring
at
Pos
Pos
Slot
21 -ends.
23-2422

the seal
Shut of valve
Figure 10 Beof thedont
aware seal ring
the ring
electrical
ringsorwith
hot new
oil
(Only 75 - 90°C
set)
while assembly
Clean
Assemble (167 -the
the surfaces the
before 194°F)distance ring.
Clean
assembly
the axle
the press
ring oil
in contact
to the bearing
the
untilaxle the
coolflange
down
wheel bolt.
surface and
seal ringcup
Tree Bond 5111to lock the Prepare stand for the hub work over
screw plug.

1)
le the Return mechanism- piston Assemble the gear wheel
Calculation example: For more details to contact with the bearing
about assembling 1)
le
Measure A.................................. 47,10
Legend to the sketch: of the return inner ring. seeAssembleAssemble
mechanism, the inner bearing.
the gear wheel
Measure B.................................- 6,40
p
1 = Pin (3) Clean the to
axle and apply
contact oil bearing
with the
Gives:..........................................= 40,70 description in the Shop Manual,
Gripping rings Check
2 = unit.................................. - 38,60 the rolling resistance.NOTE: before assemble the bearing.
inner ring.
m
Discs
=Apply front
2,10 oil
Resistance : to 17axle,
8 -the Nm. Do
partshub
and not
place the press !
assembly. 2)
a
Clearance..................................
3 = Cup springs
NOTE: Heat the bearing with
Prepare
NOTE: Do not press !
to assemble the roller bearing: With no press rotate the axle
x
Allowed clearanse 1,7 - 2,1 At
mmthis stage, no preload on the bearing electrical heater
Cleanorthe
hothub
oil axle and bearing cup. 20 times.
E
Temp 75 - 90°C
Resistance :
Apply lubricant.
X = Installation dimension (Free
1 The spinning)
Gripping
outer rings 8.2
disc (5 +0.3mm
pcs, different thickness available)
8 - 17 Nm.
aceRemove
the "linethe toolup tool" Pressure test: (167 - 194°F)
in assembly
EL
oxy part No. 514663
rack after assemble 1000 mm
2 The inner disc (4 pcs. thickness 4,7 mm)
gn cup
ubricate
and
mechanism
theseal
the
parts and
ring. Increase
seal ring
lock
test pressure up to p = 50 bar and close the
connection to the HP-pump by means the Now, remove
Lubricate area
an the bearing surface and During a 5 min. testing time a pressure drop of max. 2 %
ssemble the carrier.
before inserting
emble the bearing cup
the
(1 bar) is allowed!
pressure tester,
piston.
Assemble
into the
guide ring
Clean the surface
return and
Use glue: Loctite
Assemble
place
Assemble the
the no.406
guide
theO-ring
piston ring
ring
at both
Pos
Pos
Slot
21 -ends.
23-24 22
pin 6x20 DIN 1481
3)
urn the hubCheck
housing the rolling resis- The press is stay on !
tance.
he bearing cup and 0 bar
he seal
Example, resistance: Lubricate sealring Assemble
8 - 17 Nm. Insert the plug 50 bar the outer bearing.
Note: Be aware and careful
Shut of valve
At this stage, no Beof thedont
aware seal ring
the ring
preload on the lower electrical
Handle with care, replace
end of the hubasworn heater
ringsorwith
hot new
oil
bearing. while
assembly
Clean
Assemble
(Only 75
the surfaces the
the
- 90°C
set)
distance
Clean
(167 - 194°F)
before assembly
the axlering.
2)
the press
ring oil
in contact
to the bearing
hub to the axle.With noaxlepress,
(Free spinning) withAssemble
the
until the
coolflange
down
rotate
wheel the hub
bolt.
Remove thehousing 20 times
Use hydraulic press or
ful with the seal ring
an the bearing
ean surface and
surface and
emble the bearing
semble seal ringcup Preassemble the distance ring
screw plug.

re details about assembling 1)

eturn mechanism, seeAssembleAssemble the inner bearing.
the gear wheel
Clean
Place the endthe axle
plate
to and
and apply
with
contact oil bearing
2 screws
with the
ption in the Shop assembled,
esistance. Manual,before assemble
torque the the
screw
inner ring. bearing.
until the NOTE!
xle,
partshub
Nm. and assembly.
place the rolling resistance now is +20 Nm
NOTE: Do not press ! 2)
At this stage the screw for
by one. Heat the bearing
from previous check with
28 - 37toNm.
Prepare (total)the roller bearing: With no press
assemble rotate the axle
connection the gear wheel
eload on the bearing Measureelectrical
the heater
clearanse
Cleanorthe
hothub
betweenoilend
axle and bearing cup. 20 times.
with outer disc. and the carrier not is
sg)
8.2 +0.3mm Temp
plate and the75 - 90°C
axle end.
Apply lubricant.
(167
(Example - 194°F)
2,20 mm)
assembled
1000 mm
(4 pcs. thickness 4,7 mm)
e up to p = 50 bar and close the
P-pump by means theNow, remove
ng time a pressure drop of max. 2 %
the slot pin
pressure tester,
chanism connect lifting device
481
0 bar

Shut of valve
Beof thedont
aware seal ring
the ring
electrical
Handle with care, replace wornheater
ringsorwith
hot new
oil
lower end of the hub
Temp 75
Dont mix the rings (Only as set)- 90°C
while assembly
Clean
Assemble (167 -the
the surfaces the
before 194°F)distance
Clean
assembly
the axlering.
CheckHold and
the press
ring to apply
is the oil
in contact
bearing
the
untilaxle the
coolflange
down
wheel bolt.
mble the distance ring

pcs. screws plug and O-ring
e the O-ring and use
compound (tread lock) SHOP MANUAL MT41 - 01.2005
d 5111to lock the Prepare stand for the hub work over
mble the Return mechanism- piston

Calculation example: For more details about assembling Locate the shims (example
1) 2,2 mm)
le
4
Measure A.................................. 47,10
Measure B.................................- 6,40
Assemble Assemble
the inner bearing.
the gear wheel
p Locate the shims.

1 = Pin (3)40,70 Clean
Place the endthe axle
plate
to and
and apply
with
contact oil bearing
2 screws
with the
3 Gripping rings Check
Gives:..........................................=
before assemble the bearing.
(Example 2,2 mm)
2 = unit.................................. - 38,60 the rolling resistance. assembled,0,1 torque the screw
inner
0,5 ring.0,5 until the
m
Discs 0,5 0,5 0,1 NOTE!
=Apply
2,10 oil: to
Resistance 8 -the parts and place the rolling moment now is +20 Nm
17 Nm. 2)
a
Clearance..................................
3 = Cup springs
NOTE:
NOTE: Do not press !
Heat thecheck
from previous bearing
28 -with
Prepare
assemble the roller bearing: With no press
37toNm. rotate the axle
Ex
4 = Support shim brake disc, one by one. connection the gear wheel
2 Place 5 = the
Allowed
Circlipshims inAt
clearanse 1,7 - 2,1 mmorder
this stage, no preload on the
Start assembly with outer disc. bearing Measureelectrical
the heater
clearanse
Cleanorthe
hothub
between oilend
axle and bearing cup. 20 times.
and the carrier not is
asthefigure. Tempthe75 - 90°C
Resistance :
plate and axle end.

Apply lubricant.
1 The spinning)
Gripping
outer rings 8.2
disc +0.3mm
(5 pcs, different thickness (167
available) assembled
8 - 17 Nm.
PlaceRemove
thePlace
"linetoolup
thetool"end plate, as- (Example 2,20- 194°F)
mm)
ub in
0.9 EL
Moxy part
assembly
semble
rack
No. 514663
after assemble
2 The
Pressure inner
test: disc (4 pcs. 1000 mm
thickness
screws. Increase test pressure up to p = 50 bar and close the
4,7 mm)
ng
374
urn cup
Lubricate
and
mechanismScrew
the
the
parts
seal ring
lock ring. connection to the HP-pump by means the
andM16x50 ISO4017- Now, remove
HV Lubricate seal area
assemble 10.9
the carrier.
before inserting
EL
the During a 5 min. testing time a pressure drop of max. 2 %
pressure tester,
piston. Assemble 6 pcs. of the slot pin
(1 bar) is allowed!
Assemble
the
intoLoctite
guide ring
Clean the surface
return and
Apply locking Use liquid:
glue:
Assemble Treeno.406
Assemble the pistonring
place the
the guide
O-ring ring
Bond 1374 Pos 21 - 22 at both
Pos Slot
23-24ends.pin 6x20 DIN 1481
Thightening torque 280
Nm. The press is stay on !
the seal
Shut of valve
Beof thedont
aware seal ring
the ring
electrical
ringsorwith
hot new
oil
(Only 75 - 90°C
set)
while assembly
Clean
Assemble
the surfaces the
the
(167 - 194°F)
before
distance
Clean
assembly
the axlering.
the press
ring oil
in contact
to the bearing
the
untilaxle the
coolflange
down
wheel bolt.
areful with the seal ring
surface and
seal ringcup
screw plug.
Thightening torque 280 Nm.

4.05 4 Calculation example: For more details aboutLocate assembling

thethe
Place end(example
shims plate
1) , assemble2,2 mm)
screws.
le
Measure A.................................. 47,10 ScrewAssemble
M16x50 ISO4017-10.9 theEL
Measure B.................................- 6,40
of the return mechanism, see the inner bearing.
Assemble gear wheel
p
A 4.0 (3)40,70 Cleanendthe axle and apply oil
3
1 = Pin
Gives:..........................................=
Check description in the Shop PlaceManual,the
Tightening
before
plate
to
torque
assemble
and
contact
280
with 2 screws
with the
Nmbearing.
the
bearing
2 = unit..................................
Gripping rings Finally - 38,60 the
checkrolling resistance.
the rolling moment. assembled, torque the
inner screw
ring. until the
m
Discs 0,5 0,5 0,1 0,1 0,5 0,5 NOTE!
=Apply
Resistance front
oil: to 17axle,
8 -the partshub
Nm. and assembly.
place the rolling moment now is +20 Nm 2)
a
Clearance..................................
3 = Cup springs 2,10
3.8 28 - 37 Nm
Heat the NOTE:
bearing Do
with not press ! At this stage the screw for
: :
NOTE: from previous check 28 -

Prepare 37
toNm.
assemble the roller bearing: With no press rotate the axle
- 37 Nm.
x
4 = Support shim brake disc, one by one. connection the gear wheel
Resistance
2 Allowed clearanse 1,7 - 2,1 At mmthis stage, no preload on the bearing electrical heater or hot oil 20 times.
E
5 = Circlip Start assembly with outer disc. Measure the clearanse
Cleanbetween
the hub end
axle and bearing cup. and the carrier not is
4.0 1 PlaceRemove X = Installation dimension (Free
1 The spinning)
Gripping
outer rings 8.2
disc 1000
+0.3mm
(5 pcs, mm
different
Temp
plate and
thickness (167
the75
available)
- 90°C
axle end.
Apply lubricant. assembled
28 Nm.
Resistance
the "line up tool" Pressure

the tool (Example 2,20 - 194°F)
mm)
ce the hub ELin assembly rack after assemble
50 ISO4017-10.9 inner disc (4 pcs.1000
2 The test: mm
thickness 4,7 mm)
he 4.0
: Tree
ce bearing
thebond
1374 cup
return and the lock
8 - 17
-ISO 7089 300HVLubricate theseal

Lubricate parts
areaand connection to the HP-pump by means the Now, remove
280 Nm. assemble the carrier.
(1 bar) is allowed!
pressure tester,
piston.
Assemble
Clean the surface
into the
guide ring
return and
Use glue: Loctite
Assemble
place
Assemble the
the no.406
guide
theO-ring
piston ring
ring
at
Pos
Pos
Slot
both pin
21 -ends.
23-2422
6x20 DIN 1481
Finally check the rolling
resistance. 28 - 37 Nm
the seal
Shut of valve
Beof thedont
aware seal ring
the ring
electrical
ringsorwith
hot new
oil
(Only 75 - 90°C
set)
while assembly
Clean
Assemble
the surfaces the
the
(167 - 194°F)
before
distance
Clean
assembly
the axlering.
the press
ring oil
in contact
to the bearing
the
untilaxle the
coolflange
down
wheel bolt.
Be careful with the seal ring 28 - 37 Nm
reassemble Clean
the Return mechanism-
surface
the bearing surface andpiston
and
seal ringcup
assemble the bearing Preassemble the distance ring Assemble the scoop ring.
4.05 4 Calculation example: For more details about Screw assembling
M6x20 ISO4162-8.8 Locate
Insert 2 pcs. screws plug and O-ring thethe
Place end(example
shims plate
1) , assemble 2,2 mm)
screws.
le
Measure A.................................. 47,10
of the return mechanism, see Lubricate the O-ring and use Apply Screwlocking
M16x50
Assemble liquid:
theTree
innerBond
ISO4017-10.9
Assemble theEL
1374
bearing.
gear wheel
Measure B.................................- 6,40 locking compound (tread lock) Thigetening torque: 9,5and
Nmapply
p
4.0 3 1 = Pin
2 = Gripping rings
(3)40,70
Gives:..........................................=
Check
Discs unit..................................Finally the Tree Bond
rolling 5111to lock the
resistance.
- 38,60 check the rolling moment. 0,5
Place
NOTE
Clean
the
Tightening
endthe
before
assembled, torque
axle
plate
to
assemble
torque
and
contact
inner280
the
with
Nm
with
Prepare
the
screw
ring.
oil
2 screws
the
bearing.
until
bearing
stand for the hub work over
the
m
screw plug.
0,5 0,1
Be aware the 0,1 scoop0,5 ring 0,5 NOTE!
=Apply
Resistance oil: to
8 -the parts and place the rolling moment now is +20 Nm
17 Nm. 2)
a
Clearance..................................
3.8 Assemble the scoop ring. 28 - 37 Nm had to be assembled
Heat NOTE:
thecheck at the
bearing Doassemble
28 -with
not press ! At this stage the screw for
: :
NOTE: from previous Prepare 37toNm. the roller bearing: With no press rotate the axle
28 - 37 Nm.
HS Ex
RHS
Resistance
Allowed clearanse 1,7 - 2,1 mm correct hub.

electrical heater or hot oil
2 5 = Circlip At this stage,
Start assemblyno preload on the disc.
with outer bearing Measure the clearanse
Cleanbetween
the hubendaxle and bearing cup. 20 times.and the carrier not is
4.0 1 PlaceRemove Apply lockingdimension
X = Installation liquid: (Free Tree
1 The
Bond
spinning)
Gripping
outer rings 8.2
disc 1000
+0.3mm
(5 pcs, differentmm
thickness
Se the- figure
Temp
plate and the75axle90°C
available)
end.
at left
Apply lubricant.
Thigetening torque: 9,5 Nm
assembled
Nm.
Resistance
1374
the "linethe tool up tool" Pressure (167
(Example - 194°F)
2,20 mm)
he hub ELin assembly rack after assemble inner disc (4 pcs.1000
2 The test: thickness mm4,7 mm)
Moxy partTightening
O4017-10.9
4.0 No. 514663 torque: 9,5 test Nmpressure up to p = 50 bar and close the
bearing
bond
he 1374 cup
return and
mechanism the ring. Increase
seal ring
lock
8 - 17
089 300HV Lubricate theseal

Lubricate parts
area and connection to the HP-pump by means the Now, remove
Clean the bearingNote
surface and During a 5 min. testing time a pressure drop of max. 2 %
m. assemble the carrier.
before inserting
the
Be aware cup the scoop (1 bar)ring
Assemble hadofto
6 pcs.
is allowed! the slot pin
pressure tester,
piston.
be assembled Assemble
at
Clean
into the guide ring
correct
the surface
the return and hub.
Use glue: Loctite
Assemble place the
Assemble no.406
the guide
theO-ring ring
piston ring
at
Pos
Pos
Slot
21 -ends.
23-2422
Se figure below.
Turn the hub housing Preassemble the Return mechanism- piston The press is stay on !
Assemble the scoop ring.
180 ° whileBassembly 4.05 4 Calculation example: For more details about Screw
assembling
Placethethe end(example
shims plate
1) , assemble2,2 mm)
screws.
le
Apply
Screw locking
M16x50 liquid:
theTree
innerBond
ISO4017-10.9 1374
the bearing cup and Measure A.................................. 47,10
Legend to the sketch: of the return mechanism, see 0 bar
Assemble Assemble theEL
bearing.
gear wheel
Measure B.................................- 6,40 Thigetening torque: 9,5 Nm
p
A 4.0 1 = Pin (3)40,70 Place Clean
the endthe axle
plate
to and
and apply
with
contact oil
2 screws
with the bearing
the seal description in the Shop Manual,
Gives:..........................................= NOTE
Tightening
before torque
assemble280 Nmbearing.
the
3 2 = unit..................................
Gripping rings Finally Check
- 38,60 the rolling
check resistance.
the rolling moment. assembled, 0,1 torque the
inner screw
ring. until the
m
Discs 0,5 0,5 Be 0,1
aware the NOTE!
scoop0,5ring 0,5
direction when machine 3.8 is driving forward Lubricate sealring
Apply
Resistanceoil: to
8 -the
17 parts
Nm. and place the rolling moment 2)
now is +20 Nm
LHS Exa
Clearance..................................
3 = Cup springs = 2,10
28 - 37 Nm NOTE:
had to be assembled at the Do not press ! At this stage the screw for
X
brake disc, one by one. Assemble the

fromouter bearing.
Heat the bearing
28 -with
: :
NOTE: previous check

Prepare assemble the roller bearing: With no press
37toNm. rotate the axle
- 37 Nm.
Insert theAllowed
4plug
= Support shim 50 bar correct hub.
RHS
Resistance
2 5 = Circlip surfaces.
clearanse 1,7 - 2,1 At
mmthis stage, no preload on the bearing
Start assembly with outerClean
1000
Measure
disc. the axle
mm
electrical
and theapply
Se the
heater
clearanse
Clean
figure
orthe
at
hothub
oilbetween
left
oilend
axle and bearing cup. 20 times.and the carrier not is
Thigetening torque: 9,5 Nm
4.0 1 PlaceRemove X = Installation
up tool" NOTE:
dimension(Free spinning)
Gripping
1 The outer rings 8.2 +0.3mm plate
before thickness
disc (5 pcs, different assemble
Temp
and the
the
75 - 90°C
axle end.
Apply
bearing.
available)
lubricant. assembled
28 Nm.
Resistance
Place the flange

20 pcs . screw PlaceISO4017-10.9
M16x50
the "line
the tool
the hub ELin assembly rack afterAssemble Be
assemble aware
2 The test:
Pressure inner and
disc ring
the seal
careful
(4 pcs.1000
thickness mm4,7 mm)
(167
(Example - 194°F)
2,20 mm)
Figure 26
of the
Place
4.0
Treebearing
thebond
1374 cup
return and the lock
mechanism seal ringring.Beof thedont
aware seal bend
Shut
ring
Increase test pressure up of50valve
on
to p =
the ring
bar and close the
8 - 17

Lubricate parts
areaand Now,
connection to the HP-pump by means the remove
Clean the bearing surface and DuringHandle with care, electrical
time a replace wornheater
rings2or hot new
%with oil
Tightening torque: 280 Nm. assemble the carrier.
piston.
lower
Assemble
(1 bar)Dont
end
6 pcs.
is allowed!
of
a 5 min. testing
the
slot pin
therings
mixofthe
hubdrop
pressure
Temp
(Only 75
of max.
pressure
- 90°C
as set)
tester,
Assemble
while guide ring
Clean the surface
into theguide
Cleanassembly
return and
the
Assemble
surfaces the
mechanism the
(167 - 194°F)
before
distance
Clean
connect
assembly
the axle
lifting ring.
device
Use glue:
Assemble
place Loctite
the
the no.406
theO-ring ring
Assemble
Slot
piston ring
pin 6x20 DIN 1481 CheckHold the pressandisapply
ring oil
in contact
at
Posboth
21 -ends.
23-24 to the bearing
Pos
hub to the axle.
22
withAssemble
the
untilaxle the
coolflange
down
Turn the hub housing wheel bolt.
the bearing cup and
0 bar
the seal lifting device. sledgehammer.
Rolling direction when machine is driving forward
Insert the plug
Lubricate sealring
Assemble
Be careful with the seal ring surfaces. Clean the axle and apply oil
Shut of valve
surface and
Clean the bearing surface and Beof thedont
aware seal ring
the ring
seal ringcup
assemble the bearing Preassemble the distance ring end of theelectrical
Handle with care, replace
lower hubasworn
(Only 75
heater
ringsorwith
- 90°C
set)
hot new
oil
Insert 2 pcs. screws plug and O-ringwhile assembly
Clean
Assemble (167 -the
the surfaces the
before
distance
Clean
194°F)
assembly
the axlering.
the press
ring oil
in contact
Lubricate the O-ring and use hub to the axle. to the bearing
locking compound (tread lock) withAssemble
the
untilaxle the
coolflange
down
Tree Bond 5111to lockSHOP wheel bolt.
the MANUAL
Remove theMT41 - Prepare
01.2005
Use hydraulic press stand
or for the hub work over
screw plug.
Assemble the scoop ring.
Calculation example: For more details about Screw
assembling
Placethethe end(example
shims plate
1) , assemble 2,2 mm)
screws.
e Ch 3 page 156 DRIVE LINE

theTree
innerBond 1374
l
Measure A.................................. 47,10 Screw M16x50 ISO4017-10.9 theEL
Measure B.................................- 6,40
Assemble
Thigetening torque:
Assemble
9,5and
bearing.
Nmapply
gear wheel
p
(3)40,70 Apply
Place locking
Clean
the endthe liquid:
axle
plate
to andTree
contactwithBond 1374
oil
2 screws
with the bearing
Connect the gear wheel
1 = Pin
Gives:..........................................=
2 = unit..................................
Gripping rings Finally Check the rolling resistance.
NOTE
Tightening
before
assembled, torque
assemble
torque 280
the
inner Nmbearing.
the
screw
ring. until the
and the carrier.
- 38,60 check the rolling moment.
m
Discs 0,5 0,5 Be 0,1
aware the 0,1 scoop0,5 ring 0,5 NOTE!
=Apply
Resistance oil: to
8 -the parts and place the rolling moment now is +20 Nm
17 Nm. 2) M16x50 ISO4017-10.9 EL
Screw
a
Clearance..................................
28 - 37 Nm NOTE:
had to be assembled
Heatat the Do not press !
the bearing with
: :
NOTE: from previous check 28 - 37toNm.

Prepare With no press
assemble the roller bearing:Apply locking rotateTree
the axle
28 - 37 Nm.
x
4 = Support shim brake disc, one by one. liquid: the Bond 1374
RHS
connection gear wheel
Resistance
mmthis stage, no preload on the bearing correct

Allowed clearanse 1,7 - 2,1 At hub.
electrical heater or hot oil 20 times.
E
5 = Circlip Start assembly with outer disc. Measure the clearanseCleanbetween
the hubendaxle and bearing cup. Washer 17x30x3 NS-ISO
and the carrier7089 300HV
not 9,5
is
1 The spinning)
Gripping
outer rings 8.2
disc +0.3mm
(5 pcs, 1000 mm
different thickness (167
Se
Temp
plate and
the
the75
available)
figure
- 90°C
axle end.
at left
Apply lubricant.
Thigetening
Tighteningassembled
torque:
torque 280 Nm
Nm
Nm.
Resistance
aceRemove
the "line
the toolup tool" Pressure - 194°F)
(Example 2,20 mm)
Ln assembly rack after assemble
oxy partConnect
No. 514663
2 The test: 1000 mm
inner disc (4 pcs. thickness 4,7 mm)
Increase test pressure up to p = 50 bar and close the
cup and
mechanism the the
ring. connection toand
seal ring
lock gear wheel the car-
8 - 17
bricate
Lubricatetheseal
parts
rier.
area and the HP-pump by means theNow, remove
n the bearing surface and During a 5 min. testing time a pressure drop of max. 2 %
semble the carrier.
before inserting
mble the bearing cup
the
(1 bar) is allowed!
pressure tester,
piston.
Washer 17x30x3 Assemble
Clean the
into NS-ISO
the
guide ring
surface
return 7089
and 300HV connect lifting device
mechanism
Use glue: Loctite no.406
Screw M16x50 Assemble
place
Assemble
at both
ISO4017-10.9
Slot
the
the
pin
guide
theO-ring
piston
6x20
ring
ring
DIN EL
1481
Pos
Pos 21 -ends.
23-24 22
urn the hub housing The press is stay on !
Tightening
e bearing cup and torque 280 Nm. 0 bar
e seal
on when machine is driving forward
Insert the plug
Lubricate sealring
Assemble
Be aware and
careful
Shut of valve
Beof thedont
aware seal ring
the ring
electrical
ringsorwith
hot new
oil
(Only 75 - 90°C
set)
while assembly
Clean
Assemble (167 -the
the surfaces the
before 194°F)distance
Clean
assembly
the axlering.
the press
ring oil
in contact
to the bearing
the
untilaxle the
coolflange
down
wheel bolt.
ul with the seal ring
surface and
an the bearing surface and
seal ringcup
emble the bearing Preassemble the distance ring
screw plug.

correct hub.
electrical heater orthe
hothub
oilend
Measure
c.ring DRIVE the clearanse
Cleanbetween axle andChbearing cu
0 mm Se the figure at left 3 page 157
LINE
plate andTemp
the75 - 90°C
axle end.
Apply lubricant.
ent thickness
(Example
available)
(167 - 194°F)
2,20 mm)
0aressand
mm 4,7 mm)
close the
Now,
ns the remove
re drop of max. 2 %
pressure tester,
connect lifting device
(2)
0 bar B
( 2,2 )
ate sealring Assemble

es. Clean the axle and apply oil
before assemble the bearing.
are and careful
e seal ring
Shut of valve
seal ring on
nt bend the ring
electrical
dle with care, replace wornheater
ringsorwith
hot new
oil
end of the hub
mix the rings Temp
(Only 75 - 90°C
as set)
assemblyAssemble
n the surfaces the
the
(167 - 194°F)
before
distance
Clean
assembly
the axlering.
the press
ring in oil
contact
to the bearing
the axle.
withAssemble
the
untilaxle the
coolflange
down
wheel bolt. SHOP MANUAL MT41 - 01.2005
Cooling cirquit rear brake
Oil level
The oil from the

tandem housing is
circulate through the
brake chamber and
cool the disc


Note:


Axle and Tandem housing Bearing

Cross section
DRIVELINE-VIEW BOGGI AXLE
The tandem housing reduction gear consists of a pinion gear which transfers the rotation power through idle
gears, end gears, and wheelshafts to the driven wheels.
The tandem (spur) gears are in constant mesh, driving both wheels at the same side.
Tandem bogie
32
37
45
32
37
Distance ring
Ball-bearing
45
Pinion unit
Distance ring
Ball-bearing
Tandem bearing
Ø 740
Ø 563
Ø 560
Ø 475
6,5
32
37
27
45 78
102,5
150
13
27 Ø460
Ø725

Checking clearance in the Tandem bearing.
Check the diametric clearanse.
1. Place the magnetic stand on the outer

side of the frame bar.
2. Reset the indicator to zero
3. With crane or hydraulic jack, lift one of

the sides until the wheels are clear from
the floor.
4. Lower the machine.
5. Read the indicator value.
Max diametric clearance: 1,50 mm
using Rhs
Tandem ho
ON
OFF
Axle housing
OFF ON
Check the axial clearanse.
1. Place the magnetic stand on the axle

housing underside. See figure.
2. With crane or hydraulic jack, lift one
of the sides until the wheels are clear
from the floor.
3. Reset the indicator to zero
4. Lower the machine.
5 Read the indicator value.
Max axial clearance: 1,00 mm

View of the Tandem bearing
B
C

Calculation of the Tandem bearing
A B C
C Diametric
Screw to
the tandem
housing
Screw to the
axle housing
Axial
D
E F
New bearings, axial clearance example: Insert the measuring out values
Measure A: 5,01
Measure F: 50,02
Sum A,F,: 55,03 55,03
Measure B: 4,98
Measure C: 44,98
Measure E: 4,95
Sum B,C,E,: 54,91 -54,91
Clearance: 0,12
Min: 0,08 mm
Max: 0,15 mm
See the Parts Cataloque
for other sizes of the thrust
bearing (B and E).
Available from 4,9 - 5,3 mm.
Insert the measuring out values
New bearings, diametrical clearance example:
Measure F 650,02
Measure D (thickness x 2) 4,84
Measure C (diametric) + 644,99
Sum D+C = 649,83 -649,83
Sum clearance: = 0,19
Min: 0,10 mm
Max: 0,40 mm

Disassemble Tandem housing unit

Safety precautions.
Connect the articulation lock to front frame.
Secure the machine with wheel chocks on the

front wheel.
Drain the oil from axle housing and tandemhousing.
Note:
Draining of oil from tandem housing is not necessary if removal
takes place just for work on the tandem bearing.

Disassemble the tandem unit from the rear frame
It is also possible to disassemble the tandem housing without

disassemble the axle housing. See note on next page.
Unfasten the rear propeller shaft from the differential flange
M12x60 DIN912-12.9
Secure the rear propeller shaft for damage with a strop
1 Disassemble 2 brake hoses from Tandem housing

LHS and RHS
2 Disassemble 2 lubrication hose from Tandem housing

LHS and RHS 1 2
3 Disassemble axle housing screws (4 in each side).
By crane:
Lift the rear frame up and move the tandem
unit backwards
Place safety supports under the rear frame.

Be aware of the propeller shaft.

Note.
If it is not possible to lift the rear frame off the tandem unit, the tandem unit could be pulled off the rear axle
housing by using the arrangement as shown on the figure.
Place the arrangement between the wheels. Adjust the arrangement and the jack according the angle of the
tandem housing. Pull the tandem unit off the rear axle housing.
The tandem unit is approx 10,5 ton. (Including axle housing and oil)
One tandem housing with wheel is approx 4,8 ton
One tandem housing without wheel is approx 3,1 ton
#100x100x6
160
650
150
100
65
0
90 750
0
750

Disassembly the axle housing from the tandem-

housing
Lift one side of the tandem unit and place safety supports under the axle housing.
Be sure that the tandem unit is safely placed at

the safety support.
Safeguard the tandem housing with the crane
Disassemble the wheel nut
20 pcs Width across flat: 30 mm
Take the wheel away.
Disassemble the outer screws for the bearing unit

28 pcs. M20
Move tandem housing away from rear axle unit, and lower safely
to ground.
Clean the mating flanges for traces of sealing compound.

Disassemble the tandem bearings
Remove the actual tandem bearing.
On top of the bearing, remove the M12 hexagon plug, fasten a

lifting device in upper mounting holes and lift to take the weight
of the tandem bearing.
Unscrew the 30 M20- screw attaching the tandem bearing to the

rear axle housing.
Lift bearing out from the rear axle unit, and lower to the ground.
Clean the mating flanges.
Assemble new bearing unit to the axle housing.

Grease the sealing and the sealing surfaces

Torque limit: 560 Nm. Axle housing
Tandem
housing

Assemble the tandem housing to the axle

housing.
Assemble the tandem unit
Screw M20x150 ISO4014-10.9
Apply locking loquid: Loctite 245
After attraction, test the movement with to lift the end of

Tandem housing.
500 -
1000 Nm
Fill oil on the axle housing.
Fill up the machine with oil when it is placed on a straight level
Check the level of oil in the Tandem housing

Assemble the wheel.
20 pcs Width across flat: 30 mm
By crane:
lift the rear frame up and move the tandem
unit backwards
1 Assemble axle housing screws (4 in each side).

3
Torque limit: 960 Nm 2
2 Assemble 2 brake hoses from Tandem housing
LHS and RHS
3 Assemble 2 lubrication hose from Tandem housing

LHS and RHS 1
Assemble the propeller shaft to flange

of the differential.


Wheel hub, rear

Safety precautions.
In order to disassemble the hub from the tandem unit, do the following:
1 It is not necessary to disassemble the tandem unit from the machine
2 Jack up the machine so the wheels are above floor level, then drain oil from the tandem unit
3 Secure the machine with safety support and dismantle the wheels
4 Disconnect the brake lever from the tandemunit and the hub
5 Disconnect the brake calipper
6 Place the hub to a strap and release the axle from the tandem unit
Make sure the machine has the articulation lock

assembled.
Place wheel chocks to the front wheel

Sectional drawing of the wheel hub.
10 1 Brake disc
20 4 Slot. pin
30 4 Slot. pin
40 16 Screw
50 16 Washer
60 1 Carrier
70 16 Screw
80 1 Wheel axle
90 20 Wheel bolt
100 20 Wheel nut
110 1 Seal ring
120 1 Roller bearing
130 1 Wheel hub
140 1 Roller bearing
150 1 Gear wheel
160 1 Plate
170 1 Shim 0,1mm
180 1 Shim 0,35mm
190 1 Shim 0,5mm
200 4 Screw
220 1 Protection upper
230 1 Protection lower
240 8 Screw
250 8 Washer
260 1 Seal ring
270 2 Ring
280 16 Screw

Disassembly the wheel hub
Lift the rear wagon until the wheel is above the floor
Secure with safety supports under the axle housing.
Disassemble the wheel.
Drain oil from the tandem housing
Disassemble protection shield for the brake pipes.

Disassemble brake pipes.
Disassemble brake calipper.
Disassemble screws
Use lifting device to take out the hub.

Place the hub safely.
Disassemble screws from the wheel axle end

M16x55 DIN912-12.9
Unfasten plate and lift the gear wheel off the hub.
To loosen the hub it may be neceserry to use a hydraulic press.
Lift hub of the wheel axsle.
Disassemble screw for the carrier

M16x50 ISO4017-10.9

Take off the carrier with the brake lever
Disassemble the brake lever from the carrier
Remove the roller bearing.
To take the roller bearing off, it

must be destroyed.
Use a chisel and a

hammer to cut the
roller’s external ring.
Bend the ring and take it away
Use a chisel and a hammer to cut the roller’s external ring.

To loosen the ring, heat up (until colour is blue).

Bee quick so the axle does not begin to heat.
Use protective gloves and safety glasses.
When the bearing are cooling down the ring will crack.
Now the ring easely can be removal off the axle
Take off the adjuster ring:
Quickly heat up the adjuster ring.
Use chiesel and hammer to move the ring of the axsle.
With crowbar, lift the ring up

Remove the O-ring
Clean all parts which may be used again.

Assemble the wheel hub
Assemble the brake disc to the carrier
Hole Ø18 for the slot pin.
In the brake disk 4 hole Ø18 is for the slot pin.
Assemble 4 pcs. slot pin.

S18x50
The slot pin is in direction

to the inner side.
Assemble the inner slot pin

S11x35
(in opposite way to the outer slot pin).

4 + 4 slot pins assembled
Assemble 16 screws M18x70 DIN912-12.9 with washer
Torque limit 463 Nm

Pre-assembly the wheel hub axle
Apply grease to the lower part of the axle
Place the O-ring in the adjuster ring.
Assemble the adjuster ring with O-ring.

It is necessary that the ring is assembled in line to the axle
so the plane ring to the axle has optimal contact.
Assemble the bearing:
Before the assemble, heat the bearing with

oil or in hot cabinet, minimum 100°C
If the roller bearing is not heated, a hydraulic press with a capacity

of 10 - 20 ton is needed.

Control that the bearing is in

correct position
Grease the bearing.
Assemble the carrier with the brake disc to the axle.
Assemble screw to fix the carrier to axle.
M16x50 ISO4017-10.9
Locking liquid.Tree Bond 1374
Torque limit. 277Nm

Pre-assembly the wheel hub

Apply grease to the hub bearing retainer
Before assembly; Cool the bearing in freezer, approx -20°C
Fix the bearing liner to the hub.
Use suitable plate and plastic hammer to squeeze the

bearing cup into the hub.
Controll that the bearing cup are

in correct position.
Apply to packing ring holder:
Loctite Permatex Form -A- gasket No. 3

Fix the packing ring to the hub
Use suitable plate when assemble the

packing ring into the hub.
This plate must have a recess so the

packing ring is not damaged.
Use plastic hammer to squeeze evenly and

careful the packing ring into the hub.

Assembly the wheel hub to the axle
Turn the hub 180° and connect to the wheel axle.
Be careful so the packing ring is not damaged.
Assemble the roller bearing:
Heat the bearing in oil or in hot cabinet.
Use plastic hammer and sleeve

(or hydraulic press)
Make sure that the bearing

is in line with the axle.

Assemble the gear wheel to the hub
Assemble the gear wheel.
Be aware that the correct side is facing up.
See figure.
NOTE !
Find the zero-point.

1000 mm
Zero-point is when the bearings are in physical
contact.
Rotate the hub several times.
Calculation example:
Top of gear wheel to axle end.........: 1,55 mm 15-20 Nm

Gives shims.....................................: 1,45 mm
Rotate the hub while measuring the

rolling resistance, e.g. 15 Nm. 1000 mm
Measure the distance between
axle end and top of the gear wheel,
e.g. 1,55 mm.
This will give shims 1,45 mm.
35-40 Nm
Assemble the shims, plate and torque the screws.

Check the rolling resistance, it should now be 20 Nm. higher.
15 Nm + 20 Nm = 35 Nm
If more or less, adjust with shims.
M16x55 DIN912-12.9
Locking liquid: Tree Bond 1374

Assembly the hub to tandem huousing
Assemble the hub to tandem housing
M16x60 ISO4014-10.9
Assemble the brake calipper.
M20x70 ISO4014-10.9
Connect brake pipes.
Assemble brake pipe shield

M10x20 ISO4017-8.8 fzb
Torque limit: 47 Nm
Assemble wheel
Oil the bolts.
Bleed air from rear brake.

Disassemble the tandem housing’s innside parts
See the section: Safety precautions.
Use the same precaution when changing the tandem housing

and disassembling the hub.
Drain oil from the tandem housing and the axle housing
Disassemble the brake hoses.

Protect the hose against moisture, dust and mud.
Move tandem housing away from rear axle unit, and lower safely
to ground.
Clean the mating flanges for traces of sealing compound.

NOTE.
Pos.no. refers to the exploded drawing on previous side.
Disassemble the bolt (pos 33)
Take away the pos. 29-32-33-34
Disassemble screw from bolt on the other side (pos 24)

M10x20 ISO4017-8.8 fzb
Disassemble screws from the same bolt on opposite side of

tandem unit
Use hammer and mandrel to knock out the bolt circa 20 mm

Place the tandem housing with the inside down.

Disassemble 20 pcs screw
M16x60 ISO4014-10.9
Loosen the hub from the tandem housing by putting 2 screws

M12 or M16 into the tierce hole.
(See arrow)
By using crane, lift the hub up from the tandem housing.
See the section for disassembling the wheel hub.
Disassemble cover for the pinion drive
Now take away the bolt for the idle gear.

Move the idle gear to the side and by

lifting the device, take it out
501555
Disassemble the conical roller bearing

Control the idle gear for damage.
Clean before assemblage.
Lift out the piniong drive.

Disassemble the snap ring

Take out the thrust washer
Disassemble the bearings
Take out the snap ring and thrust washer with the O-ring.
Disassemble the O-ring.
Take out the oil seal
Clean the tandem housing inside before assemblage.

Assemble the idle gears in the tandem house
Pre-assemble the idle gear.

20 pcs, M16x45 DIN912-12.9
Apply locking liquid: Tree Bond 1374 501555

Assemble the bearing cup to the pinion drive. (Cool down to -
20°C before assembly)
Use plastic hammer to install the bearing cup.
Be aware that the bearing cup is at the bottom.
Place the roller bearing into the cup.
Prepare to install the idle gear.

Use steel plate (5 x 200 x 550 mm) to help skid the idle gear.
Bend the end of the plate so the end is 45 mm high
Use lifting device to install the idle gear to the tandem housing
Assembly
plate
Keep the lowest bearing and guide the idle gear

into place in the tandem housing
Move the idle gear in position.
Take away the plate
Apply sealing compound on flange befor assembly the bolt.
Loctite 574

Line up the part and assemble the bolt

(It is advantageous to cool down the bolt to -20°C Screws
before assembly)
Bolt
Ball-bearing
Distance ring
O-ring
Shims
Washer
Screw
Use plastic hammer to knock the bolt in.
Fasten the bolt

Locking liquid:Tree Bond 1374

Torque limit: 68 Nm
Turn the tandem housing and place the shims for the
pre-tensioning
See the next page.

Measuring equipment:
Micrometer 0 - 25 mm
Ring D 85 - d 70 x h10,00
Place the ring in the mashining groove, with the

micrometer measure distance from top of the ring
an to the bolt.
Calculation example:
Measure to the bolt end....................... 11,45 mm
Less the ring 10mm............................ −10,00 mm
Difference............................................. 1,45 mm
Pre-tensioning .....................................− 0,05 mm
Necessary shim ................................... 1,40 mm
Available shim: 0,50 - 0,35 - 0,10 mm
Assemble the pre-tensioning bolt.
Assemble the O-ring, calculated shim, plate, washer and screw

M20x50 ISO4017-10.9
Locking liquid:Tree Bond 1374

10 Nm
Check the pre-tensioning:
10 Nm
Assemble the hub to the tandem housing
See section: Assemble the hub to the tandemhousing.
Note:
When both idle gears are assembled, assemble the pinion gear.

Assembly piniong in the tandem house
Assemble new oil seal
Assemble the pinion drive
2 Distance ring
2 pcs. ball-bearing
1 pcs. thrust washer
1 pcs. O-ring
1 pcs. snap ring
Assemble the distance ring.

Heat the ball bearing to circa 100°C
and assemble to the end of the pinion drive.
Assemble the O-ring to the thrust washer,
apply oil and assemble the thrust washer
into the pinion drive.
Assemble the snap ring

Grease the sealing ring
Assemble the pinion drive.
Use plastic hammer to assemble the pinion drive into the

tandem housing.
Assemble the cover.
Apply sealing compound Loctite 574 to the flange

Use plastic hammer to knock the cover gradually
down.
M10x25 ISO4017-8.8 fzb
Torque limit: 47 Nm

Tyres
A tyre consists of four primary components;

casing plies, beads, belts and tread. All four
components are primarily responsible for the
fundamentar characteristics of the tyre.
BELTS.
Extra layers of rubber-coated cord are placed between the outer plies and the tread, in order to protect the
plies, preventing cuts from reaching the ply cords and absorbing shock.
CASING.
A tyre is composed of several layers of plies, which are coated on both sides with a rubber compound. These
layers maintain the inflation pressure of the tire in supporting the load. Composed of high-tensile nylon cords,
it has greater resistance to heat, shock and cutting, adding to the durability of the tyre. The term “Ply Rating”,
according to the TRA, is defined as follows: “A given tyre with its maximum recommended load when used in
a specific type of service. It is an index of tyre strength and does not necessarily represent the number of cord
plies in the tyre.
INNER LINER.
The inner liner is a rubber layer covering the inside of a tyre from bead to bead, and corresponds to the tube
of an ordinary tyre using a tube. It keeps the inflation pressure constant, while reducing weight and simplifying
maintenance by eliminating the tube.
BEAD.
All plies are tied into bundles of steel wire. The beads are the parts which fit the tyre perfectly on the rim, pre-
venting the tire from slipping out of the rim contour while the vehicle is in motion.
SIDEWALLS.
Sidewalls are covers made of a flexible rubber compound which protect the sides of the tyre. They are de-
signed, under ordinary usage, to cushion the plies from shock and cutting, and to flex and bend without crack-
ing.
TREAD.
The tread compounds used in Bridgestone tyres are highly resistant to abrasion and cutting. Different tread
patterns are employed according to the particular usage of the tyre. This patterns feature excellent traction,
longer serviceability and higher resistance to cutting.

Note

MOXY Drive Line

Uploaded by

Copyright:

Available Formats

You might also like

MOXY Drive Line

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MOXY Drive Line

Uploaded by

Copyright:

Available Formats

DRIVE LINE Ch 3 page 1

SHOP MANUAL MT41 - 01.2005

SHOP MANUAL MT41 - 01.2005

Wet disc brake ....................................................................................... 95

SHOP MANUAL MT41 - 01.2005

Fig 3.1 Drive Line Overview

SHOP MANUAL MT41 - 01.2005

CAUTION When assembling the transmission, absolutely observe the indicated

Lined plates must not be washed. They must be cleaned with a

DANGER When using detergents, observe the instructions given by the

SHOP MANUAL MT41 - 01.2005

Structure of the Repair Manual

Important information on industrial safety

Serves as reference to special working procedures, methods, information,

REFERENCE: Prior to starting the checks and repair works, thoroughly

SHOP MANUAL MT41 - 01.2005

Denomination of standard dimensions

Note: linear density in kg/m; areal density in t/m2

Force F N (Newton) kp 1 kp = 9,81 N

Work A J (Joule) kpm 0,102 kpm = 1J = 1 Nm

1 kg (Kilogramm) = 2,205 lb (pounds)

9,81 Nm (1 kpm) = 7,233 lbf x ft ( pound force foot)

1,356 Nm (0,138 kpm) = 1 lbf x ft (pound force foot)

1 kg / cm = 5,560 lb / in (pound per inch)

1 bar (1,02 kp/cm 2 ) = 2

1 Liter = 0,264 Gallon (Imp.)

4,456 Liter = 1 Gallon (Imp.)

1 Liter = 0,220 Gallon (US)

3,785 Liter = 1 Gallon (US)

1609,344 m = 1 Mile (Landmeile)

0° C (Celsius) = + 32° F (Fahrenheit)

SHOP MANUAL MT41 - 01.2005

TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF - STANDARDS 148

Metric ISO Standard thread Metric ISO Fine thread

SHOP MANUAL MT41 - 01.2005

SHOP MANUAL MT41 - 01.2005

SHOP MANUAL MT41 - 01.2005

10 1 •Hub carrier cpl. 300 3 •Planet gear

SHOP MANUAL MT41 - 01.2005

See also the following draft.

SHOP MANUAL MT41 - 01.2005

Front reduction gear cross section

Wheel hub RP-17 i= 6.353- MT41

SHOP MANUAL MT41 - 01.2005

Tool for RP17.

504232 8344 504213 505766 505766 505760

505754 505771 504210 504196

505768 505764 505769 505757 504256 505765 504175 504173 504170

SHOP MANUAL MT41 - 01.2005

Connect the framelink lock to front frame

Secure the machine with to block the rear wheel

Prepare Disassembly front wheel hub, RP-17

Disassembly front wheel

Place safety the front frame bar, 2 car ramps.

On each car ramp = 5 ton

SHOP MANUAL MT41 - 01.2005

Disassembly the brake pipes

Disassembly the brake calliper

Apply Locking liquid: Loctite 245