Repair instructions

GP25 drive unit

Ident-No.: 4699 825 013 4699 825 027
4699 825 014 4699 825 028
4699 825 016 4699 825 029
4699 825 017 4699 825 030
4699 825 018 4699 825 031
4699 825 019 4699 825 032
4699 825 020 4699 825 033
4699 825 021 4699 825 037
4699 825 022 4699 825 038
4699 825 024 4699 825 039
4699 825 025 4699 825 042
4699 825 026 4699 825 048
4699 825 049
 ZF Gotha GmbH
Passauer Strasse 1
99867 Gotha
Germany
Tel.: +49 3621 311-0
Fax: +49 3621 311–4419
E-mail: aftermarket.zfgotha@zf.com
Internet: www.zf.com

Version: 01 June 2010

Manufacturer's repair instructions

© ZF Gotha GmbH 2010

The reproduction, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation is pro-
hibited. Offenders will be held liable for the payment of damages. All rights
reserved in the event of the grant of a patent, utility model or design.

Technical modifications
We reserve the right to make technically related modifications in production,
processing and frequency of publication for all editions.

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Table of contents

Table of contents
1 Basic information.................................................................................................. 7
1.1 Notes on the repair instructions ............................................................. 7
1.2 Warranty and liability ............................................................................. 7
1.3 Customer service department of manufacturer ....................................... 8

2 Safety ....................................................................................................................9
2.1 Safety colours and signal words ............................................................. 9
2.2 Representation of safety instructions ...................................................... 9
2.3 General safety information ................................................................... 10
2.4 Demands on personnel ........................................................................ 10
2.5 Safety information regarding technical condition .................................. 11
2.6 Safety information regarding transportation.......................................... 11
2.7 Safety information Repair work ............................................................ 12
2.8 Safety information on handling consumables and operating materials .. 13

3 Technical description (in brief)...........................................................................15

4 General notes on repair work.............................................................................17

4.1 Standard tools ..................................................................................... 18
4.2 Special tools ........................................................................................ 21
4.3 Wear parts and consumables............................................................... 23

5 Dismantling.........................................................................................................25
5.1 Motor disassembly............................................................................... 26
5.2 Removing the housing cover ................................................................ 28
Housing cover...................................................................................... 28
Inner disc carrier .................................................................................. 29
Pressure disc ....................................................................................... 30
Spur gear............................................................................................. 30
Axial bearing........................................................................................ 32
Cylindrical pin ...................................................................................... 32
5.3 Housing disassembly ........................................................................... 33
Brake disc set ...................................................................................... 33
Protective cap...................................................................................... 33
Cylindrical pin ...................................................................................... 34
Grooved nut......................................................................................... 34
Planet carrier ....................................................................................... 35
Planetary gears .................................................................................... 36
Gear shaft ............................................................................................ 36
Wheel shaft taper roller bearing ........................................................... 37
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Internal gear.........................................................................................38
Wheel shaft sealing ring .......................................................................38
Wheel shaft side bearing cup ...............................................................38
Planet carrier side wheel shaft ..............................................................39
6 Installation .......................................................................................................... 41
6.1 Housing reassembly .............................................................................42
Wheel shaft side bearing seat ..............................................................42
Shaft sealing ring – (Parts Kit available) ................................................42
Bearing cups ........................................................................................43
Internal gear – (Parts Kit available) .......................................................45
Gear shaft ............................................................................................46
Measuring and adjusting ......................................................................49
Planet carrier........................................................................................50
Grooved nut .........................................................................................52
Wheel shaft drag torque.......................................................................54
Cylindrical pin ......................................................................................55
Protective cap ......................................................................................56
Planetary gears – (Parts Kit available) ...................................................56
6.2 Refitting the housing cover ...................................................................57
Grooved ball roller bearing ...................................................................57
Spur gear – (Parts Kit available)............................................................58
Axial bearing ........................................................................................59
Inner disc carrier ..................................................................................60
Disc set – (Parts Kit available)...............................................................62
Cylindrical pin ......................................................................................66
6.3 Refitting the motor ...............................................................................68
Motor ...................................................................................................68
7 Waste disposal ................................................................................................... 70
7.1 Cleaning agents, additives and operating fluids ....................................70
7.2 Scrapping ............................................................................................70
7.3 Disposal of electrical and electronic components..................................70

8 Attachment ......................................................................................................... 72
8.1 Clamping/unclamping/turning ..............................................................72
Clamping .............................................................................................72
Unclamping..........................................................................................72
Turning ................................................................................................72
8.2 Brake lever ...........................................................................................73
8.2.1 Dismantling..........................................................................................73
Retaining ring.......................................................................................73
Guide pin .............................................................................................73
Pressure pin .........................................................................................73
8.2.2 Installation............................................................................................74

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Brake lever........................................................................................... 74
Brake lever play ................................................................................... 75
Brake test ............................................................................................ 75
8.3 Breather............................................................................................... 76
Removal .............................................................................................. 76
Refitting............................................................................................... 77
8.4 Wheel studs ........................................................................................ 78
Removal .............................................................................................. 78

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Basic information

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Basic information

1 Basic information

1.1 Notes on the repair instructions

These repair instructions explain all repair work procedures on the GP25 drive
unit (hereafter called drive unit). It can be used by maintenance staff to famil-
iarise themselves with the assembly and disassembly of the drive unit.
Information on the fitting, operation and removal of the drive unit may be
found in the assembly manual, document number 4699 750 042 in German
(4699 750 043 in English).
The repair instructions have been prepared on the basis of the standards DIN
EN 62079 “Preparation of instructions - Structuring, content and presenta-
tion” and ANSI Z535.6-2006 “American National Standard for Product Safety
Information in Product Manuals, Instructions, and other Collateral Materials”.
The repair instructions are divided into 8 chapters. Each page contains a
header containing the title of the particular chapter. The footer comprises the
unit type, document number, version number, edition date and page number.
A list of contents precedes the body of the text and shows the contents of the
manual under bullet points.
These repair instructions shall be kept in a place where they can be easily
found at any time by persons performing maintenance of the product.
ZF Gotha GmbH reserves the right to develop the technology of their prod-
ucts. As a result, work procedures may become necessary which are different
from those described here. In such cases, ZF Gotha GmbH will inform its cus-
tomers and provide them with the amended pages of the instructions.
It is the sole responsibility of the customer to replace previous sheets with the
amended versions, thereby keeping these instructions constantly up-to-date.
If you are not sure whether your version of the manual is up-to-date, you may
order the currently up-to-date version from the customer service department
of ZF Gotha GmbH.

1.2 Warranty and liability

The terms and conditions of sale and delivery which were supplied to the ve-
hicle manufacturer are applicable in all cases.
ZF Gotha GmbH will accept no claims for warranty or liability for personal or
material damage, or operational breakdowns if these can be attributed to one
or more of the following causes:
ˆ Faulty installation
ˆ Unauthorised modifications to the drive unit
ˆ Work on the drive unit which was performed improperly

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Basic information

ˆ Repair work which was performed improperly or unprofessionally leading

to consequential damage
ˆ Operating errors
ˆ Catastrophic events caused by foreign objects or force majeure
ˆ Use of non-genuine ZF replacement parts and special tools

1.3 Customer service department of manufacturer

ZF Gotha GmbH
Passauer Strasse 1
D-99867 Gotha
Germany
Telephone: +49 3621 311-0
Telefax: +49 3621 4419
E-mail: aftermarket.zfgotha@zf.com
Internet: www.zf.com
When making a request to the customer service department, the specifica-
tions on the rating plate should be kept to hand.

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Safety

2 Safety
All information in these repair instructions which relates to safety shall be ob-
served. In addition to the information on safety provided in these instructions,
all generally applicable regulations on accident prevention and environmental
protection, and local statutory regulations shall be observed.

2.1 Safety colours and signal words

The safety colours and signal words mean the following:

Injury or slight injury possible

Texts that provide information do not include safety-relevant details and are
only listed for the purpose of completeness.

Property damage is the worst possible consequence

i Notes and useful information.
Tools required for carrying out the steps of a work procedure

2.2 Representation of safety instructions

Examples of safety information are given below.
General safety information
ˆ Basic safety information
ˆ Safety information in the chapter on safety

Chapter-specific safety information

Type and source of hazard

Consequences of hazard
Measures for preventing the hazard

Safety information incorporated in the handling procedure

Type and source of hazard, consequences of the hazard,

measures for preventing the hazard

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Safety

2.3 General safety information

ˆ The drive unit may only be used for its intended purpose.
ˆ The work described in the repair instructions may only be carried out by
skilled personnel who have been trained in repair work on ZF units by ZF
Gotha GmbH. A basic knowledge of the construction and operation of
similar drive units is required. All work shall be carried out with care and
with “safety” in mind.
ˆ All safety information in these repair instructions and all accompanying
documents shall be observed and followed. All work shall be performed
with due consideration given to the instructions concerning work safety
and environmental protection.
ˆ In addition to the information on safety provided in these instructions, re-
gionally applicable and generally appropriate regulations on safety and
accident prevention shall be observed and followed. The current status of
these rules and standards shall be determined by the final producer.
ˆ When hazards are discovered which may lead to personal injury or mate-
rial damage, the drive unit shall be immediately taken out of operation.
ˆ Personnel shall read and understand the repair instructions before starting
any work on the drive unit.
ˆ The owner/operator of the final product is responsible for ensuring that
unauthorised persons do not have access to the drive unit.

2.4 Demands on personnel

The repair instructions shall be accessible to the maintenance staff at all
times. The owner/operator of the final product is advised to have it confirmed
in writing by maintenance staff that they are aware of the contents of the re-
pair instructions.
ˆ Work on the drive unit may only be carried out by personnel who have re-
ceived training, instruction and authorisation in the appropriate field (e.g.
machine fitter).
ˆ The areas of responsibility of each group of maintenance personnel shall
be clearly defined.
ˆ Before starting any operations, personnel shall be made aware of the
hazards involved in handling the drive unit.
ˆ Any person charged with undertaking repair work on the drive shall have
read and understood the entire repair instructions manual and be familiar
with all the safety information which it contains.
ˆ All safety information contained in these repair instructions and in all ac-
companying documents shall be observed and followed.

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Safety

ˆ Personnel may not be subject to any physical limitations which impair at-
tentiveness or judgement either temporarily or for longer periods. Mainte-
nance, assembly, repair or cleaning work by underage persons or persons
who are overtired or under the influence of alcohol, drugs or medication
is not permitted.
ˆ Employees shall wear the appropriate personal protection equipment, i.e.
clothing, gloves and goggles as necessary in accordance with the regula-
tions.
ˆ When hazards are discovered which may lead to personal injury or mate-
rial damage, the final product into which the drive unit has been fitted
shall be immediately deactivated.
ˆ During repair work, eating, drinking, smoking and handling naked flames
is prohibited.

2.5 Safety information regarding technical condition

ˆ No modifications, part additions or conversions may be undertaken on the
drive unit without the approval of ZF Gotha GmbH.
ˆ Each time before the drive unit is started, a check shall be made to en-
sure that it is not damaged and in a proper condition. The owner/operator
is responsible for ensuring that the drive unit is only operated if it is in
perfect condition and operationally safe. The condition of the unit shall
comply with statutory regulations at all times as far as technical aspects
are concerned.
ˆ Behaviour changes occurring in the drive unit, which affect safety, shall
be reported by personnel to the owner/operator immediately.
ˆ Operational conditions shall be compatible with the application for which
the drive unit is being used.
ˆ The drive unit may only be used within the stated technical specifications.

2.6 Safety information regarding transportation

ˆ Only adequately sized lifting equipment and lifting accessories may be
used for transportation.
ˆ When transporting the drive unit, it should be secured according to the
instructions accompanying the means of transportation employed.
ˆ Standing beneath suspended loads is prohibited.
Protective helmets shall be worn.

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Safety

2.7 Safety information Repair work

ˆ All repair work described here exclusively refers to the GP25 drive unit af-
ter it has been removed from the vehicle, and without gearbox oil. Infor-
mation on fitting and removing the drive unit in vehicles is included in the
assembly manual accompanying the drive unit.
ˆ Care and cleanliness are essential requirements for disassembling and re-
assembling the drive unit correctly and for the correct installation of re-
placement parts. Parts which are not installed correctly or damaged,
swarf or other foreign matter may damage the drive unit.
ˆ All repair work may only be carried out by trained and instructed person-
nel.

ˆ Only replacement parts and operating fluids which have been approved
by ZF Gotha GmbH may be used.
ˆ Clean and check parts before fitting. Only parts which are clean and in
perfect condition may be fitted. Worn or damaged parts shall be ex-
changed.
ˆ Only apply specified sealing agents to mating surfaces.
ˆ For all assembly work, specified adjustment values, test data and tighten-
ing torques shall be observed.
ˆ All bolts and threads in this gearbox are metric. Only metric spanners and
metric socket wrenches shall be used.
ˆ Follow the work steps in the sequence described. The pictures help to il-
lustrate the operations described.
ˆ In addition to standard type tools, special devices and special tools are
required which have been approved by ZF Gotha. Their use is essential
for carrying out all repair work in a technically correct manner.
ˆ Only genuine replacement parts may be used for all work described in
these repair instructions.

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Safety

2.8 Safety information on handling consumables and operating

materials
ˆ If lubricants and operating fluids or cleaning agents come into contact
with the skin or eyes, take the following action:
‒ After skin contact: wash the skin with soap and water.
‒ After eye contact: bathe eyes under running water for at least 10 min-
utes and, if necessary, seek medical help.
‒ After inhaling: administer fresh air or oxygen and, if necessary, seek
medical help.
‒ After swallowing: seek medical help immediately.
ˆ Observe the following for use of lubricants, operating fluids and cleaning
agents:
‒ Currently applicable regulations and EC safety data sheets from the
manufacturer concerned regarding storage, handling, use and dis-
posal.
‒ Safety data sheets for handling cleaning agents.
ˆ Lubricants and operating fluids, cleaning agents and their containers may
not be disposed of through the company or domestic waste disposal sys-
tem or be allowed to seep into the ground. Please observe the notices on
the corresponding data sheets.
ˆ Only use containers which have been approved for each lubricant/fluid.
Label each container accordingly.
ˆ Do not use any aggressive cleaning agents.
Use lint-free cleaning cloths.
Only work with dry, filtered compressed air.
After all repair work, carry out a visual inspection and functional test.

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Safety

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Technical description (in brief)

3 Technical description (in brief)

The GP25 drive unit is a drive unit of modular design for use in pairs in elec-
tric front wheel drive, counterbalanced forklifts.
The drive unit is connected to the vehicle chassis via fixings mounted on the
drive unit. See assembly instructions, document number 4699 75 042 in
German (4699 75 043 in English).

Fig. 1: Overview
1. Housing
2. Lid
3. Brake lever
4. Motor

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Technical description (in brief)

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General notes on repair work

4 General notes on repair work

Risk of accident and injury from crushing of hands or fingers.

Be careful not to place your hands or fingers between the punch and the tool
when working with the hand lever press.

Risk of accident and injury caused by hot surfaces.

When heating components, use the specified protective equipment and tools.

Risk of accident and injury caused by the drive unit or its components falling.
The total weight of the drive unit and its individual components may be up to
78 kg. During all fitting and removal work, make sure that you use sufficiently
dimensioned lifting gear and attachment equipment.
Before removal, secure the drive unit and all components against falling.

Risk of contaminating the environment with cleaning agents, auxiliary materi-

als and operating fluids.
Cleaning agents, auxiliary materials and operating fluids shall be collected in
containers provided for that purpose and disposed of in accordance with en-
vironmental protection regulations. These fluids may not seep into the ground
or sewer system.

The number quoted in brackets behind the individual part designation is the
assigned number which can also be found in the spare parts list. For example
“grooved ball roller bearing (103.210)”.
The availability of suitable presses and appropriate screw fixing tools is re-
quired.

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General notes on repair work

4.1 Standard tools

Allen key External circlip

pliers

Adjustable Internal circlip pliers

torque wrench and
Allen key inserts
size 8 and 14

Paintbrush Water pump pliers

Drift Nylon hammer,

Two arm puller Dial gauge

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General notes on repair work

Screwdriver Brass drift

Compressed-air Assembly lever

screwdriver

Double ended ring Electronic

spanner depth gauge
size 24

Eye bolt Paint roller

Compressed air gun Tap holder and tap,

size M6

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General notes on repair work

Centre punch Twist drill

∅ 3.0 mm

Twist drill Screw extractor

∅ 7.1 mm M11 -M14

Tap Thread plug gauge

M14x1.5 M14x1.5 6H
(e.g.: EMUGE
L0100100.0331)

Hammer

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General notes on repair work

4.2 Special tools

Tool 1 Tool 2
361463.0 220224

Tool 3 Tool 4
A96.25173.0 215.21

Tool 5 Tool 6
63438-02 62174

Tool 7 Tool 8
63913G27.01 63777.01

Tool 9 Tool 10
63049.01 Assembly sleeve

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General notes on repair work

Tool 11 Tool 12
63916.0 V14116

Tool 13 Tool 14
0301002 63926.0

Tool 15 Tool 16
63058.0 62757-0

Tool 17 Tool 18
62705 489564

Tool 19 Tool 20
62313-03

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General notes on repair work

4.3 Wear parts and consumables

Designation Use for

Klüberplex BEM 34-132 Planet carrier toothing

or alternatively
Optimol White Paste T
Loctite 243 Screw/nut locking agent
Loctite 574 Housing mating surfaces
Loctite 270 Wheel bolt screw locking agent
Multipurpose grease Shaft sealing ring inner lip (wheel shaft mounting)
(e.g. Shell Alvania RL3)
Nilos ring
Wheel shaft side taper roller bearing
Spacers
Planet carrier O-ring
Motor O-ring
Spray cleaner Component cleaning
Loctite 7061

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General notes on repair work

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Dismantling

5 Dismantling

Risk of accident and injury from crushing of hands or fingers.

Be careful not to place your hands or fingers between the punch and the tool
when working with the hand lever press.

Risk of accident and injury caused by hot surfaces.

When heating components, use the specified protective equipment and tools.

Material damage through damage to surfaces.

All support pieces used for disassembly shall be made of such material that
they do not damage the surfaces of parts or assemblies which are set down
on them and do not destroy protective coatings which may have been ap-
plied.

When disassembling the drive unit, the documentation of the vehicle manu-
facturer shall be observed.
The work steps for disassembly described in these repair instructions should
only be carried out as far as is required to locate the source of the fault and to
be able to remove the faulty part, which is then to be replaced.

i Information on draining and filling gearbox oil may be found in the as-
sembly manual, document number 4699 750 042 in German (4699 750
043 in English).
i For more detailed information on clamping and unclamping, and turning
in the assembly fixture, see attachment 8.1
“Clamping/unclamping/turning”, page 72.

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Dismantling

5.1 Motor disassembly

i Information on removing the motor pinion may be found in the assembly
manual, document number 4699 760 042 in German (4699 760 043 in
English.

Clamp the drive unit in the assembly fix-

ture.
Tool 20

Turn the drive unit.

Fasten the motor (170.020) to suitable

lifting gear using approved attachment
equipment.

i This secures the motor against fal-

ling.

Attachment equipment
Lifting gear

Undo the 3 Allen bolts (170.010)

and remove.

Compressed-air screwdriver
Socket wrench socket
WAF 17

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Carefully remove the motor (170.20)

from the drive unit and set it down on a
suitable support piece.
Secure the motor against falling.

i Be careful not to dam-

age the pinion.

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5.2 Removing the housing cover

i The brake lever shall be removed before removing the housing cover. For
more detailed information, see appendix 8.2 “Brake lever”, page 73.

Turn the gearbox.

1 Housing cover
1.1 Undo the 8 Allen bolts (101.30) and
remove from the housing (101.020)
cover.

Socket wrench insert, size 5

Compressed-air screwdriver

1.2 Release the housing cover (101.020)

using assembly levers and raise slightly
and evenly.

Assembly lever

1.3 Remove the housing cover (101.020)

from the housing (101.010).

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2 Inner disc carrier

2.1 Place the housing cover (101.020) in
tool 1.

i As this is done, the spur gear

(102.020) meshes with the fixed in-
put pinion in tool 1.

i The spur gear and input pinion may

not tilt out of line.

tool 1
2.2 Undo the 6 Torx bolts (103.240).

Torx bit T50

Compressed-air screw driver

2.3 Manually remove the retaining plate

(109.080) from the spur gear (102.020)
together with the 6 Torx bolts
(103.240).

2.4 Manually remove the 3 pressure springs

1.6x8.0x21.5 (109.070) from the spur
gear (102.020).

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2.5 Manually remove the inner disc carrier

(103.230) from the pressure disc
(109.050).

3 Pressure disc
3.1 Manually remove the pressure disc
(109.050) from the spur gear
(102.020).

4 Spur gear
4.1 Remove the spur gear (102.020) retain-
ing ring (103.220).

Outer circlip pliers

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Dismantling

4.2 By levering the spur gear (102.020) al-

ternately on both sides, manually re-
move it from the housing cover
(101.020).

i Be careful not to dam-

age the toothing when
levering.

Assembly lever

Risk of accident and in-

jury from crushing. When pressing out
the grooved ball roller bearing, do not
place hands between the punch and
the tool.
4.3 Remove the grooved ball roller bearing
(103.210) from the spur gear (102.020)
using tool 2 and the hand lever press.

i The punch of the hand lever press,

tool and spur gear shall be posi-
tioned vertically to each other with-
out deflection.

Support piece
Tool 2
Hand lever press

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5 Axial bearing
5.1 Lever the axial bearing (109.010) out of
the housing cover (101.020) using a
screw driver and remove.

i Check the heigh of the cylindrical pin

(109.020) for a value of 5,5mm -0,3.
(please refer to capture Installation,
paragraph 3.1). If the measured va-
lue is found different from the given
specification please remove the cy-
lindrical pin (109.020) by using pliers
and replace it by a new one installed
at the correct mounting height.

pliers

5.2 Turn the housing (101.010).

6 Cylindrical pin
6.1 Remove the 2 cylindrical pins (101.040)
from the housing cover (101.020).

i If one or both of the cylindrical pins

remain in the housing during disas-
sembly, they shall be removed using
pliers. The pins will be destroyed in
the process and shall be replaced
during reassembly.

Support piece
Pin drift
Soft head hammer
Optional: pliers

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Dismantling

5.3 Housing disassembly

i When changing the disc set in one gearbox, the disc set of the gearbox
on the other side of the vehicle shall also be changed. If this is disre-
garded, there may be a pronounced difference in braking effect between
the left-hand and right-hand gearbox. The difference in braking effect
may lead to longer braking distances or to the vehicle breaking out to the
side.

Clamp the drive unit in the assembly fix-

ture.

1 Brake disc set

1.1 Remove the brake disc set from the in-
ternal gear (103.030).

i The disc set consists of:

3 inner discs (109.04)
4 outer discs (109.03)
1 pressure disc (109.06)

1.2 Turn the housing (101.010).

2 Protective cap
2.1 Release the protective cap (103.200)
from the wheel shaft (103.010) and re-
move manually.

Screwdriver

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3 Cylindrical pin
3.1 Remove the cylindrical pin (103.190)
which secures the grooved nut from the
wheel shaft (103.010).
To do this, screw the thread of tool 3
fully into the cylindrical pin and draw
out the cylindrical pin.

Tool 3

3 Grooved nut
3.2 Undo the grooved nut (103.090) from
the wheel shaft (103.010) and remove
manually.

Tool 4
Adjustable torque wrench or alterna-
tively compressed-air screwdriver,
approx. 500 Nm

Turn the housing (101.010).

3.3 Unclamp the housing (101.01) from the

assembly fixture.

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3.4 Place the housing (101.01) on the press

table with the mating surface facing
downwards.

Hydraulic press

4 Planet carrier
Risk of accident and in-
jury from crushing. When pressing out
the planet carrier, do not place hands
between the punch and the tool.
Press the planet carrier (103.020) out of
4.1 the housing (101.010).

i The punch of the hand lever press

and the tool shall be at right angles
to each other.

Punch
Hydraulic press
Clamp the housing (101.01) in the as-
sembly fixture.

4.2 Remove the planet carrier (103.020)

from the housing (103.020).

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4.3 Remove the spacers (103.070) from the

housing (101.010).

5 Planetary gears
5.1 Clamp the planet carrier (103.020) in a
vice.

i Fit the jaws of the vice with protec-

tive jaws (e.g. copper, aluminium or
brass) to prevent the surfaces from
being damaged.

Remove the 3 planetary gears

5.2 (103.060) from the planet gear
(103.020).

Vice with protective jaws

Assembly lever
Two arm puller

6 Gear shaft
6.1 Drive the wheel shaft (103.010) out of
the housing (101.010).

i Secure the drive against falling from

below with your hand.

Soft head hammer

Tool 5

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6.2 Release the O-ring (103.180) using a

screwdriver and manually remove from
the wheel shaft (103.010).

Screwdriver

7 Wheel shaft taper roller bearing

Risk of accident and in-
jury caused by hot surface.
If necessary, heat the taper roller bear-
ing to facilitate removal. Wear pre-
scribed protective equipment and use
appropriate tools.
7.1 Remove the wheel shaft side taper
roller bearing (103.150) from the wheel
shaft (103.010).

i If necessary, heat the

taper roller bearing.

Two arm puller

7.2 Remove the planet carrier side taper rol-
ler bearing (103.160).

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8 Internal gear
8.1 Remove the 12 Torx bolts (103.110)
from the internal gear (103.030).

Torx bit T50

Compressed-air screwdriver

8.2 Remove the internal gear (103.030)

from the housing (101.010).

i If the internal gear is damaged, it

shall be replaced as a complete unit.

9 Wheel shaft sealing ring

9.1 Drive the wheel shaft (103.130) sealing
ring downwards and out of the housing
(101.010).

i The shaft sealing ring is destroyed in

the process. During reassembly, a
new shaft sealing ring shall be used.

Tool 6
Soft head hammer
10 Wheel shaft side bearing cup
10.1 Drive the wheel shaft side bearing cup
of the taper roller bearing (103.150)
downwards and out of the housing
(101.010) by impacting it alternately on
opposite sides.

Soft impact drift (e.g. aluminium,

copper or brass)

10.2 Turn the housing (101.010).

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11 Planet carrier side wheel shaft

11.1 Drive the planet carrier side bearing cup
of the taper roller bearing (103.150)
downwards and out of the housing
(101.010) by impacting it alternately on
opposite sides.

Soft impact drift (e.g. aluminium,

copper or brass)

11.2 Turn the housing (101.010).

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6 Installation

Risk of accident and injury from crushing of hands or fingers.

Be careful not to place your hands or fingers between the punch and the tool
when working with the hand lever press.

Material damage through damage to surfaces.

All support pieces used for disassembly shall be made in such a way that they
do not damage the surfaces of parts or assemblies which are set down on
them and do not destroy protective coatings which may have been applied.

Gearbox damage or failure due to faulty parts.

All parts to be installed, particularly the bearings, shall be cleaned before as-
sembly and checked to ensure that they are in perfect condition and operate
correctly. Worn or damaged parts shall always be replaced.

Gearbox and environmental damage caused by escaping gearbox oil.

If it is necessary to remove the cover again after it has already been sealed on
the housing, all traces of sealant shall be fully removed from the surfaces of
the cover and housing. It can only then be guaranteed that no leaks will occur
when the cover and housing are again sealed.

i All support pieces used for reassembly shall be made of such material
that they do not damage the surfaces of parts or assemblies which are set
down on them.
i Before reassembly, all mating surfaces shall be clean, grease-free and
undamaged.
i For more detailed information on clamping and unclamping, and turning
in the assembly fixture, see attachment 8.1
„Clamping/unclamping/turning“, page 72.

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6.1 Housing reassembly

Clamping and turning the housing

(101.010) in the assembly fixture

1 Wheel shaft side bearing seat

1.1 Clean the wheel shaft side bearing seat
of the taper roller bearing (103.150) in
the housing (101.010).

Lint-free cloth
Spray cleaner

2 Shaft sealing ring – (Parts Kit avail-

2.1 able)
Place the shaft sealing ring (103.130)
into the wheel shaft side bearing seat of
the taper roller bearing (103.150).

i The closed side of the shaft sealing

ring shall be facing the flange con-
nection for the wheel.

2.2 Drive the shaft sealing ring (103.130)

into the wheel shaft side bearing seat of
the taper roller bearing (103.150).

i The shaft sealing ring shall be driven

in far enough until its top edge lies
below the chamfer of the bearing
seat.

Tool 7
Soft head hammer

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3 Bearing cups
3.1 Drive the wheel shaft side bearing cup
of the taper roller bearing (103.150)
into the bearing seat.

i The inside of the bearing cup shall

narrow to a taper towards the bear-
ing seat and the wide edge of the
bearing cup shall be positioned at
the bottom.

Tool 8
Soft head hammer

3.2 Coat the inner lip of the shaft sealing

ring (103.130) with multipurpose
grease.

Multipurpose grease
Paintbrush

Turn the housing (101.010).

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3.3 Drive the planet carrier side bearing cup

of the taper roller bearing (103.160) in-
to the bearing seat.

i The inside of the bearing cup shall

narrow to a taper towards the bear-
ing seat and the wide edge of the
bearing cup shall be positioned at
the bottom. Drive in the bearing cup
until a dull metallic sound signals
that the bearing cup is resting
against the bearing seat.

Tool 9
Soft head hammer

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4 Internal gear – (Parts Kit available)

4.1 Manually slot the toothed disc (103.04)
into the internal gear (103.03).
Lay the ring (103.05) into the groove of
the internal gear (103.03).
Place the internal gear (103.03) into the
housing (101.01) by hand.

4.2 i The opening of the ring (103.05)

shall be visible (see arrow).
Bolt on the internal gear (103.03) with
12 Torx bolts (103.11).
1. Pretighten the bolts with a com-
pressed-air screwdriver in a cross-
wise pattern.
2. Firmly tighten the bolts using a
torque wrench.

i When tightening the bolts, note the

tightening torque of 79 Nm.

Torx bit T50

Compressed-air screwdriver
Adjustable torque wrench

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4.3 Check whether it is still possible to

move the internal gear in a rocking mo-
tion after tightening the bolts.
3 If it is possible, continue with work
step 5.
2 If it is not:
z Remove the internal gear again

and replace it.

or
z Remove from the housing all the

parts which have so far been in-

stalled and replace the housing.

i The rocking motion of the internal

gear is important for being able to
compensate for the oscillations gen-
erated by the planetary gears.

5 Gear shaft
5.1 Coat the Nilos ring (103.120) with mul-
tipurpose grease.
Paintbrush
Multipurpose grease

5.2 Slide the Nilos ring (103.120) onto the

wheel shaft (103.010).

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5.3 Grease the O-ring (103.180).

Multipurpose grease
Paintbrush

5.4 Insert the O-ring (103.180) into the

wheel shaft (103.010).

i The O-ring shall lie securely in the

groove provided in the wheel shaft.

5.5 Push the taper roller bearing onto the

wheel shaft.

5.6 Grease the taper roller bearing

(103.150).

Multipurpose grease
Paintbrush

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5.7 Place the wheel shaft (103.010) on the

press table so that the wheel studs
(103.080) point downwards.

i The wheel shaft shall stand on a suit-

able sleeve and the wheel studs shall
be clear of the table.

Tool 10
Hydraulic press

Unclamp the housing (101.010) from

the assembly fixture.

5.8 Fit the housing (101.010) perpendicu-

larly onto the wheel shaft (103.010).

i The mating surface of the housing

shall face upwards.

5.9 Place the taper roller bearing (103.150)

onto the seat of the wheel shaft
(103.010).

Risk of accident and in-

jury from crushing. When pressing the
taper roller bearing onto the wheel
shaft, do not place hands between the
punch and the tool.
5.10 Press the planet carrier side taper roller
bearing (103.150) onto the wheel shaft
(103.010).

i The punch of the hand lever press,

tool and taper roller bearing shall be
positioned vertically to each other

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without deflection.

Tool 11
Hydraulic press
5.11 Clamp the housing (101.010) in the as-
sembly fixture.

Assembly fixture
5.12 Check the wheel shaft (103.01) for
smooth running.

i It shall be possible to move the

wheel shaft easily by hand.

i In order that the taper rollers can

align themselves correctly in the
bearing races, a soft head hammer
should be used to tap at various
points around the wheel shaft.
3 If the taper rollers are correctly
aligned, continue with work step 6
2 If they are not:
z Remove the wheel shaft again.

Check both bearings (wheel shaft side

and planet carrier side) for any damage
which may have occurred during the
press fitting procedure. Î If damage is
found, remove the bearings and replace
with new ones.

6 Measuring and adjusting

6.1 Measuring the distance between the
bearing surface of the taper roller bear-
ing (103.16) and the surface of the
wheel shaft (103.01).

1. Rest tool 12 on the mating surface

of the housing (101.01).
2. Set the depth gauge onto tool 18.

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i It shall be ensured that the greatest

possible contact area of the depth
gauge is resting on tool 12.
3. Adjust the depth gauge to the sur-
face of the wheel shaft.
4. In the position, zero the depth gauge.
5. Adjust the depth gauge to the sur-
face of the taper roller bearing
(103.16).
6. Read off the difference between the
two settings.
7. Repeat the measurement on the op-
posite side.

i The difference in measurement may

not exceed 0.5 mm.
8. Select spacers.

i The thickness of the spacer set shall

be the same as the difference be-
tween the measurements. A preload-
ing on the wheel shaft is then
achieved. The preloading on the
wheel shaft shall be between 3 and 7
Nm.

Depth gauge
Tool 12
7 Planet carrier
7.1 Place the housing (101.010) on the
press table so that the wheel shaft
(103.010) is facing downwards.

i The wheel shaft shall stand on a suit-

able sleeve and the wheel studs shall
be clear of the table.

Assembly sleeve
Hydraulic press

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7.2 Coat the toothing of the planet carrier

(103.020) with Klüberplex BEM 34-132
(Klüber Lubrication) or Optimol White
Paste T.

Klüberplex BEM 34-132 or Optimol

White Paste T
Paint brush

7.3 Blow out the seating of the planet car-

rier in the housing with compressed air
and fit the planet carrier.

Compressed air connection

Air gun

7.4
Risk of accident and in-
jury from crushing. When pressing in
the planet carrier, do not place hands
between the punch and the tool.
Press the planet carrier (103.020) into
the wheel shaft (103.010).

i Make sure that the outer toothing of

the planet carrier and the inner
toothing of the wheel shaft mesh to-
gether correctly.

i The punch of the hand lever press,

tool and wheel shaft shall be posi-
tioned vertically to each other with-
out deflection.

Tool 13
Hydraulic press
Clamp the housing (101.010) in the as-

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sembly fixture.

7.5 Manually check the wheel shaft

(103.010) for ease of movement in the
housing (101.010).

i It shall be possible to turn the wheel

shaft easily by hand.

Turn the housing (101.010).

8 Grooved nut
8.1 1. Fit the grooved nut (103.090) to the
wheel shaft (103.010).
2. Fit tool 4 to the grooved nut.
3. Slightly tighten the grooved nut with
a compressed-air screwdriver.

Tool 4
Compressed-air screwdriver
Adjustable torque wrench

Turn the housing. (101.010).

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8.2 Fit tool 14 to the wheel shaft (103.010)

and lock in place with the screws
Tighten the grooved nut to a tightening
torque of 535 Nm.

Tool 4
Tool 14
Adjustable torque wrench

Turn the housing (101.010).

8.3 Remove tool 14 from the wheel shaft

(103.010) and check the wheel shaft for
freedom of movement.

i The wheel shaft shall be easy to turn

in the housing (101.010).

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9 Wheel shaft drag torque

9.1 Check the drag torque on the wheel
shaft (103.010).
1. Attach tool 15 to the wheel shaft.
2. Attach the torque wrench.
3. Turn the wheel shaft with the torque
wrench.
4. Read off the drag torque from the
torque wrench.

i The drag torque shall be between 3

and 7 Nm.

3 If it is, continue with work step 9.2

2 If it is not:
z Correct the spacers as follows:
z Drag torque too high: The spacers
chosen are too thick Î Remove
parts back to work step 5 and re-
determine the correct spacer
thicknesses.
z Drag torque too low: The spacers
chosen are too thin Î Remove
parts back to work step 5 and re-
determine the correct spacer
thicknesses.
Tool 15
Adjustable torque wrench

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9.2 Lock the grooved nut (103.090) at two

points opposite each other.

Tool 16
Soft head hammer

10 Cylindrical pin
10.1 Insert the cylindrical pin (103.190) into
the wheel shaft (103.010) and drive it
in.

i The taper on the cylindrical pin shall

point downwards.

Pin drift
Soft head hammer

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11 Protective cap
11.1 Fit the protective cap (103.200) to the
wheel shaft (103.010) and tap it lightly
until it snaps into place.

Turn the housing. (101.010).

12 Planetary gears – (Parts Kit available)

12.1 Fit the planetary gears (103.060) to the
planet carrier (103.020) with the letter-
ing facing upwards.

i The teeth of the planetary gears and

the internal gear shall mesh together
correctly.

Tool 17
Soft head hammer
12.2 Lock the planetary gears (103.060).

Tool 16

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6.2 Refitting the housing cover

1 Grooved ball roller bearing
Risk of accident and in-
jury from crushing. When pressing in
the brake piston, do not place hands
between the punch and the tool.
1.1 Press the grooved ball roller bearing
(103.210) into the spur gear (102.020)
using the hand lever press.

i The punch of the hand lever press,

tool and brake piston shall be posi-
tioned vertically to each other with-
out deflection.

1.2
Manually check the grooved ball roller
bearing (103.210) for ease of move-
ment in the spur gear (102.02).

i It shall be possible to turn the

grooved ball roller bearing easily
by hand.

3 It if is easy to turn, continue with

work step 1.3.
2 If it is not:
z Check the bearing for any damage

which may have occurred during

the press fitting procedure.
Î If damage is found, remove the
bearing and replace with a new
one.
Support piece
Tool 2
Hand lever press

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2 Spur gear – (Parts Kit available)

2.1 Place the housing cover (101.020) on a
suitable support piece on the hand lever
press, with the mating surface facing
upwards.

i The housing cover shall be empty.

Risk of accident and in-

jury from crushing. When pressing in
the brake piston, do not place hands
between the punch and the tool.
2.2
Press the spur gear (102.020) onto the
housing cover (101.020).

i The side of the spur being worked on

shall face upwards.

i The punch of the hand lever press

and input pinion shall be positioned
vertically to each other without de-
flection.

Tool 2
Hand lever press

2.3 Manually check the spur gear (102.020)

for smooth running

i The input pinion shall be easy to turn.

3 If it is, continue with work step 2.4.
2 If it is not:
z Check the bearing for any damage
which may have occurred during
the press fitting procedure.
Î If damage is found, remove the bear-
ing and replace with a new one.

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2.4 Remove the housing cover (101.020)

from the hand lever press and place it in
the assembly fixture with the mating
surface facing upwards.

Support piece
Assembly fixture

2.5 Fix the housing cover (101.020) in

place with the locking lever of the as-
sembly fixture.

i The toothing on the spur gear

(102.020) and on the fixed gear on
tool 1 shall mesh together correctly.

Assembly fixture

3 Axial bearing
3.1 Drive the cylindrical pin (109.020) into
the housing cover (101.020) to a
size of 5.5mm -0.3.

3.2
Insert the axial bearing (109.010) in
the housing cover (101.020) by
hand.
The lubrication groove of the axial
bearing shall face upwards.

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i Please assure proper position of the

axial bearing related to the cylindrical
pin (109.020)!

109.020

3.3 Insert the spur gear (102.020) retaining

ring (103.220).

Outer circlip pliers

4 Inner disc carrier

4.1 Place the pressure plate (109.050) on
the spur gear (102.020) by hand.

i The bulge in the pressure plate shall

be at the top.

i The holes in the pressure plate and

the spur gear shall be positioned on
top of each other.

4.2 Fit the inner disc carrier (103.230) onto

the spur gear (102.020) by hand.

i The inner disc carrier fits onto the

spur gear in one position only.
Find out by trial and error the posi-
tion in which the inner disc carrier
needs to be set in relation to the spur
gear.

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4.3 Insert the 3 pressure springs

1.6 x 8.0 x 21.5 (109.070) into the inner
disc carrier (103.230) by hand.

4.4 Place the fixing plate (103.220) over the

pressure spring (109.070) by hand.

i The springs shall be firmly seated in

the recesses in the retaining ring.

4.5 Insert the 6 Torx bolts (103.240) into

the fixing plate and screw them down
into the spur gear (102.020).

i The bolts shall be tightened in a

crosswise pattern

Torx bit T50

Compressed-air screwdriver

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4.6 Tighten the 6 Torx bolts (103.240) to a

tightening torque of 70 Nm using an
adjustable torque wrench.

Adjustable torque wrench

Torx bit T50

5 Disc set – (Parts Kit available)

5.1 Place the disc set – consisting of 3
driven discs (109.040), 4 drive discs
(109.030) and 1 pressure disc
(109.060) – into the internal gear
(103.030).

1. Insert the pressure disc (109.060).

2. Insert a drive disc (109.030).
3. Insert a driven disc (109.040).
4. Insert drive and driven discs alter-
nately.

i Insert the driven discs so that the

side on which the teeth are rounded
off faces upwards. The driven discs
are completely even in circumference
direction. They are non-sinusoidal.
You do not need to bring them in a
specific order prior installation.

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5.2 Determining the thickness of the pres-

sure disc
W=X+Y
Z=V-W
Z [mm] Pressure disc thickness
5.58 to 6.10 4.8 mm thick
6.11 to 6.70 5.3 mm thick
6.71 to 7.22 5.8 mm thick

i “X” is the distance be-

tween the plane face of
the cover and plane face
of the pressure disc.

i “Y” is the thickness of

the disc set when it is
compressed.

i “W” is a reference di-

mension calculated by
adding X and Y.

i “V” is the distance be-

tween the plane face of
the housing and the con-
tact surface of the pres-
sure disc in the internal
gear.

i “Z” is a reference dimen-

sion calculated by sub-
tracting V and W.

i Do not use a different

way of measurement as
the described one!

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5.3 Arrange the driven discs (109.040).

i The teeth on all driven discs shall be

positioned precisely in line with each
other.

Screwdriver

5.4 Apply Loctite 243 as a locking agent in

the threaded holes for the bolts
(101.030).

Loctite 243

5.5 Coat the mating surface of the housing

(101.010) and the housing cover
(101.020) with Loctite 574.

Loctite 574
Paint roller

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5.6 Fit the housing cover (101.020) to the

housing (101.010) by hand.

i Care shall be taken to ensure that the

guide of the inner disc carrier
(103.230) comes to rest in the nee-
dle sleeve (103.140).

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6 Cylindrical pin
6.1 Drive the cylindrical pin (101.040) into
the housing (101.01).

i The cylindrical pins shall be driven in

so that they are flush with the sur-
face

Soft head hammer

Optional: pin drift

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6.2 Screw the 8 Allen bolts (101.030) into

the housing cover (101.020) by hand
and slightly tighten with a compressed-
air screwdriver.

Allen key size 5

Compressed-air screwdriver

6.3 Tighten the 8 Allen bolts (101.030) to a

tightening torque of 9.5 Nm.

Allen key size 5

Compressed-air screwdriver

6.4 Manually check the wheel shaft

(103.010) for smooth running.

i It shall be possible to move the

wheel shaft easily by hand.

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6.3 Refitting the motor

i Information on fitting the motor pinion may be found in the assembly
manual, document number 4699 760 042 in German (4699 760 043 in
English.
i The brake lever shall be fitted before fitting the housing cover. For more
detailed information, see appendix 8.2 “Brake lever”, page 72.

Turn the gearbox.

Assembly fixture
1 Motor
1.1 Fasten the motor (170.020) to suitable
lifting gear using approved attachment
equipment.

Attachment equipment
Lifting gear

1.2 Position the motor (170.020) in front of

the drive unit and manually mesh the
motor pinion with the spur gear pinion.

i When meshing the motor pinion with

the spur gear, make sure that both
sets of teeth are not tilted or dam-
aged.
The motor connections shall be at
the top in the installation position.

1.3 Fasten the motor (170.020) to the drive

unit with the 3 Allen bolts (170.010).

i Screw in the shorter Allen bolt at

the top of the drive unit and each of
the two other bolts into the right-
hand and left-hand side of the drive
unit.

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1.4 Firmly tighten the 3 Allen bolts

(170.010) to a tightening torque of 23
Nm.

Socket wrench socket SW 17

Compressed-air screwdriver
Adjustable torque wrench

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Waste disposal

7 Waste disposal

7.1 Cleaning agents, additives and operating fluids

Cleaning agents, additives and operating fluids, in particular oil and oil-
contaminated waste (lubricants) in this instance, pose a great threat to the
environment.
Collect and store these items of waste in a suitable container.
Disposal of this hazardous waste should be carried out by a specialist com-
pany in accordance with the international, national and local rules and regula-
tions valid at the time of disposal.

7.2 Scrapping
When scrapping components, adhere to the international, national and local
rules and regulations valid at the time of scrapping.

i Make sure material recyclability and the removability and separability of

materials and assemblies receives the same attention as that given to en-
vironmental and health and safety considerations during recycling and
disposal. Disposal shall be performed in accordance with applicable in-
ternational, national and regionally specific regulations.

Material groups, such as plastics and metals of different types, shall be sorted
before submitting to the recycling and disposal process.

7.3 Disposal of electrical and electronic components

Disposal and recycling of electrical and electronic components shall be car-
ried out in accordance with the relevant laws and national directives.
Comply with special instructions contained in the supplier documentation.

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Attachment

8 Attachment

8.1 Clamping/unclamping/turning

Risk of accident and injury caused by falling parts.

Make sure that the drive unit and housing are placed in the assembly fixture
correctly and clamped with clamping claws and clamping bolts.

Clamping
1. Place the drive unit or gearbox in the
assembly fixture.
2. Tighten the clamping jaws with a
ring spanner.
Unclamping
1. Release the clamping claws with a
ring spanner.

2. Remove the drive unit or gearbox

from the
assembly fixture.
Turning
1. Press the lever backwards and hold it
in that position.

2. Turn the drive unit or gearbox to-

gether with the assembly fixture as
one piece.

Tool 20
Ring spanner WAF 24

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8.2 Brake lever

8.2.1 Dismantling

1 Retaining ring
1.1 Release the retaining ring (103.220) of
the brake lever (109.110).

i The retaining ring is located on the

motor side.

Screwdriver

2 Guide pin
2.1 Release and remove the guide pin.

Remove the brake lever (109.110) from

the housing cover (101.020).

i Insert the guide pin back

in the brake lever imme-
diately and secure.

Screwdriver
3 Pressure pin
3.1 Remove the pressure pin (109.100).

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8.2.2 Installation

1 Brake lever
1.1 Insert the brake lever (109.110) in the
housing cover (101.020).

1. Select the pressure (109.100) ac-

cording to
length.

i The play on the brake lever may be

0,4mm +0,6. Select a pressure pin
which is able to guarantee the speci-
fied amount of brake lever play.

2. Coat the sealing ring (109.09) with

grease.
3. Manually insert the pressure pin
(109.110) in the sealing ring
(109.09) in the housing cover.
4. Remove the circlip from the retain-
ing pin of the brake lever (109.110)
and remove the retaining pin from
the brake lever.
5. Fit the brake lever (109.110) in the
guide in the housing cover
(101.020).
6. Fasten the brake lever to the hous-
ing cover with the retaining pin.
7. Fit the retaining pin circlip.

Multipurpose grease
Paintbrush
External circlip pliers

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2 Brake lever play

2.1 Measure the brake lever play.

1. Set the dial gauge sensor on the

brake lever (109.101).

2. Adjust the dial gauge to 0.

3. Press the brake lever down by hand.
4. Read off the brake level play from
the dial gauge.

i The play on the brake lever may be

0,4mm +0,6.

Dial gauge

3 Brake test
3.1 Test the brake manually.

Turn the wheel shaft (103.010) by

hand. At the same time, push the brake
lever (109.110) up, using a screwdriver.

i It shall be possible to detect a brak-

ing effect when the wheel shaft is
turned.

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8.3 Breather
1 Removal
1.1 Remove the cap of the breather
(101.070).

Screwdriver

1.2 Screw a suitable tool (e.g. thread tap)

into the breather (101.070) and pull it
out to the front.

Tap holder
Thread tap M6

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2 Refitting
2.1 Push the breather (101.070) into the
drill hole by hand.

i Only use a new

breather.

2.2 Put tool 18 in position and drive the

breather (101.070) fully in using a soft
head hammer.

Tool 18
Soft head hammer

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8.4 Wheel studs

1 Removal
1.1 Screw faulty wheel studs (103.08) out
of the wheel shaft (103.01).

Water pump pliers

2 For sheared wheel studs:

2.1 Mark the stud with a centre punch and
fitter's hammer.

Centre punch
Fitter's hammer

2.2 Drill the stud using a twist drill.

Twist drill 3 mm

2.3 Drill out the hole with a larger twist drill.

Twist drill 7 mm

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2.4 Apply a tap holder fitted with an extrac-

tor and unscrew the stud.

Tap holder
Extractor

3 Refitting
3.1 Recut the thread.

Thread tap M14x1.5 6H (e.g. EMUGE

0100.100)

3.2 Check the thread with the "go" side of a

thread plug gauge.

Thread plug gauge M14x1.5 6H (e.g.

EMUGE 0100.100)

3.3 Check the thread with the "no go" side

of a thread plug gauge.

i If the "no go" side fits, the wheel

shaft shall be replaced.

Thread plug gauge M14x1.5 6H (e.g.

EMUGE 0100.100)

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3.4 Coat the part of the thread of a new

wheel stud (103.08) which is to be
screwed into the wheel shaft evenly
and around the whole circumference
with Loctite 270.
Then use the assembly fixture to fit the
wheel stud into the thread.

Loctite 270
Tool 19
Screw the new wheel stud (103.08) in-
to the wheel shaft (103.01).
Tool 19
Compressed-air screwdriver

3.5 Tighten the wheel stud with a torque

wrench.

i When fully tightening the wheel stud,

observe that the tightening torque is
60 Nm.

Adjustable torque wrench

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