Ch3 - DA30 - Drive Line and Brakes

drive line Ch 3 page 1
Chapter 3
Drive line
SHOP MANUAL DA30 - 11.2011

Ch 3 page 2 drive line

Drive line
Index
Introduction.............................................................................................. 6
General...................................................................................................... 7
Structure of the Repair Manual..............................................................................................................................................8
Important information on industrial safety.......................................................................................................................8
Denomination of standard dimensions..............................................................................................................................9
Conversion table .........................................................................................................................................................................9
Tightening torques for nuts and bolts.................................................. 10
Table.............................................................................................................................................................................................. 10
Drive line components........................................................................... 11
Front reduction gear.............................................................................. 12
DA30 parts list........................................................................................................................................................................... 13
Front reduction gear cross section.................................................................................................................................... 14
NAF special Tools for DA30................................................................................................................................................... 15
Assembly..................................................................................................................................................................................... 16
Drive shafts............................................................................................. 29
Front frame................................................................................................................................................................................. 29
Rear frame................................................................................................................................................................................... 30
The intermediate shaft........................................................................................................................................................... 31
Front differential and transmission...................................................... 32
Brakes..................................................................................................... 33
Service brakes (DA30)............................................................................................................................................................. 33
Service brake description...................................................................................................................................................... 35
Testing of parking brake........................................................................................................................................................ 36
Remove the Linings................................................................................................................................................................. 37
Disassembly the park brake unit........................................................................................................................................ 39
Assembly the park brake unit.............................................................................................................................................. 40
Adjust the Initial Caliper Clearance.................................................................................................................................... 41
Park brake Maintenance........................................................................................................................................................ 42
Disc ................................................................................................................................................................................................44
Troubleshooting Park brake................................................................................................................................................. 46
Rear differential...................................................................................... 47
Rear Diff, DA30........................................................................................................................................................................... 47
Exchange of the complete rear differential......................................... 48
Safety precautions................................................................................................................................................................... 48
Repairs on the rear differential............................................................. 50
Exchange of crown gear / Pinion........................................................................................................................................ 50
Determining thickness of the adjusting washer (44).................................................................................................. 54
Determining thickness of the adjusting washer (45).................................................................................................. 55
Pinion bearing adjustment................................................................................................................................................... 56
Backlash and crown gear bearing adjustment.............................................................................................................. 56
Checking contact pattern..................................................................................................................................................... 59
Exchange shaft seals............................................................................................................................................................... 60
Exchange of differential cage (compensating gearbox)............................................................................................ 61
Differential lock......................................................................................................................................................................... 62
Planetary drive DA30............................................................................. 63
Complete exchange of planetary cage............................................................................................................................ 64
Exchange of sun gear shaft................................................................................................................................................... 65

Exchange of Planetary Studs and Gears.......................................................................................................................... 65

Exchange of ring gear carrier............................................................................................................................................... 66
Wheel bearings....................................................................................... 67
Gear bearing exchange.......................................................................................................................................................... 67
Gear bearing adjustment...................................................................................................................................................... 70
Brake - DA30........................................................................................... 72
Check disc’s wear...................................................................................................................................................................... 72
Exchange of the piston for the operating brake........................................................................................................... 73
Exchange of brake disks and pressure springs for the operating brake............................................................... 74
Tandem bearings...................................................................................................................................................................... 77
Exchange of slewing ring...................................................................................................................................................... 77
Exchange of seal....................................................................................................................................................................... 80
Exchange of axle beam.......................................................................................................................................................... 80
Gear drive in tandem housing.............................................................. 81
Exchange of bearing (84)....................................................................................................................................................... 81
Exchange of gear (43) and bearing (89) / (90)................................................................................................................ 82
Exchange of gears (86)........................................................................................................................................................... 83
NAF special Tools for DA30................................................................................................................................................... 84


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
Differential
Transmission
(Chapter 2)
Right Front
Axle Drive
Assembly
Parking Left
Brake Tandem
Intermediate Housing
Drive Shaft
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 anti friction 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 residue 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 anti friction bearings, thrust
washers 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.
Important information on industrial safety
Generally, the persons repairing DOOSAN 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 DOOSAN 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.
REFERENCE: 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)

Tightening torques for nuts and bolts.

Table
Name Part no. Tightening torque

(Nm)
Breather M10x1 524194 10Nm
Plug G½” 524182 55Nm
Hex bolt M10x50 10.9 524443 67Nm + Loctite 262
Allen bolt M10x25 10.9 TI58 524181 67Nm
Flat head bolt M12x25 8.8 524424 70Nm
Hex boltM16x55 10.9 524436 290Nm
Hex bolt M10x50 10.9 TI58 524162 290Nm
Grooved nut M85x2 524195 2000 ± 120Nm + Loctite 262
Hex nut M40x1.5 524320 800 ± 50Nm + Loctite 262
Breather M14x1,5 524225 18Nm

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
torque distribution 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 to the rear axle differential. The rear differential is equipped with
limited slip. The 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 Doosan Moxy dump truck has 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

Front reduction gear and parts list: DA 30

DA30 parts list
1 524181 6 Allen screw 31 524217 27 Pressure spring

2 524404 1 Cover 32 524407 1 Thrust washer
3 524169 1 O-Ring 33 524218 1 Snap ring
5 524424 4 Hexagon bolt 34 524169 1 O-Ring
6 524425 1 Gear housing 35 524408 5 Stud
7 524182 2 Screw plug 36 524219 6 Steel disc
8 524188 2 Seal ring 36a 524351 2 Steel disc
9 524426 1 Sun gear shaft 37 524220 7 Inner disc
10 524149 8 Tab washer 37a 524352 2 Inner disc
11 524427 4 Planet gear 38 524434 1 O-Ring
12 524151 4 Needle bearing 39 524192 1 Seal ring
13 524152 4 Planetary pin 40 524173 1 O-Ring
14 524170 1 O-Ring 41 524435 1 Wheel hub
15 524428 1 Planet carrier 42 524269 12 Washer
16 524153 4 Shear pin 43 524436 12 Hexagon bolt
17 524269 4 Washer 44 524188 2 Seal ring
18 524162 4 Hexagon bolt 45 524182 2 Screw plug
19 524195 1 Nut 46 524222 1 Intermediate ring
20 524221 1 Adjusting kit 47 524211 1 Tapered roller bearing
20 524155 as req Adjusting washer 48 524223 1 Spindle ring
20 524197 as req Adjusting washer 49 524189 1 Cassette seal ring
20 524198 as req Adjusting washer 50 524437 1 Spindle
20 524199 as req Adjusting washer 51 524225 1 Breather valve
20 524200 as req Adjusting washer 52 524194 1 Breather
20 524201 as req Adjusting washer 53 524438 1 Four-point bearing
20 524202 as req Adjusting washer 54 524439 1 Cover
20 524203 as req Adjusting washer 55 524440 1 Oil seal
20 524204 as req Adjusting washer 56 524441 1 Oil seal
20 524205 as req Adjusting washer 57 524442 1 Cardan flange (MOX 04)
21 524429 1 Ring gear 57 525044 1 Cardan flange (MOX 07)
22 524430 1 Ring gear carrier 58 524320 1 Main nut
23 524208 1 Snap ring 59 524267 2 Dowel pin
24 524209 1 Tapered roller bearing 60 524443 6 Hexagon bolt
25 524431 12 Wheel bolt 61 524270 1 O-Ring
26 524432 1 Wheel hub 62 524444 12 Collar nut
27 524213 1 Cylinder 63 524267 4 Dowel pin
28 524214 1 Turcon-Glyd ring 64 524445 1 Threaded stud
29 524433 1 Piston 65 524446 1 Seal ring
30 524216 1 Turcon-Glyd ring 66 524118 2 Dowel pin
NOTE

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.

NAF special Tools for DA30
Description: WZ number Moxy part

number
Insert punch for oil seal 1160.121 (Ø80xØ100x10 BA) WZ 749 525671
Insert punch for oil seal 1160.217 (Ø80xØ100x10 BASL)
Insert punch for oil seal 1160.412 (Ø178xØ208x16/18 Cartridge WZ 731 525672
seal ring)
Insert punch for oil seal 1160.410 (Ø140xØ170x8 BA) WZ 732 525673
Insert punch for tapered roller bearing 1110.075 (Outer Ring) WZ 733 525674
Insert punch for tapered roller bearing 1110.243 (Outer Ring) WZ 734 525675
Insert punch for tapered roller bearing 1110.243 (Inner Ring) WZ 735 525676
Insert punch for tapered roller bearing 1110.075 (Inner Ring) 525677
WZ 736
Groove socket wrench for groove nut 7329.036 with mounted WZ 878 525678
shaft
Extractor plate to pull off the wheel hub with mounted shaft WZ 668 525679
Extractor plate to pull off the inner part from the planetary cage WZ 190 525680
Device to lift the complete planetary drive hub BM 215 525681

Assembly
Spindle preparation.
Secure the spindle on a convenient table using the

M16 threads. (if possible use a turn table).
Figure 45
Spindle assembly.
Assemble spindle ring and heated bearing.

WZ 736 for bearing
Spindle preparation. Figure 46
Insert O-ring.
Figure 47
Mount intermediate
ring with glue sub-
stance “Loctite 601”
and punch it twice on
opposite sides to fix its
position.
Figure 48

Wheel hub preparation.
Insert bearing race and cartridge seal ring.

1. WZ 733 for bearing race
2. WZ 731 for cartridge seal ring
Figure 49
Insert inner seal ring.

WZ 732 for seal ring
Figure 50
Fill the space with special grease “SKF

Grease LGEP 2/18”
Figure 51
Wheel hub assembly.
Set the inner wheel hub half on evenly until

the bearing race seats firmly.
During this, observe that the oil seal slides

onto the intermediate ring without damaging
or overturning the seal lips.
Figure 52

Brake preparation.
Place the O-ring into position then insert the dowel

pins.
Figure 53
Multiple disc assembly.
Assemble alternately coated disk with steel disk.

During this observe that all holes line up to build oil
channels and one of the oil channels is in top posi-
tion.
The top steel disk must lie with its measuring knob
over the wheel hub opening. The measuring knobs
of the lower steel disks must have other position.
Figure 54
Spindle coating.
Spray the spindle with Wolfrakote spray.
Figure 55
Brake cylinder assembly.
During the assembly of the brake cylinder make sure

that the 5 mm Ø bleeding bore is on the top. The 20
mm Ø oil holes of the brake cylinder must be placed
over the oil channel of the multi disks.
Figure 56

While assembling, make sure that the 5 mm Ø

bleeding bore is on the top.
Figure 57
Second wheel hub assembly.
Assemble second wheel hub and preheated

bearing. During this, observe that both assem-
bly signs (mark sinking), on the outer diameter
of the wheel hubs line up.
Figure 58
Ring gear assembly.
Assemble the ring gear with the carrier. Spray

the face of the ring gear carrier with Wolfra-
kote Paste, then mount complete ring gear
assembly onto the spindle.
Figure 59
Selection of adjusting washer for bearing

preload
Attention!
For the selection, turn wheel hub assembly
in the horizontal position to test the bearing
preload (50 Nm).
(In vertical position, the brakes drag and the
measurement would be incorrect.)
Figure 60

Selection of adjusting washer for bearing pre-

load.
Measure X1 of the spindle.
Figure 61
Measure X2 to the pre-fixed ring gear carrier.
Figure 62
Select washer thickness „d“ (No.18) of the adjusting

washer. „d“ max = „X1“ - „X2“ „d“ min = („X1“ - „X2“)
– 0.12
11. ring gear carrier

17. groove nut
18. adjusting washer
27. spindle
Figure 63

Groove nut assembly.
Firstly tighten the groove nut without glue

coating and test the preload of the wheel
bearing.
Figure 64
If preload is correct remove the groove nut

and make the glue fixation.
Figure 65
Clean the threads of the spindle and groove

nut. They must be free from oil. Install select-
ed adjusting washer and assemble groove nut
with Loctite 262 coating with tool WZ 878.
Tightening Torque is 2000±120 Nm for the
nut.
Figure 66
Check of bearing preload.
Attention!
The check of bearing preload (50 Nm) must
be done in the horizontal position.
(In vertical position the brakes drag and the
measurement would be incorrect.)
If preload is correct, mark the position of the

finally groove nut glue fixation with an yellow
colour point.
Figure 67

Planetary cage assembly.
Assemble the pre-assembled planetary cage onto

the wheel hub.
Figure 68
Attention!
Observe that the recesses of the planetary cage
and the assemble sign on the outer diameter of the
wheel hub line up.
Figure 69
Sun gear shaft assembly.
Assemble the sun gear shaft into the pre-assembled

planetary cage.
Figure 70
Figure 71

Expander plug assembly.
Assemble the expander plugs into the spindle.
Figure 72
Cover preparation.
First install four-point bearing and both oil

seals with special tool WZ 749.
Figure 73
Then turn the cover and coat the sealing face

with the fluid sealant “Loctite 518” and install
the dowel pins.
Figure 74

Four-point bearing assembly.
Assemble the first heated inner ring from the four-

point bearing.
Figure 75
Attention!
During assembly, stop the sun gear shaft on the op-
posite side.
Figure 76
Four-point bearing assembly.
Assemble the cover with the pre assembled four-

point bearing and fix it with hex bolts.
Attention!
posite.
Figure 77
Figure 78

Four point bearing assembly.
Assemble the second heated inner ring from

the four-point bearing.
Figure 79
Attention!
During assembly, stop the sun gear shaft on
the opposite side.
Figure 80
Figure 81

Cardan flange assembly.
Insert o-ring.
Figure 82
Assemble the cardan flange.
Attention!
posite side.
Figure 83
Clean the threads, coat them with glue substance

“Loctite 262” and then tighten with 800Nm.
Figure 84

Outside cover assembly.
Insert o-ring on the outside cover.
Figure 85
Assemble the outside cover.
Figure 86
Tighten with socket head screws.
Figure 87

Special Lifting device BM 215.
Special device BM 215 for lifting and

assembling in horizontal position (detail
view).
Figure 88
front reduction gear
1. Park on level ground.

2. Turn hub to fill and control position so oil level indicator is
horizontal.
3. Apply the parking brake.
4. Remove plug 33b 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.
33b
Fill and control position

Drive shafts
Front frame
A Cardan Shaft, Engine -Transmission
Part Number: 528878
Rubber coupling
Part number: 528657
Pos. Quantity Part
1 1 Rubber coupling ass'y

2 1 •Element
3 1 •Friction washer
4 1 •Friction ring
5 1 •Adapter
6 8 •Screw
E Cardan Shaft (LH and RH)
Part Number: 513458

Rear frame
Shaft in the articulation hinge
Intermediate shaft.
B Front Intermediate Shaft ( TransmissionSee next page
/ Intermediate Shaft)
Part Number: 513466
C Middle Intermediate Shaft (Intermediate

Shaft / Park Brakes)
Part Number: 527468
D Rear Intermediate Shaft (Park Brakes /

Rear Differential) Rear shaft
Part Number: 513815

The intermediate shaft (middle position)
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.
Schematic view
Legend of numbers:
2 = Engine - dependent PTO

3 = Output flange (rear axle)
4 = Emergency steering pump (option)
5 = Output flanges of LKV axle insert (front axle)
6 = Input flange
Legend of letters:
• W = converter with lock-up clutch

• RE = retarder
• Clutches = V/R/A/B/C/D/E (V=forward)
• Multi-disc brake = F
• Interaxle differential = G
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.
The differential sketch is viewed

from the top of the transmission Axle inser t "lK"
8eP-320

Brakes
Service brakes (DA30)
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.
5. Turn the wheel hubs until the rest oil drain plugs (No.52*) are positioned on top. (over the oil level).
6. Apply the service brake and remove rest oil drain plugs (No.52)
7. Measured in applied position.
8. Measure with a feeler gauge from the sure face for plug (No.52) to the test nib of the 5th disk.

Nominal size for new disks 103, +1 0,5/ -0,1 mm
Wearing size for worn disks 100, 1 0,8mm
?????????????????????????
??????????
????????
?????? ???????????????????
??????? ??
????????????????????????
?????
?????????????????
Control plug for disk wear

52
and rest oil drain plug
Measure “x” for new disks 103, +1 0,5/-0,1

Measure “x” for worn disks 100, 1 0,8
“x”

Measuring brake fluid pressure
1. Stop the machine on level ground and apply the parking brake.
2. Connect a pressure gauge to the test port (See figure below)
4. Depress brake pedal fully down.
* STANDARD VALUE: 190 bar

Service brake description
The service brake consist of:

Hydraulic pump, Accumulators, Brake pedal and Control valve
See the Shop Manual: Chapter 5
Pump
Accumulators
Left
gon
Fro
Right hand
r wa
nt w
hand
Rea
side
ago
side
Par
n
k
ing
gon
bra
r wa
ke
Rea
Brake pedal
Main valve
Brake system sketch

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.
Figure 3.1
2.
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.
ALLEN
4.
WRENCH
Use a 6 mm Allen wrench to de-adjust the brake as
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.
Figure 3.2
• To ensure that the automatic adjustment will occur:
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.
Figure 3.5
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
Assembly torqe: 560 Nm
Assembly the park brake unit.
Assemble new or overhaul calipper in reversing

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 DOOSAN 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 DOOSAN 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

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

to the center of the clevis pin while the brakes are
released.
• 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 DOOSAN MOXY parts only. Do not use parts manufactured by other suppliers.
Use of non-DOOSAN 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.
Figure 5.4
Blue Marks or Bands

Blue marks or bands indicate that the disc was very hot.
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
Rear Differential, DA30
See the DA30 parts catalogue for parts lists.

Exchange of the complete rear differential

Safety precautions.
Connect the articulation lock to front frame.
Be aware of personal injury.
Secure the machine with wheel chocks on the

front wheel.

Note:
For large damages to the differential it may be more beneficial to exchange the complete differential
instead of repairing it. Therefore it would be beneficial to remove the whole axle from the undercarriage.
1.
Drain oil from the differential (see chapter 7. operating and maintenance manual) and remove cardan shaft.
2.
Dismantle axle from the vehicle.
3.
During disassembly of the axle beam, loosen brake connections.
4.
Screw out hex. bolts (No.39) on both sides of the
differential and take off axle beam (No.22) with
complete side parts that is pull out.
Note:
Original NAF spare and repaired differentials are
properly set and adjusted from the factory.
Differentials not from NAF should be inspected
for proper bearing and contact pattern adjustm-
ent before installation.
5.
Remove rust protective coating from locating
surfaces.
6.
Replace o-rings (524285).
Fig.
Fig.44
7.
Reinstall complete side parts, with this lead the external spline of the axle shaft into the compensating gears by
light turn at the cardan flange.
8.
Then push together axle beam up to flange location, paying attention to the clamping sleeves.
9.
Insert hex. Bolts (No.39). Tightening moment is 430 +30 Nm.
10.
Install axle into vehicle, (connect brakes and cardan shaft).
11.
Fill oil into differential.
12.
Do not forget to vent brakes!
13.
Test-drive and retighten axle-mounting bolts.

Repairs on the rear differential

Exchange of crown gear / Pinion
(see Fig. 5)
Note:
The crown gear and pinion (No.13) can only be exchanged as a matched set and not separately, since
the gears have been mated to one another. The same numbers marked on the crown gear and pinion
identifies the matched sets. (Engraved with etching pen). It is advisable to replace various bearings with
this sort of repair.
1.
Remove differential.
2.
Remove pinion nut (No.50), to ease disassembly, heat to approx. 150°. Support cardan flange (No.51) with a
brace. (The loosening moment may reach up to 1500 Nm.)
3.
Loosen allen bolts (No.4) and remove flange on the crown gear side (No.6).
4.
Remove differential cage (No.11) with crown gear (No.13).
5.
Pull off cardan flange (No.51) and remove pinion (No.13) inward.
6.
Loosen all 4 hex. screws (No.58) and remove the cover (No.55) then press out the radial shaft seals (No.91/89)
to inside direction.
7.
Inspect tapered roller bearing (No.8/24) for differential cage and (No.43/48) for pinion and replace if need be.
8.
Loosen hex. bolts (No.9) and press crown gear (No.13) off of differential cage (No.11).
9.
Slide new crown gear onto differential cage (No.11) and during which insert both straight pins (No.12). Tighten
new hex. bolts (No.9) (coating on thread) cross wise with a torque wrench. Tightening moment is 290+ 10 Nm.
10.
Determine thickness of the adjusting washer (No.45) (see page 53).
11.
If replacing, press selected adjusting washer (No.45) and bearing outer ring from (No.43 and No.48) into differ-
ential housing (No.42).
12.
Install bearing inner ring from (No.8 and 24) with supporting washer (No.23), onto differential cage (No.11). As-
sembly temperature for bearing inner ring from (No.8 and 24) max. 80°.
13.
Install bearing inner ring (from No.43) with roller cage, onto pinion (No.13). Assembly temperature for bearing
inner ring (No.43) max. 80°.

14.
Determine thickness of the adjusting washer (No.44) (see page 52).
15.
Feed in pinion (No.13) from the inside of the housing (No.42) and support.
16.
Select a combination of two spacer sleeves (No.46/47) and between them adjusting washer(s) (No.44), onto the
shaft of pinion (No.13).
17.
Press bearing inner ring (from No.48) with roller cage, onto pinion (No.13). Assembly temperature for bearing
18.
Assemble cover (No.55) with installed seals (No.88/89).
19.
Clean pinion (No.13) and pinion nut (No.50), of dirt, oil and inhibitors.
20.
Coat entire diameter and length of thread of pinion (No.13) and nut (No.50), with Loctite 262.
21.
Apply wear and seizing inhibiting paste to the contact surface of the nut (No.50). (i.e. Wolfracote SSP from
Klüber).
22.
Install cardan flange (No.51) and thread pinion nut (No.50) onto pinion (No.13) and tighten with 800 Nm. The
final position must be achieved within 3 to 5 minutes in order for the Loctite to achieve its full potential.
23.
Check pinion bearing preload with a torque wrench and if need be, change adjusting washer (No.44). (Preload:
5 - 11 Nm). Document measured pinion bearing preload (see page 54).
24.
Thread on nut (No.25) approx. 1 turn, thread out nut (No.3) approx. 2 turns.
25.
Insert differential cage (No.11) complete, hold flange (No.6) and new o-ring (No.7) with allen bolts (No.4). Fas-
ten flange (No.6) additionally with for temporary assembly bolts M 18x2x50.
26.
Adjust backlash and crown gear bearing (0.15 – 0.25 play) (see page 54).
27.
Install differential (see page 46).

Fig. 5

1.Screw for locking plate 55.Drive shaft flange cover

2.Locking plate for groove nut 56.Grease nipple
3.Groove nut Crown gear side 57.Lock washer
4.Allen screw for Diff.-flange 58.Screw for cover
5.O-ring Axle beam / Differential housing 59.V-ring
6.Diff.-flange Crown gear side 60.Flange for multi disk lock
7.O-ring Diff.-flange 61.Butting ring
8.Diff.-cage bearing Crown gear side 62.Driven disk
9.Crown wheel screw 63.Screw
10.HV washer crown wheel 64.Washer
11.Diff.-cage 65.Oil drain plug Diff
12.Dowel pin for crown wheel 66.CU seal ring
13.Crown wheel / pinion 67.Butting ring
14.Butting ring for compensating gear
15.Compensating gear 89. Seal ring for Drive shaft flange
16.Cross bolt 90. Lock ring
17.Bushing 91. Seal ring for Drive shaft flange
18.Differential gear 106. Split spring for axle housing
19.Thrust washer for Differential gear
20.Screw for compression spring by MDDL
21.Compression spring
22.Allen screw Diff.-cage
23.Multi disc support
24.Diff.-cage bearing (at lock)
25.Shaft seal for piston
26.Driven disc
27.Piston Diff.-lock
28.Axial bearing
29.Adjusting washers for Diff.-cage (gear gap)
30.Drive disc
31.Piston Diff.-lock
32.Butting ring
33.Multi disc support
34.Allen screw
35.Piston seal Diff.-lock
36.Diff. flange (lock)
37.Seal ring to control plug
38.Oil control plug Diff.
39.O-ring
40.Butting ring
41.Allen screw
42.Differential housing
43.Pinion head bearing
44.Print pattern adjusting washer Diff.-housing
45.Pinion bearing adjusting washer
46.Spacer sleeve Pinion bearing
47.Spacer sleeve Pinion bearing
48.Outer Pinion bearing
49.O-ring Drive shaft flange
50.Drive shaft flange nut
51.Drive shaft flange
52.Cover
53.O-ring in Drive shaft flange cover
54.Gasket

Determining thickness of the adjusting washer

(44)
(see Fig. 5)
1.
Press in new bearing outer ring from (No.43) and (No.48) into differential housing (No.42) until stop.
2.
Install bearing inner ring (from No.43) with roller cage onto pinion (No.13). Assembly temperature for bearing
3.
Select a combination of two spacer sleeves (No.46 / 47) and between them one or two adjusting washers
(No.44). Assemble with a combine measure in the range of 36.55 mm to 38.55 mm. Note: First check work-
ing selected combination if usable. Adjusting washer thickness: 0.96 to 1.44 (with 0.04 steps) Spacer sleeve
(No.46): 24.0 ±0.02 mm Spacer sleeve (No.47): available 11.51 mm; 11.99 mm and 12.47 mm
4.
Feed in pinion (No.13) from the inside of housing (No.42) and support.
5.
First insert selected spacer sleeve (No.46), then adjusting washer(s) (No.44) and then spacer sleeve (No.47)
onto the pinion (No.13). (see Fig. 5).
Tip: Start with a select combination with a total width approximately of 34,05 (it is an empirical value)
6.
Press bearing inner ring (from No.48) with roller cage, onto pinion (No.13). Assembly temperature for bearing
7.
Klüber)
8.
Install cardan flange (No.51) and thread pinion nut (No.50) onto pinion (No.13) and tighten with 800 Nm.
9.
Check pinion bearing preload with a torque wrench and if need be, change adjusting washer (No.44). The
pinion bearing may not have any axial play but should let itself turn with 5 to 11 Nm. For used bearings, an
adjustment value of 1 to 9.0 Nm may apply. (Pinion bearing preload for new bearings: 5 – 11 Nm). Document
measured pinion bearing preload (See page 53).
10.
Upon correct bearing preload, secure pinion bearing (No.50) with Loctite. (See page 47).

Determining thickness of the adjusting washer

(45)
Note:
By selecting the adjusting washer (No.45) the contact pattern adjustment is carried-out.
Fig.
Fig. 66
Calculating thickness (Se) of the adjusting washer (No.45)

Se = L2 - Le - Lr -L1
A washer thickness between 2.5 and 3.5 mm must be achieved. Select the nearest available washer thickness.
Maximum allowable deviation of the washer thickness from the calculated thickness Se is 0.1 mm.
„L2“ = distance between bearing seat (No.43) and middle of the differential (approx. 235+0,1 mm). „Le“ =
mounting distance (engraved on pinion face approx. 112.93 mm). „Lr“ = measure and document pinion gear
head height (approx. 70.07 mm).
„L1“ = measure actual thickness of the new bearing (No.43). The measurement „L1“ can vary
near 49.212. (Slide gauge with at least 120 mm jaw length).

Pinion bearing adjustment
1.
Clean pinion (No.13) and pinion nut (No.50), of dirt, oil, and inhibitors.
2.
Coat entire diameter and length of thread of pinion (No.13) and nut (No.50), with Loctite 262.
3.
Klüber)
4.
Thread nut (No.50) onto pinion (No.13) and tighten with 800 Nm, while supporting cardan flange (No.51). After
some tap hammering on the outside of the housing in the area of the pinion bearing to align the tapered rollers.
The final location must be achieved within 3 to 5 minutes in order for the Loctite to achieve its full potential.
5.
Check pinion bearing preload with a torque wrench and if need be, correct the adjustment. The pinion bearing
may not have any axial play but should let itself turn with 5 to 11 Nm. For used bearings an adjustment value of
1 to 9 Nm may apply.
6.
Document adjusted bearing preload for later crown gear bearing adjustment.
Backlash and crown gear bearing adjustment
7.
Exchange flange (No.36) complete with „MDDL“
components again the orifice flange WZ 637
only for adjusting. Fix the orifice flange
WZ 637 with four temporary assembly
bolts M 18x2x50. (see picture below)
8.
Loosen bolt (No.1) and remove locking plate
(No.2) and turn back the nut (No.3) approx 2
rotary.
9.
Insert differential cage (No.11) complete.

10.
Mount flange (No.6) with new o-ring (No.7)and fix it with allen bolts (No.4). Fasten flange (No.6) additionally with
four temporary assembly bolts M 18x2x50.
11.
Now turn nut (No.3) until a backlash of 0.15 to 0.25 mm is achieved turn nut (No.3) till the necessary bearing
preload of 3.0 – 6.0 Nm is achieved Once the correct backlash and the adjust bearing preload is achieved,
secure nut (No.3) with locking plate (No. 2) and hex. bolt (No.1).
12.
Measure on the original MDDL-flange
(No.36) the measurement “X1”.
13.
Set the dig.-depth gauge on zero deter-
mine the measurement “X1”
14.
Through the drill hole in orifice flange WZ
637 determine now the exact distance „X2“
from flange surface to outer bearing ring.

14.
Set the dig.-depth gauge on zero deter-
mine the measurement “X2” Calculation of
the adjusting washer: Washer size „S“ = X2
– X1 (experimental value of the adjusting
washer for new installation is 1.6mm for 2
Nm bearing preload )
15.
Adjust the initial stressing for diff.-cage
bearing (No.8) and (No.24). Turn there-
fore the nut (No.3) so long till the suit-
able bearing preload of 3.0 – 6.0 Nm is
reached.
This value is determined on the pinion

nut (No.50) with a torque meter, in that to
the pinion bearing preload (documented
value from section 2.2.1.3) a moment of
1.0 to 3.0 is added.
16.
Remove the inner part from the orifice
flange WZ 637 and insert the definite
adjusting washer for an test.

17.
After the installation of the definite adjusting washer and the cover, control the bearing preload with dial gauge
Note: Trough tightening of the centre screw is no additional effect force of pressure spring onto the bearing sup-
port.
18.
When the correct bearing preload is reached, exchange the orifice flange WZ 637 again flange (No.36) with in-
clude complete „MDDL“ components. Install with it the definite adjusting washer into the original „MDDL“ flange
(No.36) and renew the o-ring (No.7/ see fig.6).
19.
Document adjusted bearing friction moment.
Checking contact pattern
1.
Loosen temporary assembly bolts and allen bolts (No.4) at the flange (No.6) and remove flange.
2.
Take out differential cage (No.11) and coat flanks from 2 teeth (= 4 tooth flanks) of the crown gear (No.13) with
thin yellow oil based paint and reinstall differential cage (No.11), flange (No.6) with temporary assembly bolts.
3.
Turn pinion, so that the contact pattern is marked by the paint.
4.
Remove flange (No.6), take out differential cage (No.11) with crown gear and assess contact pattern. With
proper adjusting washer thickness a contact pattern as per Fig. 9 should be achieved, otherwise select a new
adjusting washer (No.45) (see page 53).
Fig. 7 Fig. 8
If there is a contact pattern as per Fig. 7 or 8, by shifting the pinion with help from a change in the adjusting
washer (45) thickness, a contact pattern as per Fig. 9 is achieved. By turning the nut (No.3) and exchange ad-
justing washer (No.29) can a adjust sliding for the crown gear likewise to Fig. 7 or 8 be done.

Caution:
During the adjustment process, always pay attention to the
proper preload for the bearings (8) and (24). Likewise, when
turning the nut (3) and exchange washer (29) pay attention
to the correct backlash. Wipe oil paint from previous adjust-
When the backlash and bearing preload is correct adjusted, se-

cure nut (No.3) with locking plate (No.2) and new hex. bolts (No.1).
Exchange shaft seals
1.
Drain the oil from the differential and remove the drive shaft from the input cardan flange (51)
2.
The hex nut (50) in the cardan flange is locked with thread locker, the loosening torque may exceed 1000 Nm.
Therefore preheating the nut to 120°-160°C with a blow lamp is recommended. Loosen the nut (Wrench size
50) and pull the cardan flange from the spline end of the pinion shaft.
3.
Loosen all 4 hex. screws (58) and remove the cover (55) then press out the radial shaft seals (91/89) to the
inside direction..
4.
It is also recommended to exchange the O-ring (49), extract it from the groove in the shaft. Check the sealing
surface of the cardan flange (51) for any marks of wear and replace it if necessary.
5.
Cover preparing: First press in new shaft seal (first 89) with special tool (WZ 556 with distance ring for deep
distance), then shaft seal (91) with WZ 556 without ring for short distance) into the cover (55) and fill 50% of the
volume between the seals with grease. It should be noted that the lips of the seals are installed in the proper
orientation as illustrated.
6.
renew O-ring (53) in the grove of the cover (55) and mount the complete cover (55) into the housing (42) and fix
it with 4 hex. screws (58) with locking washers (57). When assembling the cover (55) it should be noted that the
lip of seals does not become damaged.
7.
With a steel brush remove rests of old hardened glue from the threads of shaft and nut and clean from any dirt
and grease.
8.
Install new O-ring (49), and shift the cardan flange (51) onto the spline of the shaft.
9.
Now cover the threads of shaft and nut with Loctite 262.
10.
The applying and tightening of the nut must not take any longer than 3-5 minutes to avoid any hardening of the
adhesive.
11.
The nut cannot be applied using an impact wrench since this will promote early hardening and the adhesive will
be spun off the threads. Tighten the nut with 800 Nm torque

Exchange of differential cage (compensating

gearbox)
(see Fig. 5)
Note:
The both halves of the differential cage (No.11) can only be exchanged together, note orientation mark-
ings and identification.
1.
Remove differential. (see page 46).
2.
Detach flange (No.6).
3.
Take out differential cage (No.11) with crown gear (No.13).
4.
Pull off bearing inner rings from (No.8 / No.24) and supporting washer (No.23). Check both tapered roller bear-
ing (No.8 / No.24) and replace if need be.
5.
Loosen hex. bolts (No.9) and pull crown gear (No.13) from differential cage (No.11).
6.
Remove allen bolts (No.22) and open differential cage (No.11).
7.
Take out crossbolt (No.16) with differential gear (No.18) and thrust washer (No.19) as one unit. Check compo-
nents and replace if need be.
8.
Remove compensating gears (No.15) with thrust washers (No.14). Check components and replace if need be.
9.
Perform adjustment of the differential cage by selecting thickness „s“ of the thrust washer (No.14). Thickness „s“
of the thrust washers (No.14) to select from is 1.5; 1,7; 2,0; to 2.2 mm. 1. For testing purposes, screw together
both differential cage halves with the selected parts with four uncoated temporary assembly bolts M 12 x 80. 2.
With the use of a profiled shaft end, turn the compensating transmission through. There can be no noticeable
resistance or no ascertainable jerking. The axial play at the compensating gear (No.15) must be less than 0.2
mm. 3. For a wrong thrust washer adjustment, appropriately change and repeat test method.
10.
At the correct adjustment, remove the four uncoated temporary assembly bolts and finally bolt together with
twelve new coated allen bolts (No.22). Tightening moment for allen bolts (No.22) is 115+10 Nm.
11.
Press on both tapered roller bearings (No.8 / No.24) and during replacement also press bearing shells in both
flanges (No.6 / 36).
12.
Insert differential cage (No.11) and flange (No.6).
13.
For test purposes, fasten flange side with four temporary assembly bolts M 18x2x50.
14.
Adjust backlash and crown gear bearing (see page 53).

15.
Check contact pattern (see page 56).
16.
Remove temporary assembly bolts M18x2x50.
17.
Install differential (see page 46).
Differential lock
Note!
Before opening the axle it should be urgently determined if the lock itself is damaged or the external
engaging components. Check the function of the differential lock:
1. Jack up the vehicle such that the wheels are up from up from the ground.
2. Block cardan flange and turn one wheel.
3a. When the diff.-lock is open (no line pressure) the opposite wheel must turn in the opposite
direction.
3b. When the diff.-lock is engaged neither the right nor the left wheel will turn. A small turning
action (due to backlash) is permitted.

Planetary drive
Note:
To work on the planetary drive it is not required to remove the axle from the vehicle. It is sufficient when
the side of the vehicle that is being worked on is jacked up and the wheel removed.
Fig. 10.
1 Gear rim 22. Washer 45. O-ring

2 Hex. screw 23 Butting ring 46. Ring
3 Washer 24 Seeger-ring 47. Compression spring
4 Planetary cage inner part 25 Steel disc 48. Seal ring
5 Shear sleeve 26 Coated disc 49 Snap ring
6. Cover 27 Stub axle 50. Screw plug
7 Planetary stud 28 Hex. screw 51. CU seal ring
8 Needle cage 29 Cassette seal ring 52. Screw plug
9.O-ring 30 Wheel hub 53. O-ring
10 Planetary gear 31 Tapered-roller bearing 54. Seal ring
11 Butting ring 32 Hex. screw 55. Dowel pin
12.Washer 33 Wheel bolt 56. Plug
13 Planetary cage outer part 34 Wheel hub 57. CU seal ring
14 Allen screw 35 O-ring 58. -
15 Sun gear 36 Tapered-roller bearing 59 -
16 Setbolt 37 Snap ring 60. Breather
17 Flat collar nut 38 Gear rim carrier 61. -
18 O-Ring 39 Groove nut 62. Adjusting washer
19 Dowel pin 40 Cylinder 63. Allen screw
20. Dowel pin 41.Piston 64. O-ring
21. Hex. screw 42. Piston seal 101 Axle beam
43. Piston seal 102 Axle beam
44. O-ring

Complete exchange of planetary cage
(see Fig. 10)
1.
Lift up and secure vehicle.
2.
Remove wheel.
3.
Drain oil (See chapter 7, Operating and Maintenance manual).
4.
Remove hex. screws (No.32).
5.
Pull off the complete planetary cage (No.13).
6.
Replace o-ring (No.53) and insert into the recess of the wheel hub (No.30).
7.
Assemble new complete planetary cage (No.13). For this, bring recess of the new planetary cage to the position
mark of the wheel hub. Then bring teeth of the sun gear (No.15) and the three planetary gears (No.10) in mesh-
ing location. Afterwards, slide on whole the planetary cage (No.13).
8.
Insert hex. screws (No.32). Tightening moment is 125 Nm.
9.
Fill in oil (See chapter 7, Operating and Maintenance manual).
10.
Install wheel.
11.
Lift down vehicle.

Exchange of sun gear shaft
Fig. 15. Install a retainer bolt Fig. 16. Pull out the sun gear
M12 into the shaft.
1.
Unscrew allen bolts (No.14) and remove cover (No.6).
2.
Install an retainer bolt M12 and remove the sun gear shaft (No.15).
3.
Pull out the sun gear shaft
4.
Install the new sun gear shaft (No.15) and slide it inside till it stopped.
5.
Control the gap to the thrust bolt in the cover through measurement.
6.
Replace o-ring (No.9) and insert into the recess of the cover (No.6).
7.
Mount the cover (No.6) onto the planetary hub and tighten the allen bolts with 72 Nm.
Exchange of Planetary Studs and Gears
(See Fig. 10)
1.
Remove planetary cage (No.13) (see page 62).
2.
Place planetary cage (No.13) with the opening upward.
3.
Loosen four hex. bolts (No.2).
4.
Pull out the planetary studs (No.7) with inner planetary cage (No.4). Use an M 12 knock extractor tool.
5.
Take out the unit planetary gear (No.10) with needle cage (Nor.8) and butting ring (No.11).

6.
Insert new unit (planetary gear + needle cage + butting ring) then push up the planetary stud (No.7).
Note:
The butting ring nip must showed to the outer centric in the planetary cage (No.13).
7.
Check the seat and completeness of the four shear bushings
8.
Press on the inner planetary cage (No.4).
9.
Insert four new coated hex. bolts (No.2) and tighten it with 310 Nm.
10.
Check the free floating of the planetary gears (No.10) The axial gap must have (min. 0.3 mm).
11.
Reassemble planetary cage (No.13) complete. (See page 62).
Exchange of ring gear carrier
(See fig. 10).
1.
Remove planetary cage (No.13) (See page 62).
2.
Remove snap ring (No.37).
3.
Replace ring gear (No.9).
4.
Reinsert snap ring (No.37). Note: The ring gear should have a radial play of approx. ± 0.4 mm on the ring gear
carrier (No.9).
5.
Assembly planetary cage (No.13). (See page 62).

Wheel bearings
Gear bearing exchange
1.
Remove planetary cage (No.13) complete (See page 61).
2.
Disassemble sun gear shaft (No.15) (See page 62).
3.
Screw off groove nut (No.39) with a special groove socket wrench WZ 082 .
For this, heat groove nut M 85 x 1.5 (No.39) to approx. 150°C, (i.e. with soldering torch) and loosen with the
special groove socket wrench WZ 082. The loosening moment can reach up to 2000 Nm.
4.
Remove adjusting washer (No.62) and ring gear carrier (No.38) with ring gear (No.1).
5.
Loosen 12 hex. screws (Nr.32) and install auxiliary screws M 16 x 60 in both forcing threads (M 16) of wheel
hub (Nr.30).
6.
Set in cross wise this extractor bolts to impress wheel hub (No.30) and outer gear bearing (No.36), simultane-
ously from the axle stub (No.27).
7.
Detach complete ring piston cylinder of the multi disk brake.
8.
Remove successive the lined disks (No.25) and steel disks (No.26).
9.
Detach device holder WZ 042 and lift carefully wheel hub (No. 34).
10.
Pull ring (No.46) and bearing inner ring (No.31) with an extractor from the axle stub (No.27)
11.
Remove cassette oil seal (No.29) from the wheel hub (No.34).
12.
Press out bearing outer ring from the gear bearings (No.31) from the wheel hub (No.34).
13.
Renew the oil seal ring in the wheel hub (No.48) with insert punch WZ 732.
14.
Renew bearing-outer rings (No.31 and No.36) in both wheel hubs (No.34) and (No.30) with special insert punch
WZ 734 and WZ 733.
15.
Press new oil seal (No.29) into wheel hub (No.34) with an special insert punch (WZ 731).
16.
Check the seat of the ring (No.23) and press a new bearing inner ring (No.31) onto the axle stub (No.27) again.
Assembly temperature for the bearing inner ring (No.31) max. 80°.

17.
Install the ring (No.46)
18.
Place carefully wheel hub (No.34) centrally and hold with device in position.
19.
Place the five cylinder bolts (No.20).
20.
Insert successive the multi-disk package. Incipient with lined disk with ecess lying above sparing in axle stub
(No.27), and mark one of the major oil boring on the wheel hub with a pencil.
21.
Start to insert the disk package with a lined disk (No.25) in alternate with steel disks (Nr.26). While doing this
twist the first both steel disks about one spacing (72°). (That means, the nib of the first seven steel disks shall
not positioned on opposite to the control opening (No.52). Pay attention to set the disks with oil borings super-
imposed. The last steel disk has to be positioned on opposite to the control opening (No.52). At least insert a
lined disk (No.26).
Fig. 17. Position for discs Fig. 18. Position for the last steel disc
22.
Check o-ring (No.18) and piston seal (No.43) in the ring piston cylinder if necessary renew it and coat it with
paste „Klüber-Paste Wolfracote SSP“.
Fig. 19. Pray the splindle with slide paste Fig. 20. Position for bleeding bore oil holes

Fig. 21. Bleed bore on the top Fig. 22. Note the position of ass’y sign
Fig. 23. Bearing installation Fig. 24. Ring gear assembling and spray-
ing
23.
Assemble heated bearing inner ring from (No.36) onto the axle stub (No.27) completely, use assembly sleeve
when necessary. (See Fig.23) Assembly temperature for the bearing inner ring (No.21) max. 80°.
24.
Clean thread M 85 x 2 of the axle stub (No.27) and nut (No.39) of dirt, oil, adhesive residue, and inhibitors.
25.
Coat end faces of the ring gear carrier (No.11) with paste “Klüber-Paste Wolfracote SSP” and slide it on. (See
Fig. 24)
26.
Adjust wheel bearing (See page 68) and tighten groove nut (No.39) with thread locker “Loctite 262” and use
special groove socket wrench WZ 082.
27.
Insert sun gear shaft. (No.15).
28.
Reassemble planetary cage (No.13). (See page 62).

Gear bearing adjustment
1.
Measure distance „X1“ on axle stub (No.27). (theoretical = 22 ± 0,2) „X1“ = Distance between end face on axle
stub (No.27) and shoulder for adjusting
washers.
reading value „X1“
2.
Coat end face of the ring gear carrier (No.38) with Klüber-Paste Wolfracote SSP.
3.
Screw on nut (No.39) and tighten until a bearing preload of approx. 45 to 55 Nm (with seals) is achieved at the
gear bearings. Align roller cage and gear bearing, during this turn wheel hub 1-2 times in both directions and
continuously tap hammer on the outside of the wheel hub (No.30).
4.
Measure distance „X2“. (theoretical „X2“ = 20 ± 0,75) „X2“ = Distance between end face on axle stub (No.27)
and end face of ring gear carrier (No.38).
reading value „X2“

Select washer thickness „d“ (No.62) of the adjusting washers. „d“ max = „X1“ - „X2“ „d“ min = („X1“ - „X2“) –
0.15 (see drawing below)
5.
Again loosen nut (No.39) and remove.
6.
Clean thread M85 x 2 of axle stub (No.27) and groove nut (No.39) of oil, dirt, inhibitors, and adhesive residue.
7.
Insert adjusting washer with calculate thickness „d“.
8.
Again coat end face of ring gear carrier with Klüber-Paste Wolfracote SSP (do not coat groove nut No.39).
9.
Coat entire diameter and length of thread M85 x 2 of axle stub (No.27) and groove nut (No.39) with Loctite 262.
10.
Thread on groove nut (No.39) with an special groove socket wrench WZ 082 and tighten with 2000 Nm. With the
use of the torque amplifier Sk 3.91-1007 with 5:1 ratio, tighten with 400 Nm. The final bearing preload adjust-
ment must be between 45 to 55 Nm.
11.
The final location of the axle stub nut (No.39) must be achieved within 2 -5 minutes, in order for the Loctite to
achieve its full potential.
27. stub axle

38. ring gear carrier
39. groove nut
62. adjusting washer

Brake
Check disc’s wear
(See Fig. 13)
1.
Turn the wheel hubs until the rest oil drain plugs (No.52*) are positioned on top. (over the oil level).
2.
Apply the brake and remove rest oil drain plugs (No.52)
3.
Measured in applied position.
-Measure with a feeler gauge from the sure face for plug (No.52) to the test nib of the 5th disk. Measure with a
feeler gauge from the sure face for plug (No.52) to the test nib of the 5th disk.
(nominal size for new disks 80.5 + 0.5 / -0.4 mm)
(wearing size for worn disks 77.5 - 0.8 mm

Exchange of the piston for the operating brake

(See Fig. 10)
1.
2.
3.
Screw off groove nut (No.39) with an special groove socket wrench WZ 082 .
4.
5.
hub (Nr.30).
6.
7.
8.
Look the lined disks (No.25) and steel disks (No.26) against to trop out.
9.
Remove the cylinder (No.40) from piston (No.39) with two levers.
10.
Remove piston seals (Glyd-ring / No.42) and (Glyd-ring / No.43) with a suitable tool (scriber or proper plastic
tool) from its seats. Be careful not to damage the seal surfaces in cylinder (No.40) and piston (No.39).
11.
Insert new piston seals (No.42/43) and oil it slight.
12.
Renew the o-ring (No.16).
13.
Superimposed piston (No.39) and cylinder and push it on careful till it seat on the contact face. Watch by the
assembly not to damage the piston seal (No.42/43).

14.
Coat it with paste „Klüber-Paste Wolfracote SSP“ and place the complete ring piston brake cylinder onto the of
axle stub (No.27) until it stop. Be carefully by assembling to the o-ring (No.18). Check after assembly the plain
contact from the piston to the disk package.
15.
16.
Put on new o-ring (No.35) and mount the outer part from the wheel hub (No.30) centrally and pay attention to
mesh the marks in the wheel hubs. Tip: Paint additional sign on both wheel hubs. (Original sign are spot drills in
surfaces)
17.
when needed. Assembly temperature for the bearing inner ring (No.36) max. 80°.
18.
Coat end faces of the ring gear carrier (No.38) with paste “Klüber-Paste Wolfracote SSP” and slide it on.
19.
Adjust wheel bearing (See page 80) and tighten groove nut (No.39) with an special groove socket wrench WZ
082.
20.
Insert sun gear shaft (No.15).
21.
Exchange of brake disks and pressure springs

for the operating brake
(See Fig. 10)
1.
2.
3.
Screw off groove nut (No.39) with an special groove socket wrench WZ 082 .
4.
5.
hub (Nr.30).
6.
7.

8.
Remove the lined disks (No.25) and steel disks (No.26) successive.
9.
Check or place the five existing numbers for cylinder bolts (No.20).
10.
Insert successive the multi-disk package. Incipient with lined disk with ecess lying above sparing in axle stub
(No.27), and mark one of the major oil boring on the wheel hub with a pencil.
11.
Start to insert the disk package with a lined disk (No.25) in alternate with steel disks (Nr.26). While doing this
twist the first both steel disks about one spacing (72°). (That means, the nib of the first seven steel disks shall
not positioned on opposite to the control opening (No.52). Pay attention to set the disks with oil borings super-
imposed. The last steel disk has to be positioned on opposite to the control opening (No.52). At least insert a
lined disk (No.26). (See page 65).
12.
Coat it with paste „Klüber-Paste Wolfracote SSP“ and place the complete ring piston brake cylinder onto the of
axle stub (No.27) until it stop. Be carefully by assembling to the o-ring (No.18). Check after assembly the plain
contact from the piston to the disk package.
13.
14.
Put on new o-ring (No.35) and mount the outer part from the wheel hub (No.30) centrally and pay attention to
mesh the marks in the wheel hubs. Tip: Paint additional sign on both wheel hubs. (Original sign are spot drills in
surfaces)
15.
when needed. Assembly temperature for the bearing inner ring (No.36) max. 80°.
16.
Coat end faces of the ring gear carrier (No.38) with paste “Klüber-Paste Wolfracote SSP” and slide it on.
17.
Adjust wheel bearing (See section 68) and tighten groove nut (No.39) with an special groove socket wrench WZ
082.
18.
Insert sun gear shaft (No.15).
19.

Fig. 13.

Tandem bearings
Note:
The tandem swing is mounted with a slewing ring at the axle beam. For proper operation, regular ser-
vicing as per a service plan is extremely necessary. To work on the tandem bearing it is not required
to remove the axle from the vehicle. It is sufficient when the side of the axle that is being worked on
is jacked up and the tandem swing is removed. During assembly and disassembly, proceed with great
care, so that the sealing surfaces of the slewing ring (No.60) for the seal (No.63) are not damaged.
Exchange of slewing ring
(see Fig. 13 / 14)
1.
Lower oil level in the tandem housing approx. 80 mm.
2.
To disassembly of the sun gear shaft, loosen parking brake. (Open parking brake connection at spring loaded
cylinder with pressure) Release pressure min. 18 bar max 35 bar
3.
Loosen and remove hex. bolts M10 (No.53) at bearing studs (No.51).
4.
Pull out bearing studs (No.51) complete with attached sun gear shaft (No.50). (Thread in two temporary assem-
bly bolts M 10 x 40 into the pulling thread M 10)
5.
Loosen allen bolts M18 (No.57) and remove complete side component. Take precautions not to damage the
sealing surfaces.
6.
Loosen allen bolts (No.59) and take off slewing ring (No.60).
7.
Insert new o-ring (No.64) to axle beam (No.65).
8.
Fasten new slewing ring (No.60) in the proper orientation (red marking on inner ring to be placed upwards) with
new allen bolts M18 (No.59). Tightening moment is 420 Nm.
9.
Replace seal (No.61) in tandem axle beam and coat sealing lips with grease.
10.
Apply grease to all ten grease nipples of the new slewing ring (No.60) until grease exits from the entire diameter
of the axle beam side.
11.
Insert both straight pins (No.62) into the slewing ring.

12.
Fasten complete side component to the axle beam with new allen bolts M18 (No.57) with adhesive in thread
„crosswise“. During assembly, pay attention to the sealing lips of the seal (No.63). Insert washers (No.58)
underneath the six top allen bolts (No.57) which are screwed into the outer component of the tandem housing.
Tightening moment is 420 Nm.
13.
Insert o-ring (No.52) into the bearing studs (No.51) and grease lightly.
14.
Insert bearing studs with sun gear shaft (No.50) into the axle beam and mesh into the profile of the lined disks
and the diff.-compensating gear. During this, observe that the sealing lips of the seals in the axle beam are not
damaged. To ease the meshing of the sun gear shaft into the profile of the inner disk and the compensating
gear, the axle shaft must be shortly turned back and forth. During installation of the bearing studs (No.51) pay
attention to the location of the screw plug (No.56) and proper seating of the o-ring (No.52). Tighten new hex.
bolts (No.53) with 67 Nm.

Fig. 14.
1 Roller bearing 14 Seal ring

2 Pinion Z= 33 15 Screw
3 Snap ring 16 Washer
4 Snap ring 17 Breather
5 Shaft 18 Breather
6 Sleeve 19 Slot pin
7 Adjusting pin 20 Slot pin
8 Seal ring 21 Bushing
9 Seal ring 22 O’ring
10 Washer 23 Articulation bearing
11 Bushing 24 Screw
12 Rear axle housing 25 Screw
13 Plug 26 O’ring

Exchange of seal
See pages 87/88 and Fig. 14
Exchange of axle beam
(see Fig. 14)
Note:
For the exchange of the axle beam, it would be advantageous to remove the entire axle from the under-
carriage.
1.
Drain oil from differential and the tandem swing and loosen cardan shaft.
2.
Remove axle from the vehicle.
3.
Remove hex. bolts (No.15) of differential and remove axle beam (No.12) with complete bogie housing.
4.
Loosen allen bolts M18 (No.25) and remove complete tandem swing. Take precautions not to damage the seal-
ing surfaces.
5.
Loosen hex. bolts (No.24) and take off slewing ring (No.23).
6.
Insert o-ring Ø 345 x 4,72 in new axle beam (No.12).
7.
Fasten new slewing ring (No.23) in the proper orientation (red marking on inner ring to be placed upwards) with
new hex. bolts M18 (No.24), with adhesive in thread, „cross-wise“. Tightening moment is 420 Nm.
8.
Replace oil seals (No.8) and (No.9) in axle beam (No.12) and coat sealing lips with grease.
9.
10.
11.
Fasten complete side component to the axle beam with new allen bolts M18 (No.25) with adhesive in thread
„crosswise“. During assembly, pay attention to the sealing lips of the seal (No.8 / 9). Screwed the sic top screws
(No.25) into the outer component of the tandem housing. Tightening moment is 420 Nm.
12.
Reinstall complete side component, for this mesh the external spline of the sun gear shaft into the compensat-
ing gears by light turning at the cardan flange.
13.
Then slide together axle beam until flange location, paying attention to the straight pins.

14.
Insert hex. bolts (No.15). Tightening moment is 400 +10 Nm.
15.
Install axle into vehicle, (connect brakes and cardan shaft).
16.
Fill oil into differential and into tandem housing.
17.
Do not forget to vent brake!
18.
Test drive and retighten axle mounting bolt.
Gear drive in tandem housing

Note:
To work on the gear drive it is not required to remove the axle from the vehicle. It is sufficient when the
side of the vehicle that is being worked on is jacked up and the tires with rims removed.
Exchange of bearing (84)
See Fig. 13
1.
Loosen hex. bolts (No.80) and remove tin cover (No.81) with flat gasket (No.82).
2.
Thread an impact puller into the face thread M 12 of the stud (No.83) and pull out stud.
3.
Replace needle bearing ring (No.84) and o-ring (No.85) at stud (No.83). Tipp: Between both needle bearings is
a snap ring.
4.
Insert stud (No.83) into the bore of the tandem axle beam (No.44), gear (No.86) and spacer ring (No.87).
5.
Place new flat gasket (No.82) in between and insert tin cover (No.81) with arching into the groove of the stud
(No.83).
6.
Tighten new hex. bolts with adhesive in thread (No.80) with 46 Nm.

Exchange of gear (43) and bearing (89) / (90)

See Fig. 13.
1.
Loosen allen bolts (No.95) and remove cover (No.96) with gasket (No.94). If necessary use two M 10 pulling
screws into the thread holes.
2.
Remove seal ring (No.93).
3.
Take out snap ring (No.91).
4.
Remove the cover (No.92). Use a withdrawing device into the M 10 thread holes.
5.
Pull out gear (No.43) with bearings (No.89) and (No.90) with an internal-expanding puller (WZ 628). If neces-
sary open the center adjusting screw (No.16) for the shaft on the planetary housing.
6.
Press new deep groove ball bearings (No.89) and (No.90) onto the new gear (No.43).
7.
Insert preassembled gear (No.43) into the tandem axle beam (No.44) and slide on axle shaft (No.41) again.
8.
Insert cover (No.92) and install snap ring (No.91).
9.
Press in seal (No.93) with appropriate die (shoulder Ø min 248 mm).
10.
Lay on a new gasket (No.94), insert the cover (No.96) and tighten the allen screws (No.95) with 67 Nm.

Exchange of gears (86)

See Fig. 5.
1.
Drain oil (See chapter 7, Operating and Maintenance manual).
2.
Loosen and remove hex. bolts M10 (No.53) at bearing studs (No.51).
3.
Pull out bearing studs (No.51) complete with attached sun gear shaft (No.50). (Thread in two temporary assem-
bly bolts M 10 x 40 into the pulling thread M 10)
4.
Loosen allen bolts M18 (No.57) and remove complete side component. Take precautions not to damage the
sealing surfaces.
See Fig. 13
5.
Outer studs (No.83), or depending on which of the three gears (No.86) needs to be exchanged, the outer two
studs or all three studs of a gear side are to be disassembled as per page 91.
6.
The gears (No.86) can now be removed through the large opening (Ø 230 at slewing ring). The spacer ring
(No.87) can be pressed out through the corresponding bore (Ø 71 mm).
7.
When pressing the spacer ring (No.87) note that the hardened gear face and the inner diameter bevel of each
spacer ring shows outwards to the bore (Ø 71mm).
8.
The new gears (No.86) are placed through the large opening (Ø 230 at slewing ring) into the tandem housing
and start assembling with the outer gear as per page 91.
9.
Replace seal (No.56) in tandem axle beam and coat sealing lip with grease.
10.
11.
12.
Fasten complete side component to the axle beam with new allen bolts M18 (No.57/72) with adhesive in thread
„crosswise“. During assembly, pay attention to the sealing lips of the seal (No.56). Insert washers (No.71)
underneath the six top allen bolts (No.72) which are screwed into the outer component of the tandem housing.
Tightening moment is 420 Nm.
13.
Insert o-ring (No.52) into the bearing stud (No.51) and grease lightly.
14.
Insert bearing studs with sun gear shaft (No.50) into the axle beam and mesh into the profile of the lined disks
and the diff.-compensating gear. During this, observe that the sealing lips of the seals in the axle beam are not
damaged. To ease the meshing of the sun gear shaft into profile of the compensating gear, the axle shaft must
be shortly turned back and forth. During installation of the bearing studs (No.51) pay attention to the location of
the screw plug (No.56) and proper seating of the o-ring (No.52). Tighten new hex. bolts (No.53) with 67 Nm.
15.
Fill oil (See chapter 7, Operating and Maintenance manual).
Special Tools for Mox 08 axle
Doosan Moxy Part Number
MX 526813
MX 526814
MX 526815
MX 526816
MX 526817
MX 525672
MX 525680
HAVE TO BE CREATED

Note:


Ch3 - DA30 - Drive Line and Brakes

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drive line Ch 3 page 1

SHOP MANUAL DA30 - 11.2011

SHOP MANUAL DA30 - 11.2011

SHOP MANUAL DA30 - 11.2011

Exchange of Planetary Studs and Gears.......................................................................................................................... 65

SHOP MANUAL DA30 - 11.2011

SHOP MANUAL DA30 - 11.2011

Fig 3.1 Drive Line Overview

SHOP MANUAL DA30 - 11.2011

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

SHOP MANUAL DA30 - 11.2011

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 DA30 - 11.2011

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

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 DA30 - 11.2011

Tightening torques for nuts and bolts.

Name Part no. Tightening torque

SHOP MANUAL DA30 - 11.2011

SHOP MANUAL DA30 - 11.2011

Front reduction gear

SHOP MANUAL DA30 - 11.2011

DA30 parts list

1 524181 6 Allen screw 31 524217 27 Pressure spring

SHOP MANUAL DA30 - 11.2011

Front reduction gear cross section

SHOP MANUAL DA30 - 11.2011

NAF special Tools for DA30

Description: WZ number Moxy part

Device to lift the complete planetary drive hub BM 215 525681

SHOP MANUAL DA30 - 11.2011

Secure the spindle on a convenient table using the

Assemble spindle ring and heated bearing.

Spindle preparation. Figure 46

SHOP MANUAL DA30 - 11.2011

Wheel hub preparation.

Insert bearing race and cartridge seal ring.

Insert inner seal ring.

Fill the space with special grease “SKF

Wheel hub assembly.

Set the inner wheel hub half on evenly until

During this, observe that the oil seal slides

SHOP MANUAL DA30 - 11.2011

Place the O-ring into position then insert the dowel

Multiple disc assembly.

Assemble alternately coated disk with steel disk.

Spray the spindle with Wolfrakote spray.

Brake cylinder assembly.