PES01e Manutenção em Ingles

Repair and Maintenance Manual
Tandem Axle with Differential gear
PES 01
Table of contents
1 Introduction
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Using the Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Documents and technical informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.3 Photos, graphics and text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.4 Disassembly / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.7 Spare part assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.8 Work conditions and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.9 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Model description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Model list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3.1 Technical Information and Spare parts order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3.2 Position of Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Basic information for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.4 O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.5 Adjusting washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.6 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.7 Radial seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Safety-relevant components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Safety-relevant assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.2 Safety-relevant elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.4 Adhesive-coated bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.5 Adhesives for locking nuts and bolts in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.6 Flange sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Product overview
3.1 PES 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.1 Assembly modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.1 Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.2 Spring brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.3 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Technical data
4.1 Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Brake / Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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5 Maintenance
5.1 General information on maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.1 Oil control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.2 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5 Bogie housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.1 Oil control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.2 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5.3 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Wheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6.1 Oil draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6.2 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.7 Spring loaded brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7.1 Drain leak oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8 Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.8.1 Lubrication interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.8.2 Slewing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Differential
6.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3 Bonded joints and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4 Exchange Differential as complete assembly group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.5 Replace Bearings and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.5.2.1 Mount individual parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6 Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.6.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.6.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.6.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.6.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.7 Differential cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.7.4 Montage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 Axle housing
7.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.3 Bonded joints and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.4 Replace Sun gear shaft in Axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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7.4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.5 Sun gear shaft sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.5.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.6 Replace Slewing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.6.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8 Multiple brake disk
8.2 Check wear on Multiple disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.2.1 Check Multiple disk brake from vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.3 Exchange multiple disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.4 Spring brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.4.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.4.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.4.4 Park brake release on Spring brake cylinder activate / deactivate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.4.5 Exchange Spring brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.4.6 Exchange brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.4.7 Exchange Spring brake cylinder as complete assembly group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9 Tandem housing
9.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.3 Bonded joints and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9.4 Exchange Spur gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9.4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10 Wheel end
10.1 Parts overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.3 Bonded joints and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10.4 Exchange Wheel end as complete assembly group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.5 Exchange Bearing / Face seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.5.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.6 Exchange Sun gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.6.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.6.3 Setting Axial clearance of Screw plug to Planetary gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.7 Planetary gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.7.1 Part overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10.7.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10.7.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10.7.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
11 Modifications
12/2015 - v1.0 3
12 Special tools
12.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12/2015 - v1.0 4
1 Introduction
1.1 General information
1 Introduction
At the time of public, the content of this manual is up to
date. NAF reserves the right to modify and develop fur-
ther the products to keep it up to date of technology and
to change repair and maintenance manuals as well as
service manuals without notice.
Repair and maintenance manuals from NAF are corrent
valid for several products and do not always corrospond-
ent to the exact delivered product.
1.1.1 Using the Instructions

These Instructions are designed for use solely with the
PLG Planetary Gear Drive and provides information
about assembly, disassembly, adjustment and mainte-
nance.
If you consistently follow our instructions
you will ensure a long service life for the entire drive unit
and the individual components.
Omissions in maintenance or incorrect handling lead to
an increased safety risk, premature wear and reduced
performance.
Use our many years of experience and our latest findings
for this drive unit to ensure our products consistently
perform well.
Make sure you read these Instructions carefully before
starting on any repair so that you have all the information
necessary for performing a correct repair.
If the drive unit is to be converted or modified with other
components, please obtain separate conversion instruc-
tions from the machine manufacturer.
All directions given here, e.g. right, left, up and down, are
always based on the direction of travel of the machine. In
the case of drive units that can travel in both directions,
this will be pointed out specifically in the text.
1.1.2 Documents and technical informations

Repair an Maintenance Manuals describes operations,
that must be complete by documents in Form of a tech-
nical Information.All documents which are required for
operations, are available in a Service-Portal under
www.nafaxles.com.
1.1.3 Photos, graphics and text

In order to provide additional support for repair work,
the individual steps are described with text and pictures
to ensure complete and safe repairs.
Photos and graphics are kept neutral and do not always
correspond to the exact design of the delivered drive
unit.
The pictures and illustrations shown should not be con-
sidered accurate representations of dimensions and
weights.
Our texts relating to photos and graphics are brief sum-
maries.
Bearings and threads are only illustrated schematically in
our graphics.
12/2015 - V1.1 5
1 Introduction
1.1.4 Disassembly / Assembly

These repair instructions, and our drive units, are broken
down into assemblies and sub-assemblies. The repairs to
be performed on the individual assemblies are broken
down into the themes of disassembly and assembly.
The operations in our repair instructions are always de-
scribed in terms of the disassembled drive unit.
Please refer to the instructions of the vehicle manufactur-
er to find out how our drive unit can be removed from
the vehicle.
1.1.5 Warranty
If the drive unit is subsequently changed or modified
during the warranty period, all warranty claims shall be-
come void. In respect of safety-relevant assemblies (e.g.
shifting cylinder, steering cylinder, spring brake cylinder
etc.) we strongly recommend the replacement of the
complete assembly.
If safety-relevant assemblies are subsequently modified
or disassembled, all warranty and liability claims shall be-
come void, i.e. NAF shall accept no product liability for
the drive unit.
1.1.6 Spare parts

Use NAF original spare parts only!
The use of parts from other manufacturers or reproduc-
tion parts shall render void all warranty claims and may
lead to a reduction in performance, an increased safety
risk and premature wear to the drive unit.
NAF original spare parts can only be ordered from your
machine manufacturer and not from NAF itself.
In order to avoid the supply of incorrect parts and errors,
please always state the exact type designation, serial
number and year of manufacture when ordering spare
parts. You will find the necessary details on the name-
plate of the drive unit (see section Nameplate). This infor-
mation is very important when ordering spare parts as
our parts are constantly being optimised and enhanced.
1.1.7 Spare part assemblies

NAF original spare part assemblies have been configured
with the correct settings at the factory and do not need
to be adjusted subsequently. In the event of significant
damage, we always recommend replacement of the
complete assembly. This generally results in a big saving
in terms of time and complex setting procedures.
12/2015 - V1.1 6
1 Introduction
1.1.8 Work conditions and tools

Our drive units may only be inspected and repaired by
qualified personnel.
In order to perform repairs to the drive unit properly, it is
essential to have a clean workplace with sufficient illumi-
nation.
It must be ensured that the replacement parts are always
to hand in an orderly fashion and that sufficient space is
available.
In addition to standard tools, other special tools from
NAF are employed to be able to perform assembly/disas-
sembly procedures in accordance with instructions. Use
of these special tools is recommended.
1.1.9 Symbols
These Instructions contain symbols for ease of under-
standing.
Symbol Meaning Description

This symbol indicates important information for assembly/dis-
Information
assembly of the drive unit.
This symbol indicates a risk of injury from a source of hazard.
Danger
This symbol indicates materials that must not escape into the
Environment environment and must be disposed of in accordance with reg-
ulations.
Bond connecting element with This symbol indicates that specific connecting elements must
adhesive be bonded with Loctite® adhesive.
This symbol indicates that a particular component must be
Heat
heated before installation.
This symbol indicates the use of a special NAF tool that has
Special tool been developed for the assembly/disassembly of compo-
nents.
This symbol indicates that there is additional information else-
See index
where in these Instructions.
This symbol indicates components that must be lubricated
Lubricate
with grease.
This symbol indicates that adhesive-coated bolts with Verbus
Coated bolts
plus® locking agent must be used.
This symbol indicates that a particular dimension must be
Measure
measured.
Pay attention to direction of This symbol indicates that components may only be installed
installation in one direction.
This symbol indicates that components must be libricate with
Lubricate with oil
oil.
12/2015 - V1.1 7
1.2 Model identification

NAF describes in this repair and maintenance manual the
replacement of bearings and seals as well as the overhaul
of separate assemblies.
This repair and maintenance manual is also valid for
types are listed in the table below.
1.2.1 Model description
TA P 5 4 0 3 . X X X
Model description Sequential number
Tandem axle Installation drawing
4. Code
1. Code Gear ratio external
Rim size/ Planetary drive
Pitch circle diameter
3. Code
2. Code Gear ratio internally
Size code Differential Planetary drive
Ø Crown wheel
1.2.2 Model list

Code Gear ratio Model
Axle type Differential
1 2 3 4
MOX 21 335 mm 5.33 2.333 LAP 5503.139
12/2015 - V1.1 8
1.2.3 Type plate
1.2.3.1 Technical Information and Spare parts

order
The nameplate contains important information that
must be stated when ordering spare parts from the ma-
chine manufacturer.
1.2.3.2 Position of Type plate
Neunkirchener Achsenfabrik AG 3
1 Made in Germany
91077 Neunkirchen am Brand / Germany 4

2
Tel:+49-9134-702-0
www.nafaxles.com
Pos. Description
1 Type
2 Serial number
3 Year of manufacturing
4 Part number machine manufacturer
12/2015 - V1.1 9
1.3 Basic information for repairs

Make sure you read our recommendations below care-
fully before starting on any repair work.
1.3.1 General
We recommend that the affected bearings and seals are
completely replaced during any repair activity in order to
ensure a long service life for the drive unit.
Always replace damaged parts with NAF original parts.
Before reassembly we recommend that the seals on ro-
tating parts are renewed.
1.3.2 Oil
Always drain the oil before any repair operation.
Ensure environmentally friendly disposal of used oil.
1.3.3 Cleaning
Remove major impurities before any repair or oil change.
Clean all parts before assembly with a suitable cleaning
agent. Make sure that parts are not scratched.
All parts in the drive unit should be coated with an oil film
to give long-term protection against corrosion.
1.3.4 O-rings
Before assembly O-rings and their installation space
must be properly cleaned. Foreign particles in the groove
can damage the O-ring and lead to leaks. Rolling over
sharp edges, threads or grooves should be avoided so as
not to damage the O-ring.
Special NAF tools facilitate the fitting of O-rings.
It is also helpful to lightly grease or oil the O-ring before
fitting.
1.3.5 Adjusting washers

Please use our shim kit for individual adjustments in the
drive unit. Always measure each individual shim/washer
before use.
1.3.6 Bearings
When installing bearings on a shaft we recommend they
are heated to a temperature of max. 120°C; when install-
ing in a drilled hole, cool the bearing (freezing compart-
ment). The free spaces in the bearings should then be 30-
50% filled with the the greases specified by us.
For easier assembly, lightly oil the seats of the bearing
rings.
Suitably designed extractors should be used for removal
of the bearings.
Before bearings are installed, they and their installation
spaces should be cleaned, checked and lubricated.
12/2015 - V1.1 10
1.3.7 Radial seals

Before assembly radial rings and their installation space
must be properly cleaned.
When pressing in the radial seals, always use the special
tools developed by NAF.
Never run radial seals when dry!
When assembling, therefore lightly grease or oil the shaft
and radial seal.
Radial seals have a specific direction of installation and
must be installed only in this direction.
In terms of direction of installation there is a differentia-
tion between oil side and air side.
12/2015 - V1.1 11
2 Safety
2 Safety
All NAF drive units meet the safety requirements laid
down in the EC Machinery Directive and have CE certifi-
cation in the form of a Declaration of Incorporation.
The use of spare parts that do not come from NAF and
have not been checked and approved by NAF may ad-
versely affect the design characteristics of the drive unit
and actively endanger your safety and the safety of the
machine.
Our products have been developed, designed and built
according to the state of the art and are therefore opera-
tionally safe.
There may be risks from our products if installed incor-
rectly by untrained personnel or if they are not used as in-
tended.
Warning!
Danger to life and limb if used incorrectly or other
than for the intended purpose.
Warning!
There is a risk to the product if used incorrectly or
other than for the intended purpose.
NAF rejects liability for any loss or damage occurring as a
result of unauthorised modifications to the drive unit,
e.g. non-permitted tyre sizes, non-NAF-original spare
parts or parts from other NAF drive units that have not
been approved by NAF.
If problems arise that are not dealt with in these repair in-
structions, always consult the machine manufacturer for
reasons of safety.
2.1.1 Safety information
Work clothing
Please ensure that appropriate work clothing and safety
equipment is worn for the particular repair operation.
Warning!
Wear appropriate protective and safety equip-
ment, e.g. safety goggles, safety gauntlets and
non-slip safety footwear, when performing re-
pairs on the drive unit.
Severe injury can result from insufficient protec-
tive and safety equipment.
Liquids
Skin contact with the liquids contained in the drive unit
should be avoided.
Environment
The lubricants used in our drive units require spe-
cial disposal and must not be released into the en-
vironment.
12/2015 - V1.1 12
2 Safety
Before the repair

Before any repair it must be ensured that the drive unit is
free from dirt and oil. This makes the repair work easier.
Some repairs can take place without the drive unit being
removed from the machine. The machine must then be
secured sufficiently to prevent it rolling.
The drive unit must be secured sufficiently during disas-
sembly and assembly. Complete assemblies should only
be assembled and disassembled using special lifting
gear.
Warning!
Always ensure drive unit and machine are secured
sufficiently. Serious injuries can be caused by un-
secured parts.
• Put on machine handbrake and use chocks to
prevent machine rolling.
• Secure and move drive unit with special lifting
equipment, e.g. jacks, cranes etc.
After the repair

After all repairs it should be ensured that the drive unit is
free from oil and other contaminants in order to prevent
damage to the environment.
12/2015 - V1.1 13
2 Safety
2.2 Safety-relevant components

2.2.1 Safety-relevant assemblies
Assemblies that are designated as safety-relevant in-
clude e.g. spring brake cylinders, shifting cylinders, steer-
ing cylinders etc. These assemblies must not be opened
or modified during the entire warranty period as this can
affect the safety of the overall machine. These compo-
nents may only be replaced as a complete unit.
2.2.2 Safety-relevant elements

Elements that are designated as safety-relevant include
e.g. adhesive-coated bolts, surface seals etc.
In order to maintain the securing effect specified by us,
these elements must be renewed after every repair.
2.2.3 Cleaning
The affected surfaces on which an adhesive coating or
sealing compound is applied should be free of dirt, oil
and preservatives.
2.2.4 Adhesive-coated bolts

Adhesive-coated bolts have a special securing effect.
They may not be reused and must be renewed after un-
doing. The securing affect of the adhesive no longer ex-
ists once these bolts have been used.
2.2.5 Adhesives for locking nuts and bolts in

place
Screw connections to components where high stresses
occur or a high level of safety is specified are additionally
provided with a special "threadlocker" adhesive.
To ensure that the adhesive remains effective, the ele-
ment to be joined should have reached its final position
within five minutes.
Connecting elements, such as nuts and bolts, that are ad-
ditionally bonded have a hardening period of 24 hours.
The relevant elements must not be placed under load
during this period.
Classification
Several factors need to be taken into account when
choosing the threadlocker. An extremely important fac-
tor is the required strength of the threadlocker.
Threadlockers come in three strength classes:
Low strength: easy disassembly with standard hand

tools.
Medium strength: disassembly with standard hand tools.
High strength: difficult disassembly with standard hand
tools; heat area locally (>250°)
Application
For optimal adhesion the threadlocker should always be
applied to the entire length and circumference of the
thread.
12/2015 - V1.1 14
2 Safety
2.2.6 Flange sealants

Components such as spring brake cylinders or portal
housings are additionally sealed/bonded with flange
sealant.
Flange sealants have a hardening time of approx. 6 hours
and must not be placed under load during this time.
Application
For optimal sealing, the strand thickness of the flange
sealant should be 2-3 mm.
Then apply the flange sealant evenly to the contour of
the flange to be joined.
12/2015 - V1.1 15
3 Product overview
3.1 PES 01
3 Product overview
3.1PES 01
3.1.1 Assembly modules
2
4
5
3
Pos. Assembly modul
1 Differential
2 Axle housing
3 Bogie housing
4 Wheel end
5 Spring brake cylinder
12/2015 - V1.1 16
3 Product overview
3.1 PES 01
3.1.2 Connections
3.1.2.1 Differential lock
Pos. Description Comment
On: 20 – 35 bar Mineral oil

1 Connection for Differential lock
Off: by Spring force
12/2015 - V1.1 17
3 Product overview
3.1 PES 01
3.1.2.2 Spring brake cylinder
Pos. Description Comment
1 Connection for Service brake at braking pressure 70 bar Mineral oil
min. 30 bar
2 Connection for Parking brake
max. allowed 80 bar
3 Bleeding plugs
12/2015 - V1.1 18
3 Product overview
3.1 PES 01
3.1.3 Description of function
Pos. Description Function
1 Cardan flange The Cardan flange takes the output torque of the Cardan shaft and will
be transmitted to the pinion shaft.
2 Differential cage The Differential cage takes the force from the crown wheel and will be
transmitted constant to the both Sun gear shafts. At curve runs, different
rotation speeds will be compensate.
3 Differential lock The force will be transmitted to all Wheel ends without compensating
the rotation speed if Differential lock is on.
4 Spring brake cylinder The spring brake cylinder is controlled hydraulically and operate as Park-
ing and Service brake the multi disc brake.
5 Multi disc brake Firstly the Multi disc brake prevents the vehicle from rolling at idle state,
on the other hand, by actuating the brake while driving, the rotation
speed on the Sun gear shafts will be reduced.
6 Planetentrieb The Planetary gear drive translate the force of the Sun gear shaft in order
to achieve a high torque and take it to the Wheel end.
12/2015 - V1.1 19
4 Technical data
4.1 Basic information
4 Technical data
At delivery axle is filled with oil. Take care during the
transport.
A0 A0
L2
A0 A0
HA
S1 S2
L1
4.1 Basic information
Description
VA Direction of rotation of the cardan flange and direction of

Direction of travel and rotation
HA
travel of the drive unit.
S1/S2 S1 side and S2 side
A0 Description of wheel end
4.2 Dimension
Description
L1 1869mm
L2 1300mm
Weight 1430kg (with oil)
12/2015 - v1.1 20
4 Technical data
4.3 Gear ratio
4.3 Gear ratio

Description
Differential 2,333
Tandem housing 1,59
Planetary gear drive 5,33
4.4 Brake / Differential lock

Description
Service- / Park brake hydraulic control
Differential lock hydraulic control
12/2015 - v1.1 21
5 Maintenance
5.1 General information on maintenance intervals
5 Maintenance
5.1 General information on maintenance in-
tervals
NAF drive units are developed and built on the basis of
many years of experience and knowledge of the de-
mands of working machinery.
However, problem-free functioning and consistent oper-
ational readiness depend on the drive units being treat-
ed with care and attention and regularly maintained.
This includes compliance with the maintenance inter-
vals, use of the lubricants specified by us in the lubricants
table and monitoring of the maintenance points.
Warning!
Maintenance work can be performed only, if the
machine is stopped or the drive unit is removed
from vehicle.
–Secure machine to prevent it rolling.
–Activate parking brake
Environment
Used lubricants require special disposal an must
not be released into the environment.
–Fill used lubricants in container, store and dis-
pose used lubricants correct.
Cleaning
At cleaning oil and other lubricants must not be
into the environment.
–Clean drive unit only at allowed cleaning places.
12/2015 - v1.1 22
5 Maintenance
5.2 Maintenance table
5.2 Maintenance table

General Maintenance work Maintenance intervals in operating hours
After the firs All
Before putting into Service
Annually or every 2000
As required
Daily
50 100 500 100 250 500 1000
Differential
Differential First filling
Oil level Control
Oil Change
Bogie housing
Bogie housing First filling
Oil level Control
Oil Change
Planetentrieb
Planetentrieb First filling
Oil level Control
Oil Change
Wheel nuts Control
Visual check
Visible nuts and bolts Control
Visible nuts and bolts Tighten
Leak tightness Face Control
seals at Wheel end
Seals Control
Bake
Spring loaded brake Clean*
cylinder and environ-
ment
Leak oil from Spring Drain
loaded brake cylinder
Breather at Spring Control
loaded brake cylinder
Wear at multiple disc Control
kit
Drive unit
Clean*
*Clean drive unit only at washing area.
12/2015 - v1.1 23
5 Maintenance
5.3 Maintenance points
1
2
Pos. Description
1 Oil filling plug Differential + Axle housing
2 Oil drain plug Differential + Axle housing
3 Oil dip stick
4 Spring brake cylinder
12/2015 - v1.1 24
5 Maintenance
3
5
2
4 Position „A“ Position „B“
4
2
5
3
Pos. Description
1 Oil filling plug Bogie housing
2 Oil drain plug Bogie housing
3 Residual oil drain plug Bogie housing
4 Oil drain plug Wheel end
5 Oil filling plug Wheel end
12/2015 - v1.1 25
5 Maintenance
5.3.1 Lubricant table
General information
At oil change, for the second filling it needs less oil than
for the first filling, because there is still remain oil quanti-
ty in the drive unit after oil drain.
Capacities given are approximate - work to oil dipstick/
oil control hole!
Too less oil in the drive unit may result in damage an loss
of efficiency.
Too much oil may result in damage in seals and breath-
ers.
Axle type Section Fill quantity Lubricant Viscosity Comment

classes/
SAE classes
Differential 11,6 Litre* LS Gear oil 85W-90 API GL5
Bogie housing 28,5 Litre* EP Gear oil** W90
Planetary gear
PES 01 6 Litre* EP Gear oil** W90
drive
Lithium saponified consistency

Brand EP
Slewing ring N/A class 2, water-resistance (DIN
Grease
51825)
* Fill quantity at first oil filling

**LS Gear Oil allowed
Fill quantity after first oil filling ±5%
12/2015 - v1.1 26
5 Maintenance
5.4 Differential
5.4 Differential
3
1
5.4.1 Oil control

– Park machine on horizontal underground.
– Clean the environment of the oil dip stick (1).
– Check oil level via oil dip stick (1).
The oil must be on the specified area on the oil dip stick.
If the oil level is too high or to low, oil must be filled or drain.
max
min
5.4.2 Oil drain

– Clean the environment of Screw plugs (2), (3) and (4).
– Unscrew screw plug (3).
– Unscrew screw plug (2) and drain oil completely from
Differential / Axle housing.
– Clean screw plugs (1) and (2) and screw in with Seal ring
(5) into Differential.
5.4.3 Oil filling

– Clean the environment of Screw plug (4).
– Fill Differential / Axle housing with oil.
– Control oil level.
– Clean screw plug (4) and screw in with Seal ring (5) into
Differential.
12/2015 - v1.1 27
5 Maintenance
5.5 Bogie housing
5.5 Bogie housing
2
5
5.5.1 Oil control

– Clean the environment of Screw plug (2).
– Unscrew Oil control plug and control oil level.
The oil level (6) must be on the control hole.
6 If necessary, refill oil.
– Clean Screw plug (2) and screw in with Seal ring (4) into
Bogie housing.
5.5.2 Oil drain

– Clean the environment of the screw plugs (3) and (4).
– Unscrew screw plug (2) and drain oil completely from
tandem housing.
Oil from area A can be used again.
3 A – Unscrew screw plug (4) and drain residual oil from Tan-
dem housing.
4
Oil from area B can be not used again and must be dispose
properly.
B
– Clean screw plug (4) and screw in with seal ring (5) into
Tandem housing.
– Clean screw plug (3) and screw in with seal ring (5) into
Tandem housing.
12/2015 - v1.1 28
5 Maintenance
5.5 Bogie housing
5.5.3 Oil filling

– Clean the environment of the screw plug (1) and (2).
– Unscrew screw plugs (1) and (2).
– Fill tandem housing with oil. See lubricant table.
– Control oil level.
– Clean screw plug (1) and (2) and screw with seal ring (5)
into Tandem housing.
12/2015 - v1.1 29
5 Maintenance
5.6 Wheel end
5.6 Wheel end

5.6.1 Oil draining
– Bring planetary drive in oil drain position.
The screw plug (1) must be positioned vertical to the plane-
tary drive.
– Clean environment of screw plugs (1) and (2).
– Unscrew screw plug (1) and (2) and drain oil completely
from Wheel end.
– Clean screw plugs (1) and (2) and screw with seal ring
2
3 (3) into Wheel end.
5.6.2 Oil filling

– Bring Wheel end in oil filling position.
– Clean environment of screw plug (2).
2 – Unscrew screw plug (2).
– Fill planetary drive with oil. See lubricant table.
– Clean screw plug (2) and screw with seal ring (3) into
Wheel end.
12/2015 - v1.1 30
5 Maintenance
5.7 Spring loaded brake cylinder
5.7 Spring loaded brake cylinder
General Information
Accumulated oil in the spring loaded section of the cylin-
der must be drained at regular intervals to maintain
proper function of the cylinder.
Rapidly accumulating oil will pass through the breather
externally indicating seal failure. The breather needs to
be kept clear of contamination regularly.
Information!
With accumulated oil in the spring loaded cylin-
der, the operation of the cylinder becomes slug-
gish
Brake may not release correctly.
–Drain accumulated oil from the spring loaded
cylinder.
–Check cylinder regularly, according the service
table.
Information!
Rapidly escaping oil from the breather indicates
fault oil seal (faulty state of spring loaded brake
cylinder).
Seals are damaged.
–Exchange spring loaded brake cylinder as com-
plete assembly.
Environment!
Escaping oil from the breather.
Oil reaching the soil and may contaminate
groundwater.
–Drain leak oil regularly from spring loaded brake
cylinder.
5.7.1 Drain leak oil

– Position drain pan under spring loaded cylinder.
– Remove plug (1) from bottom of cylinder.
– Let oil completely.
– Reinstall drain plug (1) and lightly tighten.
12/2015 - v1.1 31
5 Maintenance
5.8 Lubrication plan
Description
1 Slewing ring
5.8.1 Lubrication interval

Operating hours
Section Comment
50 100 250 500 1000 20000
1 Slewing ring
12/2015 - v1.1 32
5 Maintenance
5.8.2 Slewing ring

The Slewing ring is divided in 4 sections. Every section
must be lubricate separate.
Use the listed lubricants from this manual. It is not al-
lowed to use any other lubricants.
Screw plug for grease discharge
Section 1
Tapered lube nipple Section 2
Tapered lube nipple
Section 4
Section 3
Screw plug for grease discharge
– Clean slewing ring

1 – Remove plugs from lubricating points.
– Unscrew screw plug (1) and lubricate section on ta-
pered lube nipple (2).
Lubricate section until the old lubrication is completely
caved.
– Lubricate opposite section on tapered lube nipple (3).

1 Lubricate section until the old lubrication is completely
caved.
– Screw screw plug (1) on slewing ring.
12/2015 - v1.1 33
5 Maintenance

– Lubricate section on tapered lube nipple (3).
3 caved.
– Lubricate opposite section on tapered lube nipple (2).

caved.
– Screw screw plug (4) on slewing ring.
– Install all plugs on slewing ring.
12/2015 - v1.1 34
6 Differential
6.1 Parts overview
6 Differential
6.1 Parts overview
2
3
4 24
18 32
5 17 22 23 31
21
6
16
20
19 28
26
25
27
29
7
8 39 30
9
38
37
40 36
35
34
33
41
12 11
13
15 14
10 9 8 7
1 - Shifting rod 11- O-ring 21 - Adjusting kit 31 - Hexagon bolt

2 - Shifting fork 12 - Tapered roller bearing 22 - Tapered roller bearing 32 - Washer
3 - Adjusting kit 13 - Oil seal 23 - O-ring 33 - Hexagon nut
4 - Compression spring 14 - Cardan flange 24 - Tapered roller bearing 34 - Shifting lever
5 - Shifting sleeve 15 - Nut 25 - Seal ring 35 - Piston
6 - Nut 16 - Differential housing 26 - Screw plug 36 - Piston packing
7 - Hexagon bolt 17 - Seal ring 27 - Crown wheel / pinion 37 - Lip seal
8 - Locking plate 18 - Screw plug 28 - Dowel pin 38 - Cylinder
9 - O-ring 19 - Spacer bushing 29 - Differential cage 39 - Seal ring
10 - Flange 20 - Adjusting kit 30 - Tapered roller bearing 40 - Allen screw
41 - Groove nut
12/2015 - V1.1 35
6 Differential
6.2 General Information
In the event of serious damage, always replace the com-

plete Differential instead of repairing it.
In order to be able to perform repairs on the Differential,
we recommend removing the complete drive unit from
the machine.
Prepare drive unit for expanding:
–Drain oil from the area Differential/Axle housing.

See chapter Maintenance; Differential.
–Unscrew Cardan flange from Drive shaft.
–Unscrew Hydraulic lines from Spring loaded cyl-
inder.
–Unscrew Hydraulic lines from Differential lock.
–Emergency Spring loaded cylinder. See chapter
Axle housing; Spring loaded brake cylinder.
Information!
Drive unit can be moved, if tyres are mounted and
the park brake release is activated.
–Park machine on horizontal underground.
–Secure machine with chocks to prevent rolling.
–Remove drive unit from machine.
–Remove chocks and move drive unit.
Attention!
Drive unit may unexpectedly start to move, if it is
not on a horizontal underground, park brake re-
lease is activated and tyres are mounted.
–Remove Drive unit only on a horizontal under-
ground.
–Use chocks to prevent rolling.
12/2015 - V1.1 36
6 Differential
6.3 Bonded joints and Seals
Ref. Product Description Using Strength
A Loctite® 639 Threaded connection Screws and nuts on defeat High

devices, screws for Crown wheel
mounting, Spacer bushing in
Tandem housing
B Loctite® 542 Thread seal Cylinder in Differential lock, Limit

switch, Speed sensor, Elbow
C Verbus Plus® Anti rotation lock Screws and nuts Normal
12/2015 - V1.1 37
6 Differential
6.4 Exchange Differential as complete assembly group
6.4 Exchange Differential as complete as-

sembly group
In order to be able to perform repairs on the Differential,
the drive unit must be removed from the machine.
6.4.1 Disassembly
– Support drive unit with suitable Jacks.
– Drain oil from Differential / Axle housing. See chapter
Maintenance.
– Store drive unit on a horizontal underground.
– Support drive unit with a suitable additive.
– Secure Axle half with conveyors and a suitable lifting
device.
– Balance Axle half on conveyors with a pulley into a hori-
zontal position.
– Remove Axle half.
Attention!
High weight when drive unit is filled with oil.
Serious injury by lifting drive unit with improper
conveyors.
–Check weight of drive unit. See chapter Technical
1 Information.
–Check loading capacity of conveyors.
– Remove Axle half by loosen Hexagon bolts (1).

1
12/2015 - V1.1 38
6 Differential
– Screw in 2 Ring bolts M18x2 (1).
– Place Drive unit on the Wheel ends.

– Secure Differential with conveyors.
– Support Drive unit with a jack (arrow).
– Loosen Hexagon bolt (1).
12/2015 - V1.1 39
6 Differential
– Remove Differential with a suitable lifting device.
12/2015 - V1.1 40
6 Differential
6.4.2 Assembly
Determine Adjusting washer on Sun gear shaft
Axial clearance (s)= 0.7–1.2 mm
1 Sun gear shaft
2 Clamping sleeve
3 Adjusting kit
– Insert Dowel pins (1) on both sides at Differential hous-

ing.
– Install O-rings (2) on both sides on Differential housing.
Oil o-rings.
– Put Differential with a suitable lifting device on Axle
housing.
12/2015 - V1.1 41
6 Differential
– Tighten Differential on Axle housing with Hexagon

bolts (1).
1 Differential will be tighten with different screw length on

Axle housings.
Nr. Part Nm
2
1 Hexagon bolt M18x2x60 455 +35
– Measure distance X1 and record.

X1

X2
12/2015 - V1.1 42
6 Differential
– Measure distance X3 on the second Axle half and re-

cord.
– Measure pin length X4 and record.

Calculate washer thickness (s):
–
s = X1 – X2 – X3 – X4 – 1
– Insert Clamping sleeve (3) into Sun gear shaft.

– Select Adjusting washer with calculate thickness before
and mount with pin (1) to clamping sleeve (3).
3
2
1
– Place drive unit with a suitable lifting device on a jack

(1).
12/2015 - V1.1 43
6 Differential
– Mount second Axle half with a suitable lifting device to

Differential. If necessary balance axle half with a pulley
into a horizontal position.
Differential will be tighten with different screw length on

Axle housings.
1
2 Nr. Part Nm
– Fill Differential and Axle housing with oil. See chapter

Maintenance.
12/2015 - V1.1 44
6 Differential
6.5 Replace Bearings and Seals

6.5.1 Disassembly
– Remove Differential. See chapter Exchange Differential
as complete assembly.
– Heat Nut (1) to 100°C with a welding torch.
Indication of the correct temperature is, if the Loctite be-
gins to vaporise.
– Unscrew Nut (1) with an impact wrench in one step.
Support Cardan flange (2).
Information!
Interrupt of the screw operation.
2 Nut is clamping.
1
–Unscrew nut in one step from shaft.
– Remove radial seal ring (1).
– Unscrew plate (1).

2 – Unscrew Nut (2) 2 - 3 rotations.
– Remove O-ring(2).
1
– Unscrew Flange (1).
12/2015 - V1.1 45
6 Differential
– Remove Differential cage.

– Remove Differential lock. See chapter Differential lock.
– Remove pinion (1).
– Remove Tapered roller bearing (1), Spacer bushing (2)

and Adjusting washer (3).
3
2
1
– Remove bearing shell (1).
12/2015 - V1.1 46
6 Differential
– Remove Bearing shell (1) and Adjusting washer (2).
– Remove O-ring (1).
– Unscrew plate (1).

– Mark position of nut (2).
– Screw in Nut (1) to Differential housing until the bear-
2 ing shell can be removed.
– Turn Nut (2) back to initial position.
12/2015 - V1.1 47
6 Differential
– Mark the position of the nut (1).

1 – Screw in Nut (1) to Differential housing until the bear-
ing shell can be removed.
– Turn Nut (2) back to initial position.
2
– Remove Tapered roller bearing (1) and O-ring (2).
2
1
2
1
12/2015 - V1.1 48
6 Differential
6.5.2 Assembly
6.5.2.1 Mount individual parts
Calculate position of pinion
Fitting dimension Le
engraved here
Centre of Differential
Le
Lr
L1 21
s
L2
Description Dimension (in mm)
Le Distance between centre of Differential an face of pinion head (engraved)
Lr Height of head of Pinion shaft 42.43 ±0,03
L1 Thickness of Tapered roller bearing
L2 Dimension between contact surface of the adjusting washer and 147 +0,1
centre of Differential
s Thickness of Adjusting washer
The calculation of the Adjusting washer (21) determines

the contact pattern adjustment of Crown Wheel and Pin-
ion.
s = L2 – Le – Lr – L1
Example calculation:
L2 147.05 mm
Le -71.57 mm
Lr -42.45 mm
L1 -30.16 mm
s 2.87 mm
selected Adjusting washer: 2,75 mm
12/2015 - V1.1 49
6 Differential
– Insert calculating washer (1) into Differential housing.

– Fit Bearing shell (2) with special tool WZ 273 into Differ-
ential housing.
ential housing.
– Heat bearing inner ring (1) from Tapered roller bearing

(2) constant to 100°C and slide it onto the pinion shaft.
– Oil rolling elements of Tapered roller bearing.
– Insert Pinion shaft (1) into Differential housing from in-

side.
– Select adjusting washer (2) - preferably use the same
washer thickness as mounted before - and slide with
1 Spacer bushing (3) onto pinion shaft (1).
2
3
12/2015 - V1.1 50
6 Differential
– Oil rolling elements from Tapered roller bearing (1).

– Mount Tapered roller bearing (1) with special tool WZ
284 onto Pinion shaft.
– Oil O-ring (2) and fit into the groove on the Pinion shaft.
1
– Install Cardan flange (1).
1 Nr. Part Nm
2 2 Nut 800 ±80
– Rotate Cardan flange constant to align rolling ele-

ments.
– Check bearing preload with a suitable measuring tool.
Bearing preload Pinion shaft: 0.5–6 Nm
If the Bearing preload is not within the range specified by
NAF, the Bearing preload must be brought to the correct
value by changing adjusting washer.
If possible, orient to the maximum value.
– Fill 30 to 50% of the space between the two Radial seals

(1) with grease.
– Fit both Radial seals (1) with special tool WZ 682 into
Differential housing.
Information!
1
Oil loss onto Cardan flange seal.
Loss of efficiency and wear of the drive unit.
–Note installation position of the Radial seals (1).
– Insert Cardan flange (1) onto Pinion shaft.

– Wet the thread of Nut (2) with Loctite 639®.
1 – Screw down Cardan flange (1).
2 Nr. Part Nm
2 Nut 800 ±80
12/2015 - V1.1 51
6 Differential
ential housing.
Setting circumferential backlash

– Mount Crown wheel (1) with four screws (M14x40) onto
Differential cage.
1
Nr. Part Nm
2
Crown wheel onto Differential
1
cage 200 ±15
3
– Heat Tapered roller bearing to 120 °C and insert it onto
Differential cage.
– Install Tapered roller bearing (3) with special tool WZ
062.
– Oil rolling elements.
– Insert Differential cage into Differential housing.
– Mount Bearing shell (1) with special tool WZ 350 into

Flange.
– Insert and oil O-ring (2).
1
12/2015 - V1.1 52
6 Differential
– Mount Flange (1) with four screws (M18x2) onto Differ-

ential housing.
1
2
Nr. Part Nm
2 Hexagon screw 455 +35
– Measure backlash between Crown wheel and pinion

shaft with a dial gauge on Cardan flange.
Circumferential backlash: 0.15 – 0.25 mm
1
If the value for circumferential backlash is not within the
range specified by NAF, the distance between crown
wheel an pinion must be increased or decreased by turn-
ing the two nuts (1).
Setting bearing preload on Differential cage

– Remove flange.
– Remove Differential cage from Differential housing and
unscrew Crown wheel.
– Insert Differential cage without Crown wheel into Dif-
ferential housing.
12/2015 - V1.1 53
6 Differential
– Mount Flange (1) on Differential housing with four

1 2 Screws (M18x2).
Nr. Part Nm
2 Hexagon screw 455 +35
– Measure bearing preload with a suitable tool.

Bearing preload: 1.0 – 3.0 Nm
If the value for bearing preload is not within the range
specified by NAF, the bearing preload must be brought
to the correct value by turning the Nut (1).
Setting bearing preload only by turning the nut (1).

1
– Remove Differential cage.

– Fit Dowel pins (1) into Differential cage.
– Wet thread of screw with Loctite 639®.
– Mount Crown wheel (2).
1
8 5 200 +15 Nm
11 9
2
1
4 3
6 7
10 12
2
– Install Differential lock. See chapter Differential lock.

– Fit Differential cage into Differential housing.
1
– Mount Flange (2)
3 – Mount and oil O-rings (1) on both sides.
– Fit Dowel pin (3) on both sides.
Fit the long Dowel pin on the side where the flange (2)
is mounted.
12/2015 - V1.1 54
6 Differential
Check contact pattern

Information!
After each repair of adjusting on Differential cage
and / or Pinion shaft, a check of contact pattern
must be perform.
To do so:
–Remove Differential cage.
–Paint 3–4 teeth on Crown wheel (2) with marking
paint.
–Mark the range on the Differential cage (arrow).
–Install Differential cage into Differential housing.
–Screw Flange (1) with four screws M18x2.
Nr. Part Nm
1 Flange on Differential housing 455 +35
2 –Turn Differential cage from mark to mark 3–4

times.
1
– Remove Differential cage and check contact pat-
tern.
Correct contact pattern.
False contact pattern.

Change adjusting washer on the Pinion shaft bearing.
Information!
If the position of Crown wheel / Pinion is subse-
quently changed, the circumferential backlash
must be adjusted again. See chapter Setting cir-
cumferential backlash.
12/2015 - V1.1 55
6 Differential
False contact pattern.

Change adjusting washer on the Pinion shaft bearing.
Information!
If the position of Crown wheel / Pinion is subse-
quently changed, the circumferential backlash
must be adjusted again. See chapter Setting cir-
cumferential backlash.
12/2015 - V1.1 56
6 Differential
6.6 Differential lock

6.6.1 Parts overview
2
3
4
39
38
37
40 36
35
34
33
11
10
1 - Shifting rod 33 - Hexagon nut

2 - Shifting fork 34 - Shifting lever
3 - Adjusting kit 35 - Piston
4 - Compression spring 36 - Piston packing
5 - Shifting sleeve 37 - Lip seal
10 - Flange 38 - Cylinder
11 - O-ring 39 - Seal ring
12/2015 - V1.1 57
6 Differential
6.6.2 General Information

Before opening axle, it should be urgently determined if
the lock itself is damaged or external engaging compo-
nents.
Check the function of differential lock as follow:
1. Jack up vehicle, such the wheels are up from the
ground.
2. Block the cardan flange and turn a wheel.
3a. When the diff.-lock is open (no line pressure)
the opposite wheel must turn in the opposite di-
rection.
3b. When diff,-lock is engaged neither the right
nor the left wheel will turn. A small angular
movement (by the backlash) is permitted.
6.6.3 Disassembly
– Unscrew Flange (1).
– Remove Differential cage (1).
1
2
12/2015 - V1.1 58
6 Differential
– Heat Hexagon nut (1) with a welding torch until the

screw lock begins to vaporize.
– Remove Shifting lever (2) and Piston (3).
3
2
1
– Remove Lip seal (1) and Piston packing (2).
3
2 1
– Remove Piston (1) with special tool WZ 012.

– Remove Seal ring (2).
2
1
– Remove parts (1) to (4).
4
3
2
12/2015 - V1.1 59
6 Differential
6.6.4 Assembly
Information!
Before the adjusting on diff.-lock, must all adjust-
ment on crown wheel / pinion and on diff.-cage
be done.
– Install Differential cage.
1
– Screw down Flange (1).
Nr. Part Nm
– Insert Shifting fork (1) and Shifting rod (2) without Com-
pression spring and Adjusting washer until to the limit
stop into the Differential housing.
– Measure distance X1 and note.
– Insert Shifting fork and Shifting rod together with Shift-

ing sleeve into Differential housing.
Positioning Shifting sleeve so, that parts interlock.
1
– Measure distance X2 an note.
– Calculate thickness of Adjusting washer.
s = X1 – X2 + 0 5
– Remove Shifting sleeve (1), Shifting fork and Shifting

rod.
12/2015 - V1.1 60
6 Differential
– Unscrew Flange (1) and remove Differential cage.
– Insert Seal ring (2).

– Wet the thread of Cylinder (1) with Loctite 542® and
2 screw in with special tool WZ 012 into Differential
housing.
1
Nr. Part Nm
2 Cylinder 80+20
– Oil outside surface from special tool WZ 509.

– Insert Lip seal (1) and Piston packing (2) onto Sleeve (3).
5 – Insert Piston (4) into Sleeve until to the limit stop.
– Insert Lip seal (1) with Expansion mandrel (5) into the
1 groove.
3 – Pull out Piston (4) to the second groove and install Pis-
ton packing (2) with Expansion mandrel.
– Insert Piston (1) into Cylinder.
12/2015 - V1.1 61
6 Differential
– Insert Compression spring (1) with Adjusting washer

with calculated thickness before into Differential hous-
1 ing.
– Wet the thread on the Shifting rod with Loctite 639®.

– Screw down Shifting lever (1) with Hexagon nut (2).
1 Nr. Bauteil Nm
2 2 Sechskantmutter 135
– Mark position of nut (2) with a dot.
– Insert Differential cage into Differential housing and

screw down with Flange (1).
1
Nr. Part Nm
12/2015 - V1.1 62
6 Differential
6.7 Differential cage

8
7
3 4
3
1
2
1 - Differential cage
2 - Adjusting washer
3 - Differential gear
4 - Thrust washer
5 - Compensating gear
6 - Cross bolt
7 - Coupling sleeve
8 - Circlip ring
9 - Allen screw

plete differential instead of repairing it.
Special tool WZ 1597 to check Axial clearance in

Differential cage
The special tool is necessary to check axial clearance be-
tween Differential gear and Compensating gear.
3
If axial clearance is not checked, it may cause damage
into Differential cage and reduced performance of the
drive unit.
2
1
1 - Klemmbolzen
2 - Messbolzen lang
3 - Messbolzen kurz
12/2015 - V1.1 63
6 Differential
6.7.3 Disassembly
– Force out circlip ring (1).
– Unscrew upper Differential cage half.
– Remove Adjusting washer (1).

– Remove all parts from housing.
6.7.4 Montage
– Select any Adjusting washer fit into housing with
groove nut upward.
1
12/2015 - V1.1 64
6 Differential
– Mount special tool WZ 1597 (use long measuring rod).
6
6
WZ 1597
– Fit Differential gear with special tool into housing.
– Install Cross-bolt with Compensating gears (1) and

Thrust washer (2).
25
14
– Mount upper housing half with four Allen screws.

It is important to pay attention to the serial number on
1
the housing halfs. Numbers must be aligned with one
another during assembly.
Nr. Part Nm
1 Allen screw 130
12/2015 - V1.1 65
6 Differential
– Measure axial clearance.

Axial clearance 0.1 – 0.15 mm
If the axial clearance is not within the range specified by
NAF, the axial clearance must be brought to the correct
value by changing of the Adjusting washer.
– Disassemble measuring tool and mount on the second

Differential gear (use short measuring rod).
6
6
– Install Differential gear with special tool.
– Select Adjusting washer (2) and fit on Differential gear.
2
2
12/2015 - V1.1 66
6 Differential
– Insert Coupling sleeve (1).
– Screw down upper housing half with four Allen screws

(1).
2
Nr. Part Nm
1 1 Allen screwM10x80 72+5
– Secure Coupling sleeve (1) with Circlip ring (2).
– Measure axial clearance.

Axial clearance 0.1 – 0.15 mm
If the axial clearance is not within the specified range by
NAF, the axial clearance must be brought to the correct
value by changing Adjusting washer.
– Disassembly measuring tool and mount upper housing

half with Verbus plus® coated Allen screws.
Nr. Part Nm
1
1 Allen screw 72+5
Functional testing with a pliers must be carried out. The

gears must be spin smoothly.
12/2015 - V1.1 67
6 Differential
12/2015 - V1.1 68
7 Axle housing
7.1 Parts overview
7 Axle housing
7.1 Parts overview
4
6
39 10
3 11
1
9
12
2 13 14
15
25
26 6 16
17
7
8
40
28 31 21
29 20
10 18
11 22 19
23
24
27
33
29
28 28
29 32
34
30
16 35 36
37
9
29 39
28
23 31
18
38
36 20
24 37 21
1 - Sun gear shaft 11 - Detent edged ring 21 - Seal ring 31 - Wedge

2 - Seal ring 12 - Screw plug 22 - Axle housing 32 - Breather
3 - Allen screw 13 - Seal ring 23 - Spring brake cylinder 33 - Oil dip stick
4 - Plug 14 - Screw plug 24 - Allen screw 34 - Threaded stud
5 - --- 15 - Seal ring 25 - Intermediate disk 35 - Seal ring
6 - Dowel pin 16 - Breather 26 - Lined disk 36 - Detent edged ring
7 - Slewing ring 17 - Dowel pin 27 - Operating disk assembly 37 - Hexagon bolt
8 - Allen screw 18 - Oil seal 28 - Pin 38 - Axle housing
9 - O-ring 19 - Adjusting kit 29 - Toothed ring 39 - Scraper ring
10 - Hexagon bolt 20 - Washer 30 - Dowel pin 40 - Clamping sleeve
12/2015 - V1.1 69
7 Axle housing

plete Differential instead of repairing it.
In order to be able to perform repairs on Axle housing
and Multiple disk brake, the drive unit must be removed
from the vehicle.
–Drain oil completely from Drive unit. See chapter

Maintenance; Differential .
–Unscrew Hydraulic lines from Spring brake cylin-
der.
–Activate park brake release on both Spring brake
cylinders. See chapter Spring brake cylinder; Park
brake release on Spring brake cylinder activate /
deactivate.
Attention!
Drive unit may unexpectedly start to move, if
drive unit is not parked on a horizontal under-
ground, park brake release is not activated and
tyres are mounted.
–Remove Drive unit only on horizontal under-
ground from machine.
–Use chocks.
12/2015 - V1.1 70
7 Axle housing
B
A
A Verbus Plus® Anti rotation lock Screws and nuts Normal
B Loctite® 518 Sealing compound Transmission and attached parts
12/2015 - V1.1 71
7 Axle housing
7.4 Replace Sun gear shaft in Axle housing

Information!
Remove Sun gear shaft with deactivated Park
brake release.
Loss of position of the Multiple disks. Sun gear
shaft can not reinstalled.
–Deactivate Park brake release or operate Parking
brake in the machine.
7.4.1 Disassembly
– Drain oil from complete Drive unit. See chapter Mainte-
nance.
1 – Unscrew Hexagon bolts (1).
– Screw in two Hexagon bolts M10(1) into the thread

holes.
– Remove bearing pin (2).
1
– Remove Sun gear shaft (1).
12/2015 - V1.1 72
7 Axle housing
– Remove Pin (1), Adjusting washer (2) and Clamping

sleeve (3) from Sun gear shaft.
2 Parts (1)–(3) can be used again, if they are not damaged.
– Remove Shaft seal (1).

– Remove Bearing inner race (2) with a suitable tool.
– Remove residual sealing compound with a suitable
cleaner and free of oil, dirt and preservatives.
– Remove residual sealing compound on flange surface

(arrow) with a suitable cleaner and free of oil, dirt and
preservatives.
7.4.2 Assembly
– Fit Cylindrical roller bearing (1) with a suitable bushing
into Sun gear shaft.
– Oil rolling elements of Cylindrical roller bearing.
1
12/2015 - V1.1 73
7 Axle housing
– Insert Clamping sleeve (3) into Sun gear shaft.

– Insert Adjusting washer (2) and Pin (1) on Clamping
sleeve.
2

X1
– Mount Shaft seal (1).

– Heat Bearing inner race (2) on 120°C and slide onto
Bearing pin.
– Slide in Sun gear shaft (1) until to the limit stop into
Drive unit.
12/2015 - V1.1 74
7 Axle housing

– Calculate axial clearance.
s = X2 – X1
Axial clearance: 0.7–1.2 mm

X2
If the axial clearance is not within the specified range by
NAF, the axial clearance must be brought to the right val-
ue by changing the Adjusting washer on the Sun gear
shaft.
– Fit Grooved dowel pin (1) into Tandem housing.
– Apply Silicon sealing compound on flange surface.

Silicon sealing compound: Engine-Silicon Fa.
Förch®
– Assemble Bearing pin (1) with Verbus plus® coated Hex-

agon bolts.
1
Nr. Part Nm
1 Bearing pin on Tandem housing 72 +5
Information!
Install Bearing Pin with hole upside (arrow).
Hole is used to identify the oil passage.
– Fill Drive unit with oil. See chapter Maintenance.
12/2015 - V1.1 75
7 Axle housing
7.5 Sun gear shaft sealing
In order to be able to replace the Sun gear shaft in the

Axle housing, the Drive unit must not removed from the
machine if there is enough space available.
Information!
The Park brake release on the Spring brake cylin-
der must not be activated to remove the Sun gear
shaft.
Multiple disks loss the position if the Park break re-
lease is activated. Reinstall of the Sun gear shaft is
not possible in this case.
–Deactivate Park break release or operate Parking
brake.
12/2015 - V1.1 76
7 Axle housing
7.5.1 Disassembly
– Drain oil complete from Drive unit. See chapter Mainte-
nance.
– Unscrew Bearing pin (1).
2 – Remove residual sealing compound on flange surface
(arrow) with a suitable cleaner and free of oil, dirt and
1 preservatives.

– Remove Washer (2).
– Remove Oil seal (3).
3
Information!
2
1
It is important to ensure, that the compression
spring of the seals is not lost in the Axle / Tandem
housing when removing.
The compression spring may damage internal
components.
–Remove Seal ring (1) and Oil seal (1) with a suita-
ble extraction tool.
7.5.2 Assembly
– Fit Spacer ring (2) onto special tool WZ 1601.
(The Spacer ring is part of the special tool.)
3 – Oil outside surface and sealing lip from Oil seal (3) –
2 ø45xø70x10 – and fit with open side to the Differential
on special tool.
1
– Press Oil seal (1) until to the limit stop into Axle housing.
12/2015 - V1.1 77
7 Axle housing
– Oil outside surface and sealing lip from Oil seal (3) –
ø45xø70x16 – and fit with open side to the Differential,
2 without Spacer ring, on special tool WZ 1601 (3).
1 – Fit Washer (2) on special tool.
3
– Press Oil seal (1) and Washer (2) until to the limit stop
into Axle housing.
– Oil outside surface (arrow) on Sun gear shaft (1) with oil.
– Slide in Sun gear shaft careful through both Seal rings
until to the limit stop.
– Apply Silicon sealing compound on flange surface.

Silicon sealing compound: Engine-Silicon Fa.
Förch®
12/2015 - V1.1 78
7 Axle housing
– Install Bearing pin (1) with Verbus plus® coated Hexa-

gon bolts.
1
Nr. Part Nm
1 Bearing pin on Tandem housing 72 +5
Information!
Install Bearing Pin with hole upside (arrow).
Hole is used to identify the oil passage.
12/2015 - V1.1 79
7 Axle housing
7.6 Replace Slewing ring

7.6.1 Disassembly
– Drain oil complete from Drive unit. See chapter Mainte-
nance.
– Remove Drive unit from machine.
– Support drive unit with a suitable additive.
– Unscrew Slewing ring on Tandem housing.
– Secure Tandem housing with a suitable lifter.
12/2015 - V1.1 80
7 Axle housing
– Unscrew Slewing ring (1) from Tandem housing.
– Remove Tandem housing with Wheel ends.
– Positioning Axle half on Wheel ends and secure with

jack.
12/2015 - V1.1 81
7 Axle housing
– Unscrew Slewing ring (1) from Axle housing.

2
– Screw in 2 Ring screws (M18x2) into Slewing ring and

remove with a suitable lifter.
– Remove Seal ring (1) and O-ring (2).
7.6.2 Assembly
– Insert Seal ring (1) and grease the seal lip.
– Oil O-ring (2) and insert into Axle beam.
1
12/2015 - V1.1 82
7 Axle housing
– Fit Slewing ring (1) with a suitable lifter on Axle hous-

ing.
– Mount Slewing ring with Red-dot-mark on 12 o’clock
1 position (arrow).
– Install Slewing ring (1) with Verbus plus® coated Hexa-

gon screws.
1
Nr. Part Nm
1 Slewing ring on Axle housing 455 +35
– Oil outside surface (arrow) of Sun gear shaft.

– Insert Sun gear shaft (1) into Axle housing.
1
– Install Seal ring (1) with special tool WZ 129 into Tan-
dem housing and oil sealing lip.
2
– Fit Dowel pins (2).
12/2015 - V1.1 83
7 Axle housing
– Screw down Slewing ring on Tandem housing.

2
1
Nr. Part Nm
1 Allen screw M18x2x90 455 +35

1
2 Allen screw M18x2x70 455 +35
Use Verbus plus® coated Allen screws on position 1 and 2.
12/2015 - V1.1 84
12/2015 - V1.1 85

The Multiple disk brake is used, depending on the func-
tion of the equipment of the drive unit, as service brake
as well as parking brake.
The Multiple disks must be checked periodically for wear
and exchange if required.
To check wear for Multiple disks, the drive unit must not
be removed from machine, unless there is not enough
space available if:
–the wear check is made through Spring brake
cylinders.
Use Measuring tool WZ 1464.
Drive unit must be removed from machine unless there is
not enough space available if:
–the permitted limit value is reached on the meas-
uring tool and the multiple disks must be
changed.
–Drain oil from section Tandem housing / Wheel

end. See chapter Maintenance; Tandem housing.
–Unscrew Drive shaft from Cardan flange.
–Unscrew Hydraulic lines from Spring brake cylin-
der.
–Activate Park brake release of Spring brake cylin-
der. See chapter Spring brake cylinder; Park brake
release on Spring brake cylinder activate / deacti-
vate.
To remove Drive unit from machine, see additional infor-
mations from machine manufacturer.
12/2015 - V1.1 86
8.2 Check wear on Multiple disks

– Clean cover.
– Unscrew cover from Spring loaded brake cylinder.
– Install measuring tool WZ 1464 on spring loaded brake

cylinder.
– Push measuring rod into the spring loaded brake cylin-

der.
If the green section on the wear tool is visible, the brake

disks are OK and must not be changed.
12/2015 - V1.1 87
If the green section is not visible any more, the brake

disks are worn and need to be replaced.
Attention!
Danger to limb and life if Multiple disks are not
checked regularly.
–Note maintenance table.
– Screw down cover on Spring brake cylinder.
– Exchange Multiple disks if necessary.
8.2.1 Check Multiple disk brake from vehicle

– Start up machine in second gear with brake activated.
If the vehicle moves, the brake disks are worn or there is
another problem.
12/2015 - V1.1 88
8.3 Exchange multiple disks
Disassembly
– Drain oil from section Differential / Axle housing. See
chapter Maintenance, Differential.
– Unscrew Axle half from Differential. See chapter Differ-
ential, Exchange Differential as complete assembly.
– Activate Park brake release and remove from Dive unit.
See chapter Spring loaded brake cylinder.
Attention!
Danger to limb and life by exploding parts. Spring
brake cylinder is under high pressure.
–Remove Spring brake cylinder. See chapter
Spring brake cylinder.
– Remove Toothed rings (1).
– Remove Multiple disk kit (1) and Operating disk assem-

bly (2).
2
Assembly
– Insert alternate 3 Steel disks (1) and 3 Lined disks into
Axle housing.
Start with Steel disk.
12/2015 - V1.1 89
Fit the first both Steel (1) disks each offset through 90°
into Axle housing.
Insert third Steel disk so that the Operating disk can snap
into the Steel disk later.
– Insert Operating disk assembly (1).

Position Operating disk assembly (1) to mate with the
wedge of Spring brake cylinder.
– Insert alternate 3 Steel disks (2) and 3 Lined disks (1)

into Axle housing.
Start with Lined disk (1).
Insert the first Steel disk so that the Operating disk can
snap into it.
Fit the last both Steel disks (1) each offset through 90°
into Axle housing.
– Fit Toothed rings (3).
– Install Axle half on Differential. See chapter Differential,
Exchange Differential as complete assembly.
– Install Spring brake cylinder. See chapter Spring brake
cylinder.
Information!
Activate Park brake release on Spring brake cylin-
der only if Axle housing is installed on Differential.
– Fill oil to Differential and Axle housing. See chapter
Maintenance; Differential.
12/2015 - V1.1 90
8.4 Spring brake cylinder

3
5
4
2
4
1
1 - Brake cylinder (Lower part)

2 - Spring loaded (Upper part)
3 - Park brake release
4 - Bleeding valve
5 - Breather
12/2015 - V1.1 91
8.4.2 Technical Data

At NAF drive units, there are two different sizes of multi
discs available. Which size is mounted in the drive unit,
can be read on the installation drawing.
The size of the multi disc can be determined from the dif-
ferential size.
Depending on Differential size, there is a distinction be-
tween Mono-Servo-Brake and Multi-Servo-Brake. There-
by the possibility’s result in the disc pack.
The size of the Brake will be determined on the Differen-
tial size.
Example of an Installation drawing:
P TA 5 6 0 0 . 1 1 4
Model description Drawing number
4. Code
1. Code
3. Code
2. Code
Differential size
Spring loaded brake cylinder
Brake Differential size Clearance Piston stroke
Multi-Servo Mono-Servo 4 5 6 7 8 2.2 mm 2.9mm
6.5“ 5.25 mm
6.5“ 5.25 mm
8.75“ 5.25 mm
12/2015 - V1.1 92

Spring brake cylinders are divided into three sub-assem-
blies: Lower part, Upper part and Park brake release.
Spring load brake cylinders must be exchanged as com-
plete assembly or one of sub assembly can be changed.
At Spare part order the complete Spring brake cylinder
must be ordered or the sub-assembly that will be re-
placed must be ordered.
Single parts are not available.
At spare parts order the Park brake release on Spring
brake cylinder is activated and must be deactivated after
the operation.
– Mount Spring brake cylinders mirror reversed.
– Mount Breather at top position.
To do so:
– Unscrew Screw plug (2).
– Screw in Breather at top position into Spring brake
1
housing.
– Screw down Screw plug (2) into hole.
Attention!
Wrong position of Breather (mounted sideways or
2
downwards).
Oil loss through the Breather at Spring brake cyl-
inder.
–Mount Breather at top position always.
Prepare Spring brake cylinder for expanding:
–Unscrew Hydraulic lines on Spring brake and

Brake cylinder.
–Activate Park brake release of Spring brake cylin-
der. See chapter Spring brake cylinder; Park brake
release on Spring brake cylinder activate / deacti-
vate.
12/2015 - V1.1 93
Attention!
Works can be performed only, if the machine is
stopped and parked on a horizontal under-
ground.
–Works perform on a horizontal underground on-
ly.
–Secure Machine / Drive unit prevent rolling with
chocks.
12/2015 - V1.1 94
8.4.4 Park brake release on Spring brake cylin-

der activate / deactivate
Activate
– Unscrew Cover (1).
– Screw in Thread stud (1) into Spring brake.

– Fit bevel spring (2) with dish to outer direction on
thread stud.
– Screw down Nut (3) onto Thread stud (1) until the bevel
springs are compressed.
1
2
3
– Screw in Cover (1) hand tight.
12/2015 - V1.1 95
Deactivate
The deactivation of the Park brake release on spring
brake cylinders, is carried out in reserve order to the acti-
vation.
– Deactivate Park brake release.

– Store Bevel spring (1), Thread stud (2) and Nut (3) into
Cover.
1
– Screw in Cover into Spring brake hand tight.
8.4.5 Exchange Spring brake

– Activate Park break release on Spring brake cylinder.
– Unscrew Hydraulic lines on Spring brake and Brake cyl-
inder.
– Unscrew outer Allen screws (arrows).
– Remove Spring brake.

– Oil new O-ring and fit into groove on Brake cylinder (2).
12/2015 - V1.1 96
– Screw down Spring brake (1).
Nr. Part Nm
1 Spring brake on Lower part 72 +5
– Deactivate Park brake release.
8.4.6 Exchange brake cylinder

inder.
– Activate Park brake release on Spring brake cylinder.
– Remove Spring brake.
– Unscrew Brake cylinder (1).
– Remove Wedge (1) and Ring (2).
2
1
12/2015 - V1.1 97
– Install Ring (2) on new Wedge (1) and fit into Brake cyl-
inder.
2
1
– Free flange surface of Axle housing from residual seal-

ing compounds.
– Apply sealing compound with a thickness of 2–3 mm
on the flange surface of Axle housing.
– Screw down Brake cylinder with Verbus plus® coated

Allen screws (M10x25 8.8) on Axle housing.
1
Nr. Part Nm
2
2 Brake cylinder on Axle housing 75 +5
– Oil O-ring (1) and fit into the groove of the Brake cylin-
der.
– Screw out Allen screw (1).

– Screw Nut (2) until to thread head of the Allen screw (1).
– Free thread of Allen screw from oil, dirt and preserva-
tives with a suitable cleaner and wet the thread of the
3 entire length with Loctite® 242.
– Wet the thread of the piston with Loctite® 242.
2
1
12/2015 - V1.1 98
– Screw in Allen screw (1) into Piston (3) until a torque of

25 Nm is reached. Screw Allen screw (1) 3.5 to 4 rota-
tions backwards - that is a length of 5.25mm.
– Secure Allen screw (1) with Nut (2).
3
With this adjustment following adjustments are reached:
Brake Clearance
2 6.5“ Mono-Servo 2.2 mm
1
6.5“ Multi-Servo 2.9mm
8.75“ Multi-Servo 2.9mm
Checking piston stroke

– Pressurize brake cylinder lower part with 10 bar com-

pressed air.
– Calculate piston stroke „L“.
L = X1 – X2
12/2015 - V1.1 99
8.4.7 Exchange Spring brake cylinder as com-

plete assembly group
inder.
– Activate Park brake release on Spring brake cylinders.
See chapter Park brake release on Spring brake cylinder
activate / deactivate.
– Remove old Spring brake from Brake cylinder. See
chapter Exchange Spring brake.
– Remove old Brake cylinder from Axle housing. See
chapter Exchange Brake cylinder.
– Unscrew Spring brake (1) from Brake cylinder (2) from
new Spring brake cylinder.
1 Unscrew the outer Allen screws only (arrow).
2
– Install Brake cylinder on Axle housing. See chapter Ex-

change Brake cylinder.
– Install Spring brake on Brake cylinder. See chapter Ex-
change Spring brake.
– Deactivate Park brake release on new Spring brake cyl-
inder. See chapter Park brake release on Spring brake cyl-
inder activate / deactivate.
12/2015 - V1.1 100

12/2015 - V1.1 101

9 Tandem housing
9.1 Parts overview
9 Tandem housing
9.1 Parts overview
1 2 3 4 7 8
5
6
6 9
6 10
14 21
15
16 13 12
11
17
18 7
29
30
31 32
19
11
20
26
20 27
25 28
26
22
23
22
24
1 - Hexagon bolt 17 - Hexagon bolt

2 - Washer 18 - Shaft seal
3 - Cover 19 - Allen screw
4 - Gasket 20 - Shear pin
5 - Pin 21 - Tandem housing
6 - Spur gear 22 - Seal ring
7 - Deep groove ball bearing 23 - Screw plug
8 - Spur gear 24 - Screw plug
9 - Needle cage 25 - Seal ring
10 - Spacer bushing 26 - Dowel pin
11 - Washer 27 - Tapered roller bearing
12 - Allen screw 28 - Tapered roller bearing
13 - Grooved dowel pin 29 - O-ring
14 - Bearing pin 30 - Cover
15 - Screw plug 31 - Screw plug
16 - Seal ring 32 - Circlip ring
12/2015 - V1.1 102

9 Tandem housing
In order to be able to perform repairs on the Tandem

housing, the Drive unit must be removed from the ma-
chine.
–Drain oil from the area Tandem housing / Wheel

end. See chapter Maintenance.
–Unscrew Hydraulic lines from Spring loaded cyl-
inder.
–Emergency Spring loaded cylinder. See chapter
Axle housing; Spring loaded brake cylinder.
Information!
Drive unit can be moved, if tyres are mounted and
the park brake release is activated.
–Park machine on horizontal underground.
–Secure machine with chocks to prevent rolling.
–Remove drive unit from machine.
–Remove chocks and move drive unit.
Attention!
–Remove Drive unit only on a horizontal under-
ground.
–Use chocks to prevent rolling.
12/2015 - V1.1 103

9 Tandem housing

A Loctite® 639 Threaded connection Screws and nuts on defeat High

Tandem housing
C Förch Engine-Sili- Outside surface, Flange Cover counterbore in Tandem

con surface housing, Bearing pin
D Fluid Film Liquid Corrosion protection Protection against corrosion on

AR Tandem housing for easier disas-
sembly
A
B
12/2015 - V1.1 104

9 Tandem housing
9.4 Exchange Spur gears

9.4.1 Disassembly
– Remove Tandem housing. See chapter Axle housing;
Slewing ring.
– Remove Bearing pin (1).
2 – Unscrew Cover (2) and remove with two Screwdrivers
from Tandem housing.
Information!
If necessary Cover (2) must be damaged to re-
move from Tandem housing.
1
–Bend outside surface with a screwdriver from
Cover (2) to remove it from Tandem housing.
–Remove Cover careful from counterbore.
– Remove Gasket (1) with a scraper.

– Remove residual sealing compound from flange sur-
face (arrow) and free of oil, dirt and preservatives with
a suitable cleaner.
– Screw in a Slide hammer M12 into Pin (1) and pull out
from Tandem housing.
12/2015 - V1.1 105

9 Tandem housing
– Position Tandem housing on Wheel ends with a suita-

ble lifter.
– Secure Tandem housing with a jack.
– Lock out Circlip ring (1) from Tandem housing.
– Remove Plugs (1) from Cover (2) and screw in two bolts
1 M10 (arrows).
– Remove Cover (2) from Tandem housing.
– Remove O-ring (1) from Cover (2).
– Remove Spur gear (1).

– Remove Spur gear on opposite side.
12/2015 - V1.1 106

9 Tandem housing
– Remove all Spur gears (1).
– Remove Spacer bushings with a suitable bearing ex-

tractor.
– Remove residual sealing compounds from counterbore
and free with suitable cleaner from oil, dirt and pre-
servatives.
9.4.2 Assembly
– Wet Spacer bushings on entire length and entire cir-
cumference with Loctite® 639.
– Install Spacer bushings with WZ 189 into Tandem hous-
ing.
12/2015 - V1.1 107

9 Tandem housing
– Slide in Spur gears (1) into Tandem housing.
– Oil bearing seat in Spur gears.

– Fit Needle cages (1) into Spur gears.
– Oil bearing seat on Pin (1).

– Align Pin (1) and install with a Soft faced hammer into
Tandem housing.
– Place Gasket (1) into counter sink.
12/2015 - V1.1 108

9 Tandem housing
– Apply sealing compound with a thickness of 2...3 mm

on flange surface.
– Fit grooved dowel pin (1).
Sealing compound: Engine-Silicon
Förch
1
– Slide Shaft seal (1) onto Bearing pin (2).
– Install Bearing Pin (1).

Install Bearing pin (1) with Verbus plus® coated Hexagon
bolts.
Nr. Part Nm
1 1 Bearing pin on Tandem housing 455 +35
Information!
Wrong installation position of Bearing pin.
Insufficient lubrication of Sun gear shaft sealing.
Loss of efficiency and high wear to Drive unit.
–Note the installation position of Bearing pin with
hole on 12 o’clock position (arrow).
12/2015 - V1.1 109

9 Tandem housing
– Apply sealing compound with a thickness of 2...3 mm

on the lower half of the outside surface (arrows).
– Fit Cover (2) into counter sink and screw down.

Install Cover (2) with Verbus plus® coated Hexagon bolts.
Nr. Part Nm
2 Cover on Tandem housing 72 +5
– Oil bearing seat of Deep groove ball bearing (1) on Spur

gear.
– Heat Deep groove ball bearing to 100°C.
2 – Mount both Deep groove ball bearings on Spur gear.
– Let cool down Bearings.
1
– Insert Spur gear (1) into Tandem housing.
12/2015 - V1.1 110

9 Tandem housing
– Fit Plugs (1) into Cover (3).

1 – Oil O-ring and fit into Cover (3).
– Clean outside surface of hole on Tandem housing (ar-

rows) and wet with corrosion protection.
– Install Cover (1) into Tandem housing and secure with

Circlip ring (2).
1
– Install Seal ring (1) with special tool WZ 129 into Tan-
1 dem housing and oil sealing lip.
– Install Tandem housing on Drive unit.See chapter Axle
housing; Assembly.
12/2015 - V1.1 111

10 Wheel end
10.1 Parts overview
10 Wheel end
10.1 Parts overview
5
39
2 6
1 2 3 4 7
17
18
10 13
19 27
20 14
8 15
21 9 16
22 11
23 12
24 8
25 26
28
29
30
34
31 35
32 38
33 37
36 38
1 - Screw plug 11 - Planet gear 21 - Ring gear 31 - Sun gear shaft

2 - Seal ring 12 - Support washer 22 - Tapered roller bearing 32 - Support washer
3 - Screw plug 13 - Shear pin 23 - O-ring 33 - Inner raceway
4 - Shim kit 14 - Planet carrier 24 - Wheel hub 34 - Hexagon bolt
5 - Planet carrier 15 - Washer 25 - Hexagon bolt 35 - Washer
6 - Flat collar nut 16 - Hexagon bolt 26 - Tapered roller bearing 36 - Spindle
7 - Lock washer 17 - Nut 27 - Wheel bolt 37 - O-ring
8 - Thrust washer 18 - Adjusting kit 28 - Face seal 38 - Shear pin
9 - Planetary pin 19 - Ring gear carrier 29 - O-ring 39 - Screw plug
10 - Needle cage 20 - Snap ring 30 - Spindle ring
12/2015 - V1.1 112

10 Wheel end

plete assembly instead of repairing it.
In order to be able to perform repairs on the Wheel end,
it is not required to remove the Drive unit from Machine,
if there is enough space available.
Prepare Drive unit:

end. See chapter Maintenance; Tandem housing /
Wheel end.
12/2015 - V1.1 113

10 Wheel end

B Loctite® 639 Threaded connection Screws and nuts on defeat High

Tandem housing
C Klüber Wolf- Screw paste Prevents fretting of bolts

rakote SSP
12/2015 - V1.1 114

10 Wheel end
10.4 Exchange Wheel end as complete assembly group
10.4 Exchange Wheel end as complete as-

sembly group
10.4.1 Disassembly
– Remove tyres. See manual from Machine manufacturer.
– Secure Wheel end with a suitable lifter.
– Unscrew Wheel end and remove.
10.4.2 Assembly
– Free flange surface of Tandem housing of oil, dirt and
preservatives.
1 2 – Fit Shear pins (1) into Tandem housing.
– Oil O-ring and mount on Spindle.
– Slide in Wheel end into Tandem housing with a suitable
lifter.
– Screw down Wheel end on Tandem housing.
Nr. Part Nm
10x
1 Hexagon bolt 310 +20
2x
12/2015 - V1.1 115

10 Wheel end
10.5 Exchange Bearing / Face seal

10.5.1 Disassembly
In order to exchange Bearing / Face seals, the Wheel end
must not removed from Machine.
– Unscrew Planetary gear drive (1) and remove with a

suitable lifter.
– Heat Nut (1) with a welding torch to 110°C.

Indication of the correct temperature is, if the screw lock
begins to vaporise.
1
Information!
Interrupt of the screw operation.
Nut is clamping.
–Unscrew nut in one step from shaft.
– Unscrew Nut (1) in one step with an impact wrench an
special tool WZ 465.
– Remove Adjusting washer (1) and Support washer (2).

– Remove Ring gear carrier with Ring gear (3).
3
2
12/2015 - V1.1 116

10 Wheel end
– Mount Extractor tool WZ 1416 on Wheel hub (2).

2 – Mount Hydraulic jack on Extractor tool.
Pressure Hydraulic jack: ca. 50 t
– Clamp a suitable Distance cylinder (4) between Spindle
4 1
and Extractor tool.
Hydraulic jack and Distance cylinder are not a part of Ex-
tractor tool WZ 1416.
3 – Remove Wheel hub (2).
Information!
Wheel hub (2) can not be removed.
Damage to the hollow profile of the Extractor tool.
–Enter impact shocks with a soft faced hammer to
the Wheel bolts on the Wheel hub.

3 – Remove Bearing shells (2) with a suitable Extractor.
1 – Remove Face seal (3).
– Remove Face seal (1).
12/2015 - V1.1 117

10 Wheel end
– Remove Spindle ring (1) and Tapered roller bearing (2)

with a suitable Extractor from Spindle.
1
2
– Remove O-ring (1) from Spindle ring.
10.5.2 Assembly
– Oil O-ring and fit into groove if Spindle ring.
– Install Spindle ring (1) with a soft faced hammer onto

Spindle.
1 – Free the seat of Face seal (arrow) from oil, dirt and pre-
servatives and check up for damages.
12/2015 - V1.1 118

10 Wheel end
– Oil bearing seat of Tapered roller bearing.

– Heat Tapered roller bearing (1) to 100°C and install with
special tool WZ 629 on Spindle.
1 – Oil rolling elements of Tapered roller bearing.
– Insert Face seal (2) into Mounting ring WZ 443 (1).
Information!
Wrong installation of Face seal by oiling of O-ring.
1
Loss of oil of Drive unit.
–Free O-ring from oil, dirt and preservatives.
2
–Wet O-ring with Ethanol.
– Insert Face seal with mounting ring WZ 443 (1) into

Spindle ring (2).
Information!
Unbalanced seat of Face seal in Spindle ring.
–Install Face seal axial to Spindle ring.
2
1
– Install Bearing shell (1) with special tool WZ 606 into

2 Wheel hub.
– Oil O-ring and insert into groove of Wheel hub (2).
12/2015 - V1.1 119

10 Wheel end
– Install Bearing shell (1) with special tool WZ 614 into

Wheel hub.
– Free the seat of Face seal (arrow) from oil, dirt and pre-
servatives and check up of damages.
– Insert Face seal (1) into Mounting ring WZ 443 (2) and
install into Wheel hub.
Information!
Wrong installation of Face seal by oiling of O-ring.
–Free O-ring from oil, dirt and preservatives.
1 –Wet O-ring with Ethanol.
2 Information!
Unbalanced seat of Face seal in Spindle ring.
–Install Face seal axial to Spindle ring.
– Heat Tapered roller bearing (2) to 110°C.

– Oil rolling elements on Tapered roller bearing.
1 – Slide Flange (1) together with Tapered roller bearing
onto Spindle.
12/2015 - V1.1 120

10 Wheel end
Setting bearing preload

X1
– Slide Ring gear (1) together with Ring gear carrier (1)
onto Spindle.
– Wet contact area (arrows) on Ring gear carrier for Nut
1
with screw paste.
– Screw down Ring gear carrier (1) with an impact wrench

and special tool WZ 465 until a bearing preload of 30–
45 Nm is reached.
1
Information!
Fretting of Nut (2) by missing screw paste.
Damaged thread at disassembling later.
–Wet contact area with screw paste.
– Measure distance between face of Spindle and face of

Ring gear carrier.
– Calculate Washer thickness „s“.
X2
s = X1 – X2
12/2015 - V1.1 121

10 Wheel end
– Unscrew nut (1).

– Free thread of Nut (1) and Spindle (arrows) of oil, dirt
3
and preservatives.
2 – Wet the thread of nut on the entire length and entire
circumference with Loctite® 639.
1 – Slide Adjusting washer (2) onto Spindle.
– Screw down Ring gear carrier (3) with an impact wrench
and special tool WZ 465.
Nr. Part Nm
1 Nut 2000
– Remove excess Loctite.

– Check bearing preload.
Bearing preload: 30–45 Nm
Information!
Incorrect setting of bearing preload.
Loss of efficiency and damages to the Driving unit.
–Bring bearing preload to the correct value by us-
ing adjustment washers.
– Insert Support washer (1) into Spindle.
– Slide in Sun gear shaft into Spindle.

– Screw down Planetary gear drive on Wheel hub.
Nr. Part Nm
3
3 Hexagon bolt 125+10
1
12/2015 - V1.1 122

10 Wheel end
10.6 Exchange Sun gear shaft

10.6.1 Disassembly
– Unscrew Planetary gear drive and remove with a suita-
ble lifter.
– Remove Sun gear shaft (1) and Support washer (2).
10.6.2 Assembly
– Fit Support washer (2) and slide in Sun gear shaft to the
limit stop.
1
– Screw down Planetary gear drive (1) onto Wheel hub.
Nr. Part Nm
Planetary gear drive on Wheel

1
hub 125+10
12/2015 - V1.1 123

10 Wheel end
10.6.3 Setting Axial clearance of Screw plug to

Planetary gear drive
– Heat Screw plug (1) with a welding torch until the Loc-
tite begins to vaporize.
– Unscrew Screw plug (1) and remove Adjusting washer
(2).
2
1
– Measure distance X1 between Sun gear shaft (1) and

Planet carrier and record.
1
2
X1
– Measure distance X2 on Screw plug (1) and record.

– Calculate Washer thickness:
s = X1 – X2
1
Axial clearance: 0.5–2.0 mm
X2
If the calculate value is positive and in the range specified

by NAF, so no Adjusting washer must be insert.
If the value is negative, the axial clearance must be
brought to the correct value by Adjusting washers.
– Insert the calculate Adjusting washer (2).

– Free thread of Screw plug of oil, dirt and preservatives
and wet on entire length and entire circumference
with Loctite® 242.
– Screw in Screw plug (1).
2 Nr. Part Nm
1
1 Screw plug 110+10
– Remove excess Loctite.
12/2015 - V1.1 124

10 Wheel end
10.7 Planetary gear drive

10.7.1 Part overview
5
6
2
1 2 3 4
9 12
13
7
14
8
15
10
11
7
1 - Screw plug 11- Support washer

2 - Seal ring 12 - Shear pin
3 - Screw plug 13 - Planet carrier
4 - Adjusting kit 14 - Washer
5 - Planet carrier 15 - Hexagon bolt
6 - Screw plug
7 - Thrust washer
8 - Planetary pin
9 - Needle cage
10 - Planet gear
12/2015 - V1.1 125

10 Wheel end

plete assembly group instead of repairing it.
In order to be able to perform repairs on the Planetary
drive, it is not necessary to remove the Drive unit from
Machine if there is enough space available.
Prepare Drive unit:

end. See chapter Maintenance; Tandem housing /
Wheel end.
12/2015 - V1.1 126

10 Wheel end
10.7.3 Disassembly
– Unscrew Planetary gear drive. See chapter Wheel end;
Exchange Sun gear shaft.
– Unscrew Planet carrier (1) and remove with Thrust
2
washer (2).
– Remove Planet gears (1).
– Pull out Planetary pins (1) with a Slide hammer.

– Remove Thrust washers (2).
2
1
– Remove Shear pins (1).
12/2015 - V1.1 127

10 Wheel end
10.7.4 Assembly
– Insert Thrust washer (1) with nose inward (arrow) into
Planet carrier.
– Insert Shear pin (1) with a soft faced hammer into Plan-
et carrier.
1
– Oil the entire outside surface of Planetary pin (1) and in-
stall with a soft faced hammer into Planet carrier.
1
– Oil the seat of Needle cages in the Planet carrier (1).

– Insert Needle cage (2) with Support washer into Plane-
1 tary gear (1).
12/2015 - V1.1 128

10 Wheel end
– Slide Planetary gears (1) onto Planetary pins (1).

1
– Grease Thrust washer (1) in order to achieve an adhe-

sion function and insert with nose inward (arrows) into
Planet carrier (2).
2
1
– Screw down Planet carrier (1).
Nr. Part Nm
1 Planet carrier 125+10
12/2015 - V1.1 129

10 Wheel end
12/2015 - V1.1 130

11 Modifications
11 Modifications
Version Modification Date Author
V1.1 Grease in lubricant table new add 15.12.2015 CR
12/2015 - V1.1 131

12 Special tools
12 Special tools 12.1General Information

NAF special tools are developed and designed for the
safe assembly and disassembly of individual parts such
as seal rings, bearings etc. We recommend the use of our
special tools for necessary repairs.
12.2 Tools
WZ 012 Groove socket wrench WZ 062 Insert punch WZ 129 Washer
WZ 189 Insert punch WZ 193 Insert punch WZ 202 Insert punch
WZ 273 Insert punch WZ 284 Insert punch WZ 443 Ring
12/2015 - V1.1 132

12 Special tools
12.2 Tools
WZ 465 Grooved socket wrench WZ 509 Expansion mandrel WZ 606 Insert punch
WZ 614 Insert punch WZ 629 Bushing WZ 678 Insert punch
WZ 682 Insert punch WZ 1408 Insert punch WZ 1416 Extractor
WZ 1464 Wear tool WZ 1597 Setting tool WZ 1601 Insert punch
12/2015 - V1.1 133

Because of the continuous improvement and develop-
ment of our products, the pictures and text in this docu-
ment are subject to change without notice.
The technical details, dimensions and weights given here

are non-binding. Errors and omissions excepted.
All rights relating to copyright are reserved.
NAF AG
Germany
NAF Neunkirchener Achsenfabrik AG

Weyhausenstr. 2
91077 Neunkirchen am Brand
Tel. +49 (0)9134 702 0

www.nafaxles.com

PES01e Manutenção em Ingles

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Repair and Maintenance Manual

Tandem Axle with Differential gear

1.1.1 Using the Instructions

1.1.2 Documents and technical informations

1.1.3 Photos, graphics and text

1.1.4 Disassembly / Assembly

1.1.6 Spare parts

1.1.7 Spare part assemblies

1.1.8 Work conditions and tools

Symbol Meaning Description

1.2 Model identification

1.2.1 Model description

1.2.2 Model list

1.2.3 Type plate

1.2.3.1 Technical Information and Spare parts

1.2.3.2 Position of Type plate

91077 Neunkirchen am Brand / Germany 4

4 Part number machine manufacturer

1.3 Basic information for repairs

1.3.5 Adjusting washers

1.3.7 Radial seals

2.1.1 Safety information

Before the repair

After the repair

2.2 Safety-relevant components

2.2.2 Safety-relevant elements

2.2.4 Adhesive-coated bolts

2.2.5 Adhesives for locking nuts and bolts in

Low strength: easy disassembly with standard hand

2.2.6 Flange sealants

Pos. Assembly modul

5 Spring brake cylinder

3.1.2.1 Differential lock

Pos. Description Comment

On: 20 – 35 bar Mineral oil

3.1.2.2 Spring brake cylinder

Pos. Description Comment

1 Connection for Service brake at braking pressure 70 bar Mineral oil

3.1.3 Description of function

Pos. Description Function

4.1 Basic information

VA Direction of rotation of the cardan flange and direction of

S1/S2 S1 side and S2 side

A0 Description of wheel end

4.3 Gear ratio

4.4 Brake / Differential lock

5.2 Maintenance table

Before putting into Service

Annually or every 2000

5.3 Maintenance points

1 Oil filling plug Differential + Axle housing

2 Oil drain plug Differential + Axle housing

3 Oil dip stick

4 Spring brake cylinder

1 Oil filling plug Bogie housing

2 Oil drain plug Bogie housing

3 Residual oil drain plug Bogie housing

4 Oil drain plug Wheel end

5 Oil filling plug Wheel end

5.3.1 Lubricant table

Axle type Section Fill quantity Lubricant Viscosity Comment

Differential 11,6 Litre* LS Gear oil 85W-90 API GL5

Bogie housing 28,5 Litre* EP Gear oil** W90