CLAAS 240-210 03 CHASSIS - ELIOS 2 WHEEL DRIVE Repair Manual – PDF DOWNLOAD

03 CHASSIS - ELIOS 2 WHEEL DRIVE

Technical support

Repair – Issue 02.2011

Nexos Elios 240-210

Reference no 00 1142 850 0

03 CHASSIS - ELIOS 2 WHEEL DRIVE

CONTENTS

GENERAL INFORMATION MANUAL USE ...................................................................................................................................................................... 6 AGREEMENTS AND DEFINITIONS .................................................................................................................................... 6 GENERAL DESCRIPTION ................................................................................................................................................... 9 RECOMMENDATIONS FOR REPAIR OPERATIONS......................................................................................................... 9

SAFETY INSTRUCTIONS GENERAL SAFETY RECOMMENDATIONS ..................................................................................................................... 12 SAFETY SYMBOLS ........................................................................................................................................................... 12 GENERAL PRECAUTIONS................................................................................................................................................ 13

GENERAL SPECIFICATIONS GENERAL DESCRIPTION ................................................................................................................................................. 16 TECHNICAL FEATURES ................................................................................................................................................... 16 ADHESIVE AND SEALANT................................................................................................................................................ 18 TIGHTENING TORQUES................................................................................................................................................... 20

DISASSEMBLY AND ASSEMBLY OPERATIONS STEERING CYLINDER GROUP ........................................................................................................................................ 22 Disassembly ....................................................................................................................................................................... 22 Assembly ............................................................................................................................................................................ 24 WHEEL HUB GROUP ........................................................................................................................................................ 26 Disassembly ....................................................................................................................................................................... 27 Assembly ............................................................................................................................................................................ 28 WHEEL HUB SUPPORT GROUP...................................................................................................................................... 31 Disassembly ....................................................................................................................................................................... 31 Assembly ............................................................................................................................................................................ 32 AXLE BEAM GROUP ......................................................................................................................................................... 35 Disassembly ....................................................................................................................................................................... 35 Assembly ............................................................................................................................................................................ 37 TOE-IN / STEERING ANGLE ............................................................................................................................................. 39 Toe-in adjustment ............................................................................................................................................................... 39 Steering angle adjustment .................................................................................................................................................. 41

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03 CHASSIS - ELIOS 2 WHEEL DRIVE

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GENERAL INFORMATION

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL INFORMATION

Manual use End users • Installer • User • Maintenance operator Maintenance CONSULT THIS MANUAL THOROUGHLY, as proper functioning and good efficiency of mechanical organs depends mostly on constant and correct routine maintenance ensuring product integrity and expected life duration.

In case of any damages or anomalies, quick intervention of specialized personnel can avoid future impairment and lengthen the working life.

Repair The disassembly/assembly procedures have been outlined for a total product overhauling. They have also been described in sequence through photographs with relevant explanation for specific interventions, thus obtaining a complete and safe guide for each and every phase of an operation.

Operation description presumes that the unit has already been removed from the vehicle. The manual supplied by the vehicle manufacturer should be consulted in case of a overhauling or maintenance intervention.

Agreements and definitions Agreements Illustrations like pictures, drawings and components of this manual are NOT in scale, because of limited space and editing limits, therefore they are NOT reliable to obtain values about size or weight.

Illustrations are supposed to point out the correct methods to working on the machine and its components, therefore they could not display exactly the same elements.

Definitions Left side: it is the left side of the unit considering the vehicle running conditions.

Right side: it is the right side of the unit considering the vehicle running conditions.

Typographic agreements Note: The notes, pointed out externally to the text they refer, include important information.

Warning: Warning indications point out the procedures, whose partial or complete non-observance can damage the machine or the connected equipment.

Danger: Danger indications point out the procedures, whose partial or complete non-observance can injure the operator.

Measurements This manual indicates all measurements in International System (SI). Use the following conversion table to convert Imperial Measure.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL INFORMATION

Conversion table S.I.

GB/USA SYSTEM

1

(mm)

0.03937

(in)

10

(mm)

0.3937

(in)

25.4

(mm)

1

(in)

6.4516

(cm2)

1

(sq. in)

2

1

(m )

1550

(sq. in)

16.378

(cm2)

1

(cu. in)

0.473

(dm2)

1

(U.S. pint)

1

(l)

61.02

(cu. in)

1

(l)

0.2642

(U.S. gal)

1.772

(g)

1

(oz)

0.4536

(kg)

1

(lb)

0.00070308

(kg/mm2)

1

(lb/sq. in)

1

(bar)

14.51

(psi)

1

(kg.m)

7.246

(lb.ft)

2.24

(lb.f)

1(daN)= 10 (N)= 1,02 (kg.f)

Symbology SYMBOLS

DESCRIPTION WARNING/DANGER Follow carefully all the manual instruction, in order to avoid the arise of damages to things or persons; also follow all the current security regulations, in relationship/agreement with the operative working ambient.

NOTE: do not follow carefully the CLAAS indications and/or current security regulations can causes serious damages to the persons or to the machines; these damages are not warranty covered.

REMOVE/INSTALL Applicable to: seals-gaskets-filters.

The NOT original CLAAS spare parts use causes the loss of the machine warranty.

NOTE: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

OIL FILLING OR OIL LEVEL/OIL DRAIN Use only the prescribed lubricant, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

NOTE: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL INFORMATION

SYMBOLS

DESCRIPTION LUBRICATION/GREASING Use only the prescribed lubricant, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

NOTE: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

ADJUSTMENTS/MEASUREMENTS Applicable to: tightening torquespreloads-backlash.

Follow carefully the indicated instructions to obtain the best result.

NOTE: do not follow carefully the CLAAS indications can causes serious damages to the machine; these damages are not warranty covered.

SPECIAL TOOLS It is recommended to use the special tools as indicated into the repair manual; avoid the use of not-tested methods that can not guarantee a good result.

ADHESIVE AND SEALING FLUIDS APPLICATION Use only the prescribed product, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

NOTE: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

MARKING Carry out the described operations in the pre-established order.

DISASSEMBLY/ASSEMBLY OF BULKY PARTS OR SUBASSEMBLIES

WARNING: RESPECT ASSEMBLY ORIENTATION The assembled elements must be oriented as described in the relative procedure or as indicated in the relative figure.

NOTE: do not follow carefully the CLAAS indications can causes serious damages to the machine; these damages are not warranty covered.

CLEANING CAREFULLY Clean with care the parts involved in the described maintenance procedure.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

APPLY PRESSURIZED FLUID Follow with great care the indicated procedure and follow all the security procedures in order to avoid damages to persons or things.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL INFORMATION

General description The machine should be checked and/or repaired only by qualified technicians, acquainted with its peculiar features and well aware of all safety instructions.

Before performing any operation it is advisable to carry out unit cleaning accurately by removing oil/ grease encrustations and accumulation.

All disassembled mechanical parts must be cleaned accurately with suitable products to avoid possible damage. Parts should be replaced if damaged, worn out, cracked, seized, etc. as they could affect proper working.

Rotating parts (bearings, gears, shafts) and that of hardware/fasteners (O-Ring, oil seals) should be examined carefully, as they are subject to major stress, wearing and ageing.

We highly advise to replace tightening parts during every teardown or repair.

Use appropriate spare parts, nuts and bolts to avoid any other problems. Moreover, use metric tools for metric nuts and bolts and Imperial tools for the others.

Some repairs are destructive for some axle components. Carefully reading and thorough understanding of these instructions will avoid damage to other components unnecessarily.

Recommendations for repair operations Before starting any disassembly and assembly operations, read carefully the fol l owing recommendations.

Shafts seals Respect the following recommendations during shaft seal assembly: – Clean shaft very carefully and ensure that the part in contact with the shaft seal is not damaged, cut or out of roundness.

– Assemble the seals so that the lip is fitted towards the oil side.

– Lubricate seal lips (use oil) and fill 3/4 of seal cavity with grease.

– Use appropriate drivers. Do not use a hammer directly on the seals.

– Do not damage the seals while assembling the shaft.

O-rings Lubricate adequately before inserting them at the right place and avoid o-ring rolling while inserting the shaft.

Bearings Its advisable to heat up bearings to 80°C - 90°C before assembling them onto their respective shafts or to cool them (dry ice) before inserting them into corresponding bore.

Always use suitable extractors to remove the bearings.

Before reassembling the bearings, clean, check and lubricate them.

Sealing Use sealing as advised by specifications. Ensure that parts to be sealed are clean, dry and completely grease free.

Cleaning Wash all moving parts (gears, bearings, etc.) accurately with diesel fuel or kerosene.

Avoid gasoline and watery alkaline solutions. Do not wash with steam or hot water, as it will be very difficult to eliminate surface humidity.

Dry all parts with a rag or air jet to avoid scratching from abrasive residuals.

All surfaces should be covered with lubricant so as to protect it from future oxidation.

Checks Examine accurately all bearings, external rings which may be still stuck in their position and pivot pins on which rolls rotate.

Replace those which are worn out or damaged.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL INFORMATION

Check all grooves: assure that they are not worn out or damaged.

Replace spoiled parts with original spare parts.

Replace seals on rotating shafts, before reassembly.

Ends of flanges and tools Be careful when hammering tool or flange ends, in order to avoid jeopardizing functionality and integrity of either the tools or the components on which you are operating.

Assembly methods In order to assemble the group, an appropriate fixture must be used.

In order to position the group a lifting system is needed.

To make disassembly and assembly operations easier, use a group assembly drawing.

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Nexos Elios 240-210 – EN

SAFETY INSTRUCTIONS

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE SAFETY INSTRUCTIONS

General safety recommendations IMPORTANT Before proceeding with any operations please read this chapter very carefully.

Safety precautions Correct use and repair of CLAAS products and of their components is very important for safety and reliability.

Recommendations and all described procedures given in this manual have been experimented and hence are effective operational methods. Please follow every procedure. Use the text as well as the illustrations.

Certain procedures show use of special tools, designed so that the operations can be carried out in a clear and correct manner.

Special tools must be used when a particular operation is being carried out.

It is impossible to advise every working method or know all possible methodologies for carrying it out or to predict risky consequences of each operation. Hence, performing procedures or using instruments which have not been advised could be dangerous for the operator/ mechanic as well as the vehicle.

Danger Safety goggles must be worn while carrying out every assembling or disassembling operations.

Safety symbols Recognize safety information

This is the safety alarm symbol; whenever you find it in the manual or see it on the machine, you are being warned about potential danger of accidents or harm to personnel. Follow the do’s and don’t’s to operate in total safety.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE SAFETY INSTRUCTIONS

Understanding written warnings DANGER WARNING CAUTION Written warning (DANGER, WARNING or CAUTION) is used along with an alarm symbol on the machine.

DANGER or WARNING signs are used near danger zones, while CAUTION sign indicates general precaution.

Follow safety instructions !

Read all suggestions given in this instruction manual very carefully.

Unauthorized changes could endanger the functioning, work safety and work span.

If you do not understand this instruction manual, contact the nearest sales representative.

General precautions Observe safety instructions, accident prevention rules and all general safety regulations in each and every step at work.

Before going ahead with maintenance or repair work ensure that all the tools, the supporting bench, stands, levers, extractors and spanners are in good condition so that the work can be carried out easily.

Risks to various parts and components will also be reduced in this way and working condition for the operator will also be safer.

CLAAS declines any responsibility in case of an accident or damage resulting due to changes made arbitrarily on product.

The product is used for any other purpose different from the one foreseen, than CLAAS declines any responsibility.

In this case all consequences will be at the customer’s expense.

Safety maintenance rules 1. Operate in a clean and dry environment.

2. Do not lubricate, handle or adjust the group underway.

3. Keep your hands, feet and clothing away from moving parts.

4. Always be prepared for fires. Keep the extinguisher and the first aid kit within reach.

5. Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within reach near the telephone set.

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03 CHASSIS - ELIOS 2 WHEEL DRIVE SAFETY INSTRUCTIONS

6. Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices.

7. Use suitable ear protection, like ear plugs, to keep out noise and prevent injury to the ears. A prolonged exposure to noise can damage your hearing.

8. The operator must be very careful with the equipment. Do not use headphones to listen music while you are working on the product or on the group.

Residual risk elimination – Risk of squashing and shearing due to the presence of moving parts.

Warning Carry out all maintenance operations when the machine is stationary.

– Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding.

Warning Use work stations equipped with dust and fume discharging systems.

Let the fumes disperse for at least 15 minutes, before welding or reheating, or working on the group again.

– Risk of fire due to the solvents used and to the oil in the machine.

Warning Keep away any heat sources from the working area.

When solvents or paint removers are used, they should be removed with soap and water, before welding.

Remove any containers of solvent, paint remover or any other inflammable products from the working area.

– Risk due to fall, drop or violent ejection of objects or oil.

Warning These residual risks and the suitable relative procedures to eliminate them completely are pointed out, in detail, in the assembly and disassembly procedures. During maintenance, follow carefully all the safety procedures indicated in the manual.

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Nexos Elios 240-210 – EN

GENERAL SPECIFICATIONS

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL SPECIFICATIONS

General description The axle described in this manual consists mainly of following groups: – AXLE BEAM: main part and load-bearing shell structure of the axle, with support parts to fix the axle to the vehicle.

– WHEEL HUB: wheel support parts.

– SPINDLE: wheel hub support parts with the steering knuckle.

– STEERING CYLINDER: hydraulic cylinder and adjustable tie rods (steering arms) for toe-in setting.

AXLE BEAM GROUP

WHEEL HUB GROUP

SPINDLE GROUP

STEERING CYLINDER GROUP Fig. 1

Technical features MACHINE

Axle

MODEL

2RM/2WD

DESCRIPTION

VALUES

Dry weight

T.B.A.

Steering angle

55°

Toe-in

A

-3 -6

ASSEMBLY MAIN DATA 2.5 ÷ 3 daN

Tapered bearings preloading (increase the load until the first split hole is serviceable)

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL SPECIFICATIONS

Shaft must be pass

Main dimensions (mm)

Fig. 2

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL SPECIFICATIONS

Adhesive and sealant Adhesive/Sealant Application Apply on the contact surfaces

Apply on bolts thread/on pins

Gasket sealant CLAAS Ref.

Presence

Adhesive make and type

Technical characteristics

Strength

A1

•

Loctite® 510

Flat surface sealing

High

Technical characteristics

Strength

Fixing adhesive

Strong bond

Fixing parts sealant CLAAS Ref.

Presence

C2

•

18

Adhesive make and type ®

Loctite 638

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL SPECIFICATIONS

Sealing compounds and adhesives

Fig. 3

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE GENERAL SPECIFICATIONS

Tightening torques

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Nexos Elios 240-210 – EN

DISASSEMBLY AND ASSEMBLY OPERATIONS

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Steering cylinder group

Fig. 1

Disassembly – Remove the nuts (4) and disjoin the tie rods (6) from the steering arms (5).

Warning: don’t damage the threaded pin of the tie rod (6).

Fig. 2

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Remove the fastening bolts (3) and disassemble the steering cylinder (1).

– Collect the washers (2).

Fig. 3

– Remove the tie rods (6, 7, 8) by loosening the nuts (11) and screws (12), then check their conditions.

– Loosen the nut (9) and unscrew the ball pin (10) from the cylinder (1) rod.

Note: remove only parts that need to be overhauled and/ or replaced.

Fig. 4

– Detach the cylinder heads (14 and 22) from the cylinder case (16) and remove it from the rod (18).

– Remove off the rod (18) from the cylinder case (16).

– Remove all the seals from the cylinder heads (14 and 22), and the rod (18).

Fig. 5

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Assembly – Assemble new seals on the cylinder heads (14 and 22) and on the rod piston (19).

– Insert the rod (18) into the cylinder body (16).

– Fit the cylinder heads (14 and 22) on the rod (18), then assemble the heads to the cylinder case (16).

Fig. 6

– Assemble the tie rods (6, 7, 8) with the bolts (12) and related nuts (11).

– Tighten the screws (12) and the nuts (11) to the requested torque (see: Tightening torques).

– Screw the ball pin (10) to the cylinder rod (1) to the requested torque (see: Tightening torques).

– Screw the nut (9) on the ball pin (10) and assemble the tie rods (8) to the ball pin (10).

– Do the same operations on the other cylinder side.

Fig. 7

– Spread a film of adhesive on the contact surfaces between the axle beam and the steering cylinder (1).

– See: Adhesive and sealant.

– Install the assembled steering cylinder (1) on the central body.

– Assemble the screws (3) and the related washers (2).

Fig. 8

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Press the cylinder heads (14) and (22) against the cylinder body (16) and tighten the fastening screws (3) to the prescribed torque (see: Tightening torques).

Warning: the heads (14) and (22) must be perfectly joined to the cylinder body (16).

Fig. 9

Warning: check that the maximum backlash between cylinder heads and cylinder body are less than 0.1 mm.

– Use a 0.1 mm feeler and check that the feeler do not pass between cylinder heads and cylinder body.

YES

NO NO

YES

Fig. 10

– Align the wheel hubs with the axle.

– Adjust the tie rods (8) so that the ball joints (6) can be inserted into the steering arms (5).

– Assemble the ball joints of the tie rods (6) to the steering arms (5).

– Assemble and tighten the lock nut (4) to the requested torque (see: Tightening torques).

Fig. 11

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Warning: screw in the lock nuts (9) of the tie rods (8) only when the toe-in adjustment has been carried out (see: Toe-in/steering angle).

Fig. 12

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Wheel hub group

Fig. 13

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Disassembly See: Steering cylinder group before disassemble the wheel hub group.

– Using a chisel, remove the wheel hub cover (9).

Note: the cover has been glued on wheel hub with sealant.

Fig. 14

– Remove the safety split pin (8).

– Unscrew and remove the nut (7).

Fig. 15

– Remove the wheel hub (4) using a soft material hammer, if necessary.

Note: the bearing cone (6) is extracted together the wheel hub (4).

– Remove the bearing cups (3) and (6) from both wheel hub sides with a hammer and a driver.

Fig. 16

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Remove the bearing cone (3) and seal ring (2) from the spindle (1) with a suitable extractor.

Note: destructive operation for seal ring.

Fig. 17

Assembly See: Wheel hub support group / Assembly before assemble the wheel hub group.

– Apply indicated sealant on the contact surface of the new seal (2) inner ring (2a).

– See: Adhesive and sealant.

– Using a hammer, fit on spindle (1) the seal (2) inner ring (2a).

Fig. 18

– Assemble the seal (2) outer ring (2b).

Note: respect the shown orientation.

Fig. 19

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Using a hammer, assemble the bearing cone (3) to the spindle (1).

Fig. 20

– Carefully clean the seats of the bearings and of the seal ring.

– Using a hammer, fit the bearing cup (3) in its seat on the wheel hub (4).

– Using a hammer, fit the bearing cup (6) in its seat on the wheel hub (4).

Fig. 21

– Assemble the wheel hub (4) to the spindle (1).

Fig. 22

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Assemble the bearing cone (6) to the wheel hub (4).

– Screw and tighten the nut (7) to the prescribed torque (see: Tightening torques).

– Screw the nut (7) further to align the notch with the hole in the wheel axis for the insertion of the safety split pin (8).

– Insert the safety split pin (8) in the hole.

– Twist the ends of the safety split pin (8) to lock it.

Fig. 23

– Apply indicated sealant on the contact surfaces of the wheel hub cover (9) and wheel hub (4).

– See: Adhesive and sealant.

– Using a hammer, assemble the cover (9) to the wheel hub (4).

Fig. 24

– Inject grease in the greasing hole on the wheel hub (4) until the excess quantity starts coming out.

– Screw the plug (5) to the prescribed torque (see: Tightening torques).

Fig. 25

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Wheel hub support group

Fig. 26

Disassembly – See: previous sections before disassemble the wheel hub support group.

Warning: support the axle beam with a suitable hoisting system.

– Remove the bolt (8) and the nut (9).

– Remove the steering arm (7).

Fig. 27

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Remove the spindle (3) from the axle beam (6).

Fig. 28

– Remove the seal ring (4) from the axle beam (6).

Note: destructive operation for the seal ring – Extract the bearing (5) from the axle beam (6).

Fig. 29

Assembly See: Axle beam group / Assembly before assemble the wheel hub support group.

– If it has been previously removed, reassemble the steering stop composed by the grub screw (1) and nut (2).

Note: do not tighten the nut (2) until the steering angle adjustment has been done.

– See: Toe-in / steering angle.

Fig. 30

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Carefully clean the seats of the bearing and of the seal ring.

– Insert the bearing (5) into the axle beam (6).

– Assemble a new seal ring (4) from the axle beam (6).

– Lubricate the seal ring (4).

Fig. 31

Warning: support the axle beam with a suitable hoisting system.

– Assemble the wheel hub support (3) to the axle beam (6).

Fig. 32

– Insert the steering arm (7) on the splined end.

Note: align the notch on the steering arm with the reference mark on the wheel hub support shaft (tooth D) – See: next figure – Assemble the bolt (8) and the nut (9).

– Tighten the nut to the prescribed torque (see: Tightening torques).

Fig. 33

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Warning: the notch on the steering arm must be aligned with the reference mark on the wheel hub support shaft (tooth D)

Fig. 34

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Axle beam group

Fig. 35

Disassembly – See: previous sections before disassemble the axle beam group.

Warning: support the axle beam with a suitable hoisting system.

– Remove the seal ring (5) from the axle beam (1).

Note: destructive operation for the seal ring;

Fig. 36

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Remove the bushes (4) from the axle beam (1) only if the wear condition make it necessary.

Note: destructive operation for the bushes.

Fig. 37

– Remove the seal rings (2) from the axle beam (1).

Note: destructive operation for the seal rings.

Fig. 38

– Remove the bushes (3) from the axle beam (1) only if the wear condition make it necessary.

Note: destructive operation for the bushes.

Fig. 39

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Assembly Warning: support the axle beam with a suitable hoisting system.

– Assemble the bushes (4) to the axle beam (1).

Fig. 40

– Carefully clean the seat of the seal ring.

– Assemble the seal ring (5) to the axle beam (1).

– Lubricate the seal ring (5).

Fig. 41

– Assemble the bushes (3) to the axle beam (1).

Fig. 42

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Carefully clean the seat of the seal ring.

– Assemble the seal rings (2) to the axle beam (1).

– Lubricate the seal rings (2).

Fig. 43

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Toe-in / steering angle

Fig. 44

Toe-in adjustment – Put two equal one-meter-long linear bars on the wheel hubs and lock them with a clamp.

Warning: the two bars must be fixed on their middle so that they are perpendicular to the wheel hub support axis.

– See: next point.

Fig. 45

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

Warning: the two bars must be fixed perpendicular to the wheel hub support axis and parallel to each other; align the two bars.

Fig. 46

– Measure the distance in mm M between the bars ends with a tapeline.

Note: keep the minimum value, swinging the measurement point.

Fig. 47

– Check that the difference of the measurements between the wheel hubs diameters ends is within the requested tolerance range.

– See: “Toe-in” in sec: Technical features.

– The nominal toe-in value A is referred to the external diameter of the wheel hubs flange, therefore the measured value M at the bars ends must be related to the ratio between length of the bar and flange diameter.

-3

nominal toe-in = A -6

-16

measured toe-in = M-32

Fig. 48

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– If toe-in is incorrect, operate with two wrenches on the guide rods (3) screwing in and out the two joint tie rods (1) equally till the toe-in is within the requested tolerance.

Fig. 49

– After adjusting, screw in the lock nuts (2) of the guide rods (3) to the requested tightening torque (see: Tightening torques).

Fig. 50

Steering angle adjustment – Carefully clean the surface of the wheel hub flange.

– Put the bar on the wheel hub and assemble it with bolt and nut to the wheel hub flange, as shown in figure.

Warning: the bar must be parallel to the wheel hub surface and on the same axis.

Fig. 51

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Put a one-meter-long linear bar on the bar and lock it with a clamp.

Warning: the linear bar must be perpendicular to the bar.

Fig. 52

– Use as reference a linear long bar perfectly leaned over the machined part of the central body.

Fig. 53

– Steer untill the end of the stroke has been reached (at the maximum steering) so that the two bars form an acute angle.

– Adjust a protractor to the angle 90°-S where S is the requested angle (see: Technical features) and position it on the long bar.

Fig. 54

Nexos Elios 240-210 – EN

43

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Move the wheel hub till it forms the angle fixed by the protractor, then screw in or out the grub screws (5) and (7) so as they touch the steering stop pads on the axle beam.

Fig. 55

– After the mechanical steering stops have been adjusted, locking them tightening the nuts (4) to the requested torque (see: Tightening torques).

Fig. 56

Warning: check the position of the stops (5) and (7) on the opposite side, both grub screws must touch the steering stop pads at the same time.

Fig. 57

44

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

– Steer on the other side and repeat the operations described at [4] ÷ [6] steps.

Fig. 58

Warning: check the position of the stops (6) and (8) on the opposite side, both grub screws must touch the steering stop pads at the same time.

Fig. 59

Nexos Elios 240-210 – EN

45

03 CHASSIS - ELIOS 2 WHEEL DRIVE disassembly and assembly operations

46

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE

Technical support

Repair – Issue 03.2011

Nexos Elios 240-210

Reference no 00 1142 850 0

03 CHASSIS - ELIOS 4 WHEEL DRIVE

CONTENT SAFETY INSTRUCTIONS GENERAL SAFETY RECOMMENDATIONS ....................................................................................................................... 6 SAFETY SYMBOLS ............................................................................................................................................................. 6 GENERAL PRECAUTIONS.................................................................................................................................................. 7

GENERAL INFORMATION MANUAL USE .................................................................................................................................................................... 16 AGREEMENTS AND DEFINITIONS .................................................................................................................................. 16 GENERAL DESCRIPTION ................................................................................................................................................. 19 SPECIAL RECOMMENDATIONS ...................................................................................................................................... 19

GENERAL SPECIFICATIONS GENERAL DESCRIPTION ................................................................................................................................................. 24 TECHNICAL FEATURES ................................................................................................................................................... 25 ADHESIVES AND TIGHTENING TORQUES..................................................................................................................... 28

DISASSEMBLY AND ASSEMBLY STEERING CYLINDER GROUP ........................................................................................................................................ 32 Disassembly ....................................................................................................................................................................... 32 Assembly ............................................................................................................................................................................ 33 EPICYCLIC REDUCTION GEAR GROUP ......................................................................................................................... 36 Disassembly ....................................................................................................................................................................... 36 Assembly ............................................................................................................................................................................ 38 WHEEL HUB GROUP ........................................................................................................................................................ 40 Disassembly ....................................................................................................................................................................... 40 Assembly ............................................................................................................................................................................ 44 AXLE BEAM GROUP ......................................................................................................................................................... 49 Disassembly ....................................................................................................................................................................... 49 Assembly ............................................................................................................................................................................ 50 TRUNNION BUSHES AND SEALS.................................................................................................................................... 52 Disassembly ....................................................................................................................................................................... 52 Assembly ............................................................................................................................................................................ 54

Nexos Elios 240-210 – EN

3

03 CHASSIS - ELIOS 4 WHEEL DRIVE

DIFFERENTIAL SUPPORT GROUP.................................................................................................................................. 58 Disassembly ....................................................................................................................................................................... 58 Assembly ............................................................................................................................................................................ 60 Bevel gear marking test ...................................................................................................................................................... 66 DIFFERENTIAL GROUP .................................................................................................................................................... 67 Disassembly ....................................................................................................................................................................... 67 Assembly ............................................................................................................................................................................ 69 PINION GROUP ................................................................................................................................................................. 71 Disassembly ....................................................................................................................................................................... 71 Assembly ............................................................................................................................................................................ 74 TOE-IN / STEERING ANGLE ............................................................................................................................................. 80 Toe-in adjustment ............................................................................................................................................................... 80 Steering angle adjustment .................................................................................................................................................. 82

4

Nexos Elios 240-210 – EN

SAFETY INSTRUCTIONS

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

General safety recommendations WARNING: before proceeding with any operations please read this chapter very carefully.

Fig. 1

Fig. 2

CAabS0022

CAabS0028

Make sure to read and comprehend all the maintenance manual (ordinary and extraordinary) before start the repair operations.

Follow with care ALL the instructions in this document, it is forbidden to use simplified procedure to curtail the working time.

Safety precautions: Correct use and repair of CLAAS products and of their components is very important for safety and reliability.

Recommendations and all described procedures given in this manual have been experimented and hence are effective operational methods. Please follow every procedure. Use the text as well as the illustrations.

Certain procedures show use of special tools, designed so that the operations can be carried out in a clear and correct manner.

Special tools must be used when a particular operation is being carried out.

It is impossible to advise every working method or know all possible methodologies for carrying it out or to predict risky consequences of each operation. Hence, performing procedures or using instruments which have not been advised could be dangerous for the operator/mechanic as well as the vehicle.

Safety symbols Recognize safety information This is the safety alarm symbol; whenever you find it in the manual or see it on the machine, you are being warned about potential danger of accidents or harm to personnel. Follow the do’s and don’t’s to operate in total safety.

Fig. 3

Fig. 4

DANGER WARNING CAUTION

CAabS0030

CAabS0001

6

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

Understanding written warnings DANGER

WARNING

CAUTION Written warning (DANGER, WARNING or CAUTION) is used along with an alarm symbol on the machine.

DANGER or WARNING signals are used near danger zones.

DANGER indicates a real dangerous situation while CAUTION indicates general precaution.

Follow safety instructions!

Unauthorized changes could endanger the functioning, work safety and machine lifespan.

If you do not understand any instruction in this manual, contact the nearest CLAAS agent.

General precautions Observe safety instructions, accident prevention rules and all general safety regulations in each and every step at work.

Before going ahead with maintenance or repair work ensure that all the tools, the supporting bench, stands, levers, extractors and spanners are in good condition so that the work can be carried out easily.

Risks to various parts and components will also be reduced in this way and working condition for the operator will also be safer.

CLAAS declines any responsibility in case of an accident or damage resulting due to changes made arbitrarily on product.

The product is used for any other purpose different from the one foreseen, than CLAAS declines any responsibility.

In this case all consequences will be at the customer’s expense.

During the maintenance and repair operations make sure that • the axle must always checked and overseen by authorized staff • in case of axle parts tampering, verify the correct working of the axle and replace them, if necessary • every modification of the safety signs and/or transfers and their relative tamper must be always previously agreed with the manufacturer WARNING: • during the lubricating and greasing operations, do not confuse the ordinary maintenance times • during the tightening operations do not confuse the tightening torques • during the axle use plugs, breathers, screws and tightening torques must be in agreement with the regulation DANGER: • do not use inflammable products like ether, oil or gasoline for the parts cleaning when the parts are at elevated temperature or under the sun rays exposure: it may causes fire • deep impacts may damage the axle mechanicalmagnetic-electrical parts • do not smoke-drink-eat during the assembly-disassembly-maintenance operations to avoid a possible contamination of the mechanical parts Safety maintenance rules 1 Operate always in a clean and dry environment.

2 Clean carefully the working environment and the machine before carry out the maintenance operations (Fig. 5).

Nexos Elios 240-210 – EN

7

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

3 Use only cleaning product in agreement with the regulations and always use them in the prescribed way.

4 Do not inhale chemical substances in dangerous concentration for the health care (Fig. 6); ventilate the environments in which sprays and solvents, with volatile chemical substances, are used.

Fig. 5

Fig. 6

CAabS0025

CAabS0019

5 Wear suitable clothing and protection such as overalls, safety gloves and ear safety devices (Fig. 7).

WARNING: Safety goggles must always be worn while carrying out every assembling or disassembling operations (Fig. 8).

Fig. 7

Fig. 8

CAabS0031

CAabS0032

6 Use suitable ear protection, like ear plugs, to keep out noise and prevent injury to the ears. A prolonged exposure to noise can damage your hearing.

7 The operator must be very careful with the equipment. Do not use headphones to listen music while you are working on the product or on the group.

8 Do not wear slings, ties or other pending clothes. Tie long hair behind the head and/or wear a protective cap.

9 Do not wear rings, armlets, necklaces or other metal objects that are dangerous when current is present.

10 Predispose always the first aid equipment in agreement with the working environments regulations, like the first aid kit (Fig. 9).

11 Keep the phone numbers of a doctor, an ambulance, a hospital and the fire department within reach near the telephone set (Fig. 10).

In case of accident it is indispensable to quickly ask for a medical intervention.

Fig. 9

CAabS0033

CAabS0034

8

Fi

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

12 Keep your hands, feet and clothing away from moving parts of the tool machines.

Keep the safety distance from the machine, if it is moving, like during the testing operations (Fig. 11).

13 Light properly the working area by using devices in agreement with the safety regulations (Fig. 12).

Fig. 11

Fig. 12

CAabS0015

CAabS0010

14 During the maintenance operations it is strictly forbidden to light free flames (Fig. 13) and smoking (Fig. 14).

Fi

Fi

CAabS0004

CAabS0003

15 Always be prepared for fires. Keep the extinguisher within reach. Before start any maintenance operation identify the extinguisher nearest to the working area and the prescribed fire regulations (Fig. 15).

Fi

Fi

CAabS0025

CAabS0002

16 The working environment must be always well aired by using devices in agreement with the safety regulations.

If local vents are not present, open doors the windows in the working area.

Do not inhale dust and fumes, they can cause sickness or death. Do not inhale toxic substances used during the product maintenance. If necessary use a certified respirator.

All the CLAAS products are in agreement with the Italian legislation and with the European Community technical requirements.

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9

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

Residual risks elimination It is recommended to follow with care the following general indications, that are important to prevent damages to persons and things.

Fig. 17

Fig. 18

CAabS0011

CAabS0009

• Risk of squashing and shearing due to the presence of moving parts.

WARNING Carry out all maintenance operations when the machine is stationary. Do not lubricate, handle or adjust the group with mechanical parts in movement.

Fig. 19

Fig. 20

CAabS0020

CAabS0023

• Squashing risk due to the machines or devices movement in the working area.

WARNING These residual risks and the procedure to eliminate them completely, are described in detail in the assembly/disassembly procedures. During the maintenance operations, follow carefully all the security procedure indicated on the repair manual.

WARNING Do not carry out any operation by using faulty or not suitable tools.

Always predispose the tools and the devices on a suitable workbench, in an orderly way.

Do not use unstable shelves or not flat surfaces as workbench.

10

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

The serviced group and used tools must be always arranged in a stable position, in order to avoid all the unstable equilibrium situations.

Fig. 21

Fig. 22

CAabS0026

CAabS0021

• Risk due to violent ejection of objects from the machine WARNING These residual risks and the suitable relative procedures to eliminate them completely are pointed out, in detail, in the assembly and disassembly procedures.

During maintenance, follow carefully all the safety procedures indicated in the manual.

Fig. 23

Fig. 24

CAabS0018

CAabS0008

• Risk due to falling loads or unhooked objects.

WARNING These residual risks and the procedure to eliminate them completely, are described in detail in the assembly/ disassembly procedures. During the maintenance operations, follow carefully all the security procedure indicated on the repair manual.

WARNING Before every operation secure all the heavy parts by using suitable supporting devices, in order to avoid casual falls and unexpected moves.

If the group is only supported by hanging ropes, do not work under the pending load.

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

The used lifting devices must be in agreement with the current regulations, in perfect conditions, verified and correctly serviced.

Fig. 25

Fig. 26

CAabS0018

CAabS0025

• Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding.

WARNING Use work stations equipped with dust and fume discharging systems.

Before welding or heating a part, remove the paint, if present. Do not use sprays or other inflammable substances near the welding area or near heat sources.

• Risk due to the pollution by dangerous substances.

Exhausted lubricant and the residual products of the cleaning/painting operations are considerate special waste.

WARNING During the CLAAS products maintenance operations, use the proper container for the liquid and for the solid waste raising.

Drain the raised liquid and solid waste in agreement with the current working environment regulations.

Fig. 27

Fig. 28

CAabS0006

CAabS0005

• Risk of fire and explosion due to the solvents used and to the oil in the machine.

WARNING Keep away any heat sources from the working area.

When solvents or paint removers are used, they should be removed with soap and water, before welding.

12

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

Remove any containers of solvent, paint remover or any other inflammable products from the working area.

Fig. 29

Fig. 30

CAabS0016

CAabS0013

• Burn risk due to elevated temperature of liquid or solid elements.

WARNING Wear the personal protective clothes, in agreement with the current regulations, adequate to the type of operation carried out. Verify the plugs and connectors correct tightening before start up the machine or before give pressure to the circuits.

Fig. 31

Fig. 32

PERICOLO!

CAabS0024

CAabS0014

• Risk due to boiling fluids ejection or pressured fluids ejection WARNING Wear the personal protective clothes, in agreement with the current regulations.

Do not search possible liquid loss on pressured pipes by using hands or others body parts (Fig. 1), use the prescribed devices or not inflammable elements (Fig. 1).

Fig. 33

CORRETTO

CAabS0012

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE SAFETY INSTRUCTIONS

14

Nexos Elios 240-210 – EN

GENERAL INFORMATION

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

Manual use End users • Installer • Qualified technician • Maintenance operator Maintenance and repair CONSULT THIS MANUAL THOROUGHLY, as proper functioning and good efficiency of mechanical organs depends mostly on constant and correct routine maintenance ensuring product integrity and expected life duration.

In case of any damages or anomalies, quick intervention of trained and highly qualified operators authorized (with certificate) by CLAAS ensure the longest life of product and avoid future impairment caused by not authorized repairing.

WARNING: CLAAS warranty does not cover every injury to personnel and damage to product caused by maintenance operations of not authorized personnel and/or by operations not in compliance with CLAAS safety regulations and prescribed procedures.

The disassembly/assembly procedures have been outlined for a total product overhauling. They have also been described in sequence through photographs with relevant explanation for specific interventions, thus obtaining a complete and safe guide for each and every phase of an operation.

Operation description presumes that the axle has already been removed from the vehicle. To remove the axle from the vehicle refer to manual provided from vehicle manufacturer.

Agreements and definitions Agreements Illustrations like pictures, drawings and components of this manual are NOT in scale, because of limited space and editing limits, therefore they are NOT reliable to obtain values about size or weight.

Illustrations are supposed to point out the correct methods to working on the machine and its components, therefore they could not display exactly the same elements.

Definitions Left side (Lh): it is the left side (left hand) of the unit considering the vehicle running conditions (Fig. 1).

Right side (Rh): it is the right side (right hand) of the unit considering the vehicle running conditions (Fig. 1).

Fig. 1

Fig. 2

Driving direction

Lh

Rh Lh

Rh Pinion side CAab07685

CAab07685

Only for axle with pinion Axle left side: it is the left side of the axle from pinion shaft point of view toward the pinion (Fig. 2).

Axle right side: it is the right side of the axle from pinion shaft point of view toward the pinion (Fig. 2).

Typographic agreements Note: The notes, pointed out externally to the text they refer, include important information.

WARNING: Warning indications point out the procedures, whose partial or complete non-observance can damage the machine or the connected equipment.

DANGER: Danger indications point out the procedures, whose partial or complete non-observance can injure the operator.

16

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

Measurements This manual indicates all measurements in International System (SI). Use the following conversion table to convert Imperial Measure.

Conversion table of units of measurement S.I.

GB/USA SYSTEM

1

mm

0.03937

in

10

mm

0.3937

in

25.4

mm

1

in

6.4516

cm2

1

sq. in

1

m2

1550

sq. in

16.378

m2

1

cu. in

0.473

dm2

1

U.S. pint

1

l

61.02

cu. in

1

l

0.2642

U.S. gal

1.772

g

1

oz

0.4536

kg

1

lb

0.00070308

kg/mm2

1

lb/sq. in

1

bar

14.51

psi

1

kg.m

7.246

lb. ft

2.24

lb. f

1(daN) = 10 (N) = 1.02 (kg.f)

Nexos Elios 240-210 – EN

17

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

Symbology used to describe maintenance (service and repair) procedures SYMBOLS

DESCRIPTION WARNING/DANGER Follow carefully all the manual instruction, in order to avoid the arise of damages to things or persons; also follow all the current security regulations, in relationship/agreement with the operative working ambient.

Note: do not follow carefully the CLAAS indications and/or current security regulations can causes serious damages to the persons or to the machines; these damages are not warranty covered.

REMOVE/INSTALL Applicable to: seals-gaskets-filters.

The NOT original CLAAS spare parts use causes the loss of the machine warranty.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

OIL FILLING OR OIL LEVEL/OIL DRAIN Use only the prescribed lubricant, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

LUBRICATION/GREASING Use only the prescribed lubricant, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

ADJUSTMENTS/MEASUREMENTS Applicable to: tightening torquespreloads-backlash.

Follow carefully the indicated instructions to obtain the best result.

Note: do not follow carefully the CLAAS indications can causes serious damages to the machine; these damages are not warranty covered.

SPECIAL TOOLS It is recommended to use the special tools as indicated into the repair manual; avoid the use of not-tested methods that can not guarantee a good result.

ADHESIVE AND SEALING FLUIDS APPLICATION Use only the prescribed product, indicated on section C; the use of products that are not in accordance with the indicated specifications involves the CLAAS warranty decline.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

18

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

SYMBOLS

DESCRIPTION MARKING Carry out the described operations in the pre-established order.

DISASSEMBLY/ASSEMBLY OF BULKY PARTS OR SUBASSEMBLIES

WARNING: RESPECT ASSEMBLY ORIENTATION The assembled elements must be oriented as described in the relative procedure or as indicated in the relative figure.

Note: do not follow carefully the CLAAS indications can causes serious damages to the machine; these damages are not warranty covered.

CLEANING CAREFULLY Clean with care the parts involved in the described maintenance procedure.

Note: when this symbol is encountered, it is recommended to follow the described procedure as well as the section Special recommendations warnings.

APPLY PRESSURIZED FLUID Follow with great care the indicated procedure and follow all the security procedures in order to avoid damages to persons or things.

General description The machine should be checked and/or repaired only by qualified technicians, acquainted with its peculiar features and well aware of all safety instructions.

Before performing any operation it is advisable to carry out unit cleaning accurately by removing oil/ grease encrustations and accumulation.

All disassembled mechanical parts must be cleaned accurately with suitable products to avoid possible damage. Parts should be replaced if damaged, worn out, cracked, seized, etc. as they could affect proper working.

Rotating parts (bearings, gears, shafts) and that of hardware/fasteners (O-Rings, seal rings) should be examined carefully, as they are subject to intense stress, wearing and ageing.

Note: in case of replacement of one part of the bevel gear set this operation requires the replacement of the other part too.

We highly advise to replace sealing parts (O-Rings, seal rings, gaskets) during every teardown or repair.

Use appropriate spare parts, nuts and bolts to avoid any other problems. Moreover, use metric tools for metric nuts and bolts and Imperial tools for the others.

Some operations are destructive for removed components.

Carefully reading and through understanding of these instructions will avoid damage to other components.

Special recommendations Before starting any disassembly and assembly operations, read carefully the following recommendations.

Shafts seals Respect the following recommendations during shaft seal assembly: • Clean shaft very carefully and ensure that the part in contact with the shaft seal is not damaged, cut or out of roundness.

• Do not damage the seals while assembling the shaft.

Nexos Elios 240-210 – EN

19

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

• Clean shaft very carefully and ensure that the part in contact with the shaft seal is not damaged, cut or out of roundness (Fig. 3).

Fig. 3

Fig. 4

CAab15728

CAst5679

• Assemble the seals so that the lip is fitted towards the oil side (Fig. 4).

• Lubricate seal lips (use oil) and fill 3/4 of seal cavity with grease (Fig. 5).

• Use appropriate drivers (Fig. 6).

WARNING: do not use a hammer directly on the seals.

Fig. 5

Fig. 6

CAab07590

CAab04054

O-rings Lubricate adequately before inserting them at the right place and avoid o-ring rolling while inserting the shaft (Fig. 7).

Fig. 7

CAab14265

Adjusting shims Respect the following recommendations during the adjustment shims assembly: • Use appropriate adjusting shims and measure each one separately (Fig. 8).

• Complete group measurement or stampings on the shims are not always reliable: check.

Bearings Respect the following recommendations during the bearings assembly: • Before reassembling the bearings, clean, check and lubricate them.

20

Nexos Elios 240-210 – EN

Fig. 8

CAab08963

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

• Its advisable to heat up bearings to 80-90 °C before assembling them onto their respective shafts or to cool them (dry ice) before inserting them into corresponding bore (Fig. 9).

Always use suitable extractors to remove the bearings (Fig. 10).

Fig. 9

Fig. 10

CAab08963

CAab08255

Split pins Respect the following recommendations during the split pins assembly: • Before assembling elastic pins, make sure that the notch is oriented towards the stressing force (Fig. 11).

• Spiral elastic pins do not need orientation.

Fig. 11

CAab16994

Fig. 12

CAab08937

Adhesive and sealant Respect the following recommendations during the adhesive and sealant application: • Use adhesive and sealant as advised by manufacturer specifications.

• Do not use adhesive or sealant where similar products has been applied previously; totally remove the old product before applying the new one.

• Ensure that parts to be sealed are clean, dry and completely grease free (Fig. 12) in the application area.

• Read the predisposed section in this manual to know the required type of adhesive and sealant and relative application areas.

Oil drain Before carry out the disassembly operations, the oil must be drained out.

WARNING: disposal of used oil must be done according to laws.

Cleaning Respect the following recommendations during the axle cleaning operations: • Wash all moving parts accurately with diesel fuel or kerosene.

• Gasoline and watery alkaline solutions are forbidden.

• Do not wash with steam or hot water, as it will be very difficult to eliminate surface humidity.

• Dry all parts with a rag or air jet to avoid scratching from abrasive residuals.

• After the cleaning operations, all the surfaces should be covered with lubricant so as to protect it from future oxidation.

Checks

Nexos Elios 240-210 – EN

21

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL INFORMATION

Respect the following recommendations during the axle control operations: • Check all grooves: assure that they are not worn out or damaged.

• Replace spoiled parts with original spare parts.

• Before the reassembly, the seals on rotating shafts must be replaced.

• Examine accurately all bearings, external rings which may be still stuck in their position and pivot pins on which rolls rotate.

• Replace those which are worn out or damaged (Fig. 13).

• Gears should not be spoiled and teething should not be excessively worn out. Teeth smoothing should not be deteriorated (Fig. 14).

Fig. 13

CAab04069

Fig. 14

CAab16995

Ends of flanges and special tools Be careful when hammering special tool or flange ends, in order to avoid jeopardizing functionality and integrity of either the tools or the components on which you are operating.

Lubricant use In order to lubricate the CLAAS axles correctly and to reach the exact operation temperature, it is important to use the recommended lubricants, keeping their level constant as indicated in this manual.

22

Nexos Elios 240-210 – EN

GENERAL SPECIFICATIONS

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

General description The axle described in this manual consists mainly of following groups: – STEERING CYLINDER: steering cylinder parts with adjusting system components – EPICYCLIC REDUCTION GEAR: planetary carrier with reduction/transmission parts – WHEEL HUB: wheel support parts containing the epicyclic reduction gears – DIFFERENTIAL SUPPORT: differential housing with ring bevel gear adjusting system – DIFFERENTIAL: differential parts with ring bevel gear – PINION: pinion with adjusting and support parts – AXLE BEAM: load-bearing shell structure of the axle Mechanical controlled brakes features f

WHEEL HUB GROUP DIFFERENTIAL GROUP AXLE BEAM GROUP

DIFFERENTIAL SUPPORT GROUP STEERING CYLINDER GROUP

EPICYCLIC REDUCTION GEAR GROUP

PINION GROUP

Fig. 1

24

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Technical features MACHINE

Front axle

MODEL

G20.16

DIFFERENTIAL TYPE

Limited slip

DESCRIPTION

VALUES

Dry weight

T.B.A.

Maximum steering angle

55°

Adjustment steering angle

min. 53° max. 55°

Toe-in

A

Bevel gear ratio

2.133/1

Epicyclic reduction gear ratio

6.000/1

Total ratio

12.800/1

0 -2

Input rotation CLOCK WISE (C.W.)



COUNTER CLOCK WISE (C.C.W.)



ASSEMBLY MAIN DATA Bevel gear set backlash

0.15÷0.21 mm

Pinion bearings preloading (1) (measured on Ø= 29.75 mm without seal)

FP= 107.5÷161.4 N

Total preloading (1) of pinion-ring gear bearings (measured on Ø= 29.75 mm without seal)

FT= (FP+50.4)÷(FP+75.6) N

Pinion bearings rolling torque (1) measured without seal

MP= 1.6÷2.4 Nm

Total pinion-ring gear bearing rolling torque (1) measured without seal

MT= (MP+0.75)÷(MP+1.21) Nm

(1) Only for new bearings

Nexos Elios 240-210 – EN

25

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Limited slip differential disks specifications

New separator plate thickness= 1.5±0.03 mm

New friction plate thickness= 2.8±0.03 mm

Plate ref. CA110643 - q.ty 10

Worn plate minimum thickness= 2.7 mm Plate ref. CA110642 - q.ty 2

New friction plate thickness= 1.6±0.03 mm Worn plate minimum thickness= 1.4 mm Plate ref. CA110644 - q.ty 8

Fig. 2

26

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Main dimensions (mm)

Fig. 3

Nexos Elios 240-210 – EN

27

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Adhesives and tightening torques Adhesive/Sealant Application Apply on the flat contact surfaces Apply on bolts thread or on pins and bushes curved surfaces Note: apply only on indicated side

Gasket sealant CLAAS Ref.

Presence

Adhesive make and type

Technical characteristics

Strength

A1

•

Loctite® 510

Flat surface sealing

High

Technical characteristics

Strength

Locking of threaded parts

High

Thread parts sealant CLAAS Ref.

Presence

B2

•

Adhesive make and type ®

Loctite 271

Fixing parts sealant CLAAS Ref.

Presence

Adhesive make and type

Technical characteristics

Strength

C2

•

Loctite® 638

Fixing adhesive

Strong bond

28

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Adhesives and tightening torques

Fig. 4

Nexos Elios 240-210 – EN

29

03 CHASSIS - ELIOS 4 WHEEL DRIVE GENERAL SPECIFICATIONS

Adhesives and tightening torques

Fig. 5

30

Nexos Elios 240-210 – EN

I

DISASSEMBLY AND ASSEMBLY

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Steering cylinder group

Fig. 1

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Loosen the nut (1) with enough turns till it is protruding over the threaded pin end of the tie rod (3).

– Beat on the nut (1) with an appropriate hammer in order to disjoin the tie rod (3) from the swivel housing (2).

Warning: don’t beat on the threaded pin end of the tie rod (3).

Note: this is a destructive operation for the nut (1).

– Repeat the whole sequence at the other side.

Fig. 2

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the tie rods (3) and (12) by loosing the nuts (4) and (12) with a suitable wrench, then check them conditions.

– Unscrew the fastening screws (6) and take the steering cylinder (7) out of its housing, if necessary use a rubber hammer.

– Remove only parts that need to be overhauled and/or replaced.

Fig. 3

– Detach the cylinder head (15) from the cylinder case (19) and remove it from the rod (17).

– Remove the rod (17) from the cylinder case (19).

– Remove the cylinder head (20) from the cylinder case (19).

– Remove all the seals and O-Rings (13, 14, 16, 18, 21 and 22) from the cylinder case (19), the cylinder heads (15, 20), and the rod (17).

Fig. 4

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Assemble new seals and O-Rings (13, 14, 16, 18, 21 and 22) on the cylinder heads (15, 20), on the rod piston (17) and on the cylinder body (19).

Fig. 5

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Assemble the cylinder head (20) to the cylinder body (19).

– Fit the cylinder head (15) on the rod (17).

– Slide the pre-assembled rod (17) into the cylinder body (19).

Fig. 6

– Fit the tie rods (3) and (12), the ball joints (5) and (10), the nuts (4) and (11) to the ends of the rod (17), then tighten with a dynamometric wrench to the requested torque.

– See: Adhesives and tightening torques.

Fig. 7

– Install the steering cylinder (7) already assembled on the central body.

– Assemble and tighten the screws (6) with dynamometric wrench to the requested torque.

– See: Adhesives and tightening torques.

Fig. 8

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Align the swivel housing (8) with the axle.

– Screw the tie rod (12) so that its ball joint can be inserted into the swivel housing (8) arm.

Note: it is important to unscrew the lock nut (11) to carry out this operation.

– Repeat the whole sequence of the mentioned operations to the other side.

Fig. 9

– Insert the ball joint of the tie rod (3) into its housing on the swivel housing (2).

– Assemble and tighten the lock nut (1) with a dynamometric wrench to the requested torque (See: Adhesives and tightening torques).

– Repeat the whole sequence of the mentioned operations to the other side.

Fig. 10

– Screw the lock nuts (4) and (11) of the tie rods (3) and (12) only when the toe-in adjustment has been carried out (see: Toe-in / steering angle).

Fig. 11

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Epicyclic reduction gear group

Fig. 12

Disassembly Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Drain the oil completely from the planetary carrier.

Fig. 13

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Unscrew and remove both fastening screws (1) of the planetary carrier (3) with a wrench.

Fig. 14

– Remove the planetary carrier (3) from the wheel hub and collect the relative O-Ring (4).

– Position the planetary carrier (3) on a workbench and check its wear conditions.

Fig. 15

– If required replace the planetary gears as follows: • remove the lock rings (9) on every pin; • remove the triangular plate (8); • remove the planetary gears (7) from the pins; • collect the needle bearings (6), checking their conditions; • collect the washer (5).

Fig. 16

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Collect all epicyclic reduction gear parts: the planetary carrier (3), the thrust washers (5), the needle bearings (6), the planetary gears (7), the triangular plate (8) and the snap rings (9) of every pin.

Note: with new planetary gears is advisable to assembly new roller bearings.

Fig. 17

– Position the planetary carrier on a workbench.

– Insert the thrust washers (5) and the epicyclic gears (7) in the planetary carrier pins.

– Insert the needle bearings (6) in the epicyclic gears (7).

Note: grease well the needles.

– Assemble the triangular plate (8) and the related snap rings (9).

Fig. 18

– Assemble a new O-ring (4) on the planetary carrier (3).

– Assemble the epicyclic reduction gear on the wheel hub.

Fig. 19

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Assemble the screws (1) and tighten them to the prescribed torque (See: Adhesives and tightening torques).

Fig. 20

– Top up the oil on the wheel hub.

– Fit the filling/drain and level oil plug (2) on the planetary carrier (3) and tighten to the prescribed torque (See: Adhesives and tightening torques).

Fig. 21

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Wheel hub group

Fig. 22

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– See: Steering cylinder group and Epicyclic reduction gear group before disassemble the wheel hub group.

– Insert a lever between the swivel housing (14) and the axle beam and fit it into the double U-Joint.

– With the lever push the double U-Joint in the direction of the wheel hub to allow the lock ring (1) removal.

Warning: do not damage the double U-Joint.

Fig. 23

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the lock ring (1) from the double U-Joint shaft.

– Collect the double U-Joint shaft washers (2, 3).

Fig. 24

– Unscrew and remove the fastening bolts (5) from the wheel carrier (7).

Fig. 25

– To extract the wheel carrier screw two of the just removed bolts (5) in the threaded holes.

– Remove the wheel carrier (7) with the epicyclic ring gear (4).

Fig. 26

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the steel lock ring (8) and disjoin the wheel carrier (7) from the epicyclic ring gear (4).

– Only if necessary, remove the centering bushes (6) from the wheel carrier with a hammer.

Fig. 27

– Remove the wheel hub (11) using levers and a hammer to facilitate the operation.

Note: collect the bearing cone (9).

Fig. 28

– Position the wheel hub (11) on a flat surface and remove the seal ring (13) with an extractor.

Note: destructive operation for the seal ring (13).

– Remove the bearing cups (9) and (12) using a hammer and a suitable drift.

– Remove the bearing cone (12) from the swivel housing end (14), using a suitable extractor.

Fig. 29

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Unscrew and remove the fastening bolts (19) and (17) from the upper (18) and lower (16) king pin.

Danger: before removing the king pins (16) and (18), secure the swivel housing (14) with a belt or a rope to a hoist or any other supporting device; observe all current safety regulations to guarantee operator’s safety.

– Remove the king pins (16) and (18)

Fig. 30

– Remove the swivel housing (14) from the axle beam and from the short shaft of the double U-Joint.

– Collect the belleville washers (25) and (27).

Fig. 31

– Position the swivel housing (14) on a flat surface and take the seal ring (23) out with an extractor.

Note: this is a destructive operation for the seal ring.

– Overturn the swivel housing and take the bush (22) out, using a suitable drift and a hammer.

Fig. 32

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– If it has been previously removed, reassemble the steering stop composed by the screw (21) and nut (20).

Note: do not tighten the nut (20) until the steering angle adjustment has been done.

– See: Toe-in / steering angle.

Fig. 33

– Force the bush (22) into the swivel housing (14) with the special tool 00 1131 401 0 and a hammer or a press.

– Assemble the seal ring (23) on the swivel housing (14) with the special tool 00 1131 423 0 and a hammer.

– Grease carefully the seal ring (23).

Fig. 34

– If the cone (15) of the spherical joint has been previously removed, reassemble it to the lower king pin (16) using the special tool 00 1131 415 0 under a press.

– Grease carefully the seats of king pin (16) and (18) with specific grease.

– Position the belleville washers (25) and (28) on the king pin (16) and (18) housings.

Fig. 35

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Danger: secure the swivel housing (14) with a belt or a rope to a hoist or any other supporting device.

– Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring (23).

– Assemble the swivel housing (14) on the axle beam and after assembly, remove completely the adhesive tape.

Fig. 36

– Assemble the king pins, the lower (16) and the upper (18), and tighten the retaining screws (17) and (19) to the requested torque.

Note: make sure that the belleville washers (25) and (27) remain in their position.

Fig. 37

– The special operation “Set Right” of the bearings (9) and (12) does not require preload or backlash adjustment. Anyway, before assembling new components check the indicated dimensions.

A = 11.975 ÷ 12.025 mm B = 52.229 ÷ 52.279 mm C = 20.000 ÷ 20.100 mm

Fig. 38

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Force both bearing cups (9) and (12) to their wheel hub (11) housings using a press or with a hammer.

– Insert the seal ring (13) into the wheel hub (11) with the special tool 00 1131 425 0 and a hammer.

Note: do not lubricate the seal ring (13)

Fig. 39

– Assemble the bearing cone (12) on the swivel housing (14) end.

– Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing cone (9).

Fig. 40

– Position the wheel carrier (7) on a workbench and force the bushes (6) to the carrier surface level with the lever.

– At least two bushes (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Fig. 41

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Preassemble the wheel carrier (7) and the epicyclic ring gear (4) with the lock ring (8) shown in figure.

Fig. 42

– Assemble the wheel carrier group on the wheel hub using the two projecting bushes as dowel pins and screw the relative screws (5) in order to put in contact the ring bevel gear with the wheel hub.

Fig. 43

– Force all the hub dowel bushes (6) completely with the lever and a hammer.

– Assemble the wheel carrier (7) fastening bolts (5) and tighten to the requested torque (see: Adhesives and tightening torques).

Fig. 44

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Insert a lever between the swivel housing (14) and the axle beam and fit it into the double U-Joint.

– With the lever push the double U-Joint in the direction of the wheel hub to make easier the lock ring (1) insertion.

Fig. 45

– Slide the thrust washers (2) and (3) onto the double UJoint shaft end (24).

– Insert the lock ring (1) at the end of the splined hub and push it into its seat.

Note: check that the lock ring (1) is correctly fitted in its seat.

– Push the double U-Joint thoroughly.

Fig. 46

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Axle beam group

Fig 47

.

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

Warning: before disassembling this group remove the wheel hub group (see previous sections); if only seal ring or bush replacement is necessary, follow the instruction in “Special repair operations”.

– Remove the two double U-Joints (6) from the axle beam (1).

Fig. 48

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the seal rings (5) from the axle beam (1).

Note: destructive operation for the seal rings.

– Remove the bush (4) from the axle beam (1) only if the wear conditions require this.

Warning: be careful not to damage the bush seat.

Fig. 49

– Remove the upper king pin bush (2) and the ball bearing cup (3) from the king pin seats using a suitable extractor only if the wear conditions require this.

Fig. 50

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Cool the upper king pin bush (2) and the ball bearing cup (3) at a temperature lower than -100 °C with liquid nitrogen.

Warning: wear safety gloves.

– Assemble the upper bush (2) on the upper king pin seat with the special tool 00 1131 404 0 and a hammer.

– Assemble the ball bearing cup (3) on the lower king pin seat with the special tool 00 1131 415 0 and a hammer.

Fig. 51

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Assemble the bush (4) on the axle beam (1) with the special tool 00 1142 433 0 and a hammer.

– Assemble the seal ring (5) on the axle beam with the special tool 00 1142 434 0 (t1) and a hammer.

– See: next point.

Note: grease carefully the seal rings.

Fig. 52

Warning: assemble the seal ring (5) as in figure.

Fig. 53

– Insert the double U-Joint (6) inside the axle beam (1).

Warning: be careful not to damage the seal ring (5).

Fig. 54

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Trunnion bushes and seals

Fig. 55

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Remove the seal ring (9) from the axle.

Note: destructive operation for the seal ring.

– Remove the bush (8).

Note: destructive operation for the bush.

Fig. 56

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the seal ring (1) and the bush (2) from the differential support (6).

Note: destructive operation for the V-ring.

Fig. 57

– Remove the sleeve (4) from differential support with an extractor (a1).

Note: use the M8 threaded extraction holes.

Fig. 58

– Remove the seal rings (3) and (5) from the sleeve (4).

Note: destructive operation for the seal rings.

Fig. 59

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Insert the bush (8) into the axle beam (7) with a hammer.

Note: position the bush with the cut upward as shown.

Fig. 60

– Insert the seal ring (9) in the axle beam (7) with a hammer.

Warning: the seal lip must be positioned on the external side.

– See: next point.

– Lubricate the seal ring (9).

Fig. 61

Warning: the seal lip of the ring (9) must be positioned on the external side.

Fig. 62

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Insert the bush (2) into the differential support with a hammer.

Note: position the bush as shown.

Fig. 63

– Assemble the seal ring (3) to the sleeve (4) with a hammer.

– Assemble the O-ring (5) to the sleeve (4).

– Lubricate the O-ring (5).

Fig. 64

– Apply sealant on the sleeve (4).

Note: apply sealant on indicated surface only.

– See: Adhesives and tightening torques.

Fig. 65

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Assemble the sleeve (4) to differential support.

Warning: align bushing slots and lube oil holes.

– See: next point.

Fig. 66

Warning: bushing slot must be positioned on lube oil holes.

Fig. 67

– Insert the seal ring (1) in the differential support a hammer.

Warning: the seal lip must be positioned on the external side.

– See: next point.

– Lubricate the seal ring (1).

Fig. 68

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Warning: the seal lip of the ring (1) must be positioned on the external side.

Fig. 69

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Differential support group

Fig 70

.

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Drain the oil completely from the differential.

– Disassemble the wheel/double U-joint group from the axle beam.

– Remove the seal ring (11) from the axle beam (12).

Warning: remove the double U-joint from the differential before disassembling the differential support group.

Fig. 71

58

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Screw out the screw (2) and the screws (3) and remove the differential support (1).

Warning: support the differential support (1) with a rope or other appropriate means.

Fig. 72

– Measure the starting total preloading FT0 of the bearings (pinioncrown gear system), using a dynamometer whose cord is wound on the pinion splined end.

Note: the value FT0 that is necessary in the bearings reassembly.

– See: Assembly - Fig. 85.

Fig. 73

– Unscrew the adjuster ring nuts (4) and (10) using the special tool 00 1142 435 0.

Note: destructive operation for the ring nuts (4) and (10).

Fig. 74

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the differential housing (7).

– The bearing cones (6, 8) are removed together with the differential housing.

Warning: do not invert the bearing cone if the bearings are not replaced.

Fig. 75

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Assemble the bearings cone (6, 8) on the differential housing (7).

Warning: do not invert the bearing cones if the bearings are not replaced.

Fig. 76

– Assemble the bushes (5) and (9) to the new nut gears (4) and (10) with a hammer.

Note: use new bushes only.

Fig. 77

60

Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Position the complete differential box with bearings on the differential carrier (1).

Warning: check the right side of the bevel crown assembly.

– Move the differential group so to place the bevel crown gear on the pinion.

– Insert the adjuster ring nuts (4) and (10).

Note: use new ring nuts only.

Fig. 78

– Assemble and tighten both adjuster ring nuts (4) and (10) in the differential support with special tool 00 1142 435 0, till the backlash is eliminated and the differential bearings are slightly preloaded.

Note: check that the differential bearings are well settled; if necessary, knock slightly with a soft hammer, in order to properly set the bearings in position.

Fig. 79

– Position a magnetic-base dial gauge on the differential support, so that the feeler stylus touches the surface of one tooth of the crown gear with a 90° angle.

Fig. 80

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Lock the pinion and move the crown gear alternatively and note the pinion-ring gear backlash, measured with the comparator.

– Repeat the operation on two or more points (teeth), rotating the crown gear, so that to obtain an average value.

– Check if the measured backlash value is within the requested range 0.15÷0.21 mm – Carry out the adjustment by operating on the adjuster ring nuts (4) and (10) with the appropriate tool 00 1142 435 0.

Fig. 81

– Adjust the ring nuts (4) and (10) by using the special tool 00 1142 435 0.

Warning: unscrew/screw the adjuster ring nuts, as indicated in the next step, both of about 30 degrees at once then check the backlash.

Fig. 82

– Adjust the ring nuts (4) and (10), remembering that: • (A) - if the measured backlash is greater than the given tolerance range, unscrew the adjuster ring nut (10) and screw in the adjuster ring nut (4) by the same measure; • (B) - if the measured backlash is less than the given tolerance range, unscrew the adjuster ring nut (4) and screw in the adjuster ring nut (10) by the same measure.

Fig. 83

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached.

Fig. 84

– Once the pinion-ring gear backlash has been established, if the bearings have been not replaced, measure the total preloading FTm of the bearings (pinioncrown bevel gear system), using a dynamometer whose cord is wound on the pinion splined end.

Warning: do not use this method with new bearings, if the bearings have been replaced see next step.

– The measured value FTm should be within the following range (see: Desassembly - Fig. 73): FTm= FT0 ÷ (FT0+10) N follow the operating procedures in step [14].

Fig. 85

– If the bearings have been replaced, measure the total preloading FTm of the bearings (pinion-crown bevel gear system), using a dynamometer whose cord is wound on the special tool 00 1142 438 0 inserted on the pinion splined end.

Fig. 86

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– The total preloading FTm is measured on the special tool 00 1142 438 0 (gauge diameter Dm = 89.25 mm).

– The measured value should be within the following range: FTm = (FPm+16.8) ÷ (FPm+25.2) N – where FPm is the effectively preloading measured on the special tool 00 1142 438 0 (gauge diameter Dm = 89.25 mm).

Warning: values for new bearings.

– See: Pinion group to measure FPm

Fig. 87

– If the measurement is not within the requested range, check well the assembly of each component and operate on the adjuster ring nuts (4) and (10) of the differential support: • (A) - if the total preloading is less than the given range, screw in both adjuster ring nuts (4) and (10) by the same measure, keeping the pinion-ring gear backlash value unchanged; • (B) - if the total preloading is greater than the given range, unscrew both adjuster ring nuts (4) and (10) by the same measure, keeping the pinion-ring gear backlash value unchanged.

Fig. 88

– Once all the adjustment operations have been completed, chalk the adjuster ring nuts (4) and (10).

– See: next point

Fig. 89

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Warning: chalk with care the adjuster ring nuts (4) and (10).

Fig. 90

– Before matching surfaces, make sure that they are perfectly clean, degrease and clean them with appropriate detergents.

– Spread a film of adhesive on the contact surface between the axle beam (11) and the differential carrier (1) (see: Adhesives and tightening torques.).

Note: check that two dowel pins (12, 13) are in their housing.

Fig. 91

– Assembly the differential carrier (1) to the axle housing (11), and tighten the fastening screw (2) and the fastening screws (3) to the requested torque (see: Adhesives and tightening torques).

Fig. 92

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Bevel gear marking test Note: To test the marks of the bevel gear teeth, paint the ring gear with red lead paint.

The marking test should be always carried out on the ring bevel gear teeth and on both sides.

Fig. 93

– OK -> Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular.

– Z -> Excessive contact on the tooth tip: Approach the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the backlash.

– X -> Excessive contact at the tooth base: – Move the pinion away from the ring bevel gear and then approach the ring bevel gear to the pinion in order to adjust the backlash.

Fig. 94

– Movements to correct: • 1 -> move the pinion for type X contact adjustment • 2 -> move the pinion for type Z contact adjustment.

Fig. 95

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Differential group

Fig. 96

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– See: section Differential support group before disassemble the differential group.

– Remove the bearing cups (2) from differential housing (5).

Warning: do not invert the bearing cups if the bearings are not replaced.

Fig. 97

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the screws (6) and remove the bevel gear crown (1).

Warning: this operation make free the spider (11).

Fig. 98

– Remove the snap rings (3).

– Extract washers (4), counterdisks (7), disks (8, 9) and sun gear (10).

Fig. 99

– Extract pin (14).

– Extract the spider (11).

– Collect all the components.

– Check the operating and wear conditions of the components.

Fig. 100

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Assembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

Note: assemble the pinion group before proceeding with differential group assembly.

– Position the differential box (5) on a workbench and assemble: spider (11), planetary gears (12), thrust washers (13), pin (14) as shown in figure.

Fig. 101

– Assemble the crown gear (1) to the differential box (5).

– Apply the prescribed sealant on fastening bolts (6).

– See: Adhesives and tightening torques.

– Assemble the bolts (6) and tighten them to the requested torque.

– See: Adhesives and tightening torques.

Fig. 102

– Position the differential box (5) on a workbench and assemble these inner components: sun gear (10), locking differential disks (8) and (9), locking differential counterplate (7) and washer (4), as shown in figure.

Note: the first disk (9) must be assembled with friction material on the disks side and the flat surface on the sun gear (10) side.

– See: Technical features.

– Assemble the snap ring (3).

Fig. 103

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Assemble the inner components on the other side of the box (5): sun gear (10), disks (8) and (9), counterplate (7) and washer (4), as shown in figure.

Note: the first disk (9) must be assembled with friction material on the disks side and the flat surface on the sun gear (10) side.

– See: Technical features.

– Assemble the snap ring (3).

Fig. 104

– Assemble the bearing cups (2) to the differential housing (5) with a hammer.

Warning: do not invert the bearing cups if the bearings are not replaced.

Fig. 105

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Nexos Elios 240-210 – EN

03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Pinion group

Fig. 106

Disassembly – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

Note: remove the differential group before proceeding with the pinion group disassembly.

– Remove the differential group.

– Measure the starting preloading FP0 of the pinion bearings using a dynamometer whose cord is wound on the pinion splined end.

Warning: note the value FP0 that is necessary in the bearings reassembly.

– See : Assembly - Fig. 128.

Fig. 107

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Lock the differential carrier with a vise.

– Unscrew the lock nut (10) using special tools 00 1131 407 0 and 00 1142 439 0.

Note: this operation will irretrievably damage the lock nut (10).

Fig. 108

– Remove the ring nut (10) and collect its retaining washer (9).

Fig. 109

– Tap the shaft with a soft hammer to remove the bevel pinion (1).

Warning: take care not to drop the bevel pinion (1).

– Collect the washers (4) and (6), the collapsible spacer (5) and the bearing cone (8).

Fig. 110

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Remove the bearing cups (3) and (8) from the differential carrier (7) using a drift and a hammer.

Fig. 111

– To remove the cone of the tapered roller bearing (3) of the bevel pinion (1), use a standard extractor.

– Collect the bearing cone (3) and the underlying shim (2).

Fig. 112

– Check all pinion components for wear.

Warning: the ring nut (10) and the collapsible spacer (5) must be replaced when reassembling the unit.

Fig. 113

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Assembly – Place the differential support (7) on a workbench.

– Fit the bearing cups (3) and (8) using a hammer.

Fig. 114

– Insert bearing cones (3) and (8) in their housings.

– Assemble the false pinion 00 1142 443 0 (a1) and its ring nut (10).

– Tighten without exceeding the ring nut, till the backlash is eliminated.

Fig. 115

– Install special tool 00 1142 444 0 (a2) to the differential group supports (7).

Fig. 116

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Use a depth gauge to measure distance “X” (distance between the axis of the differential bearings and the point at which the pinion head is supported, or base of the bearing).

Fig. 117

– To adjust bevel gear/pinion measure the distance “A” with a depth gauge.

– Calculate the value “X” as follows: X = (A + C) - B mm where “B” and “C” are known.

Fig. 118

S= X - V mm – In order to determine the necessary thickness value (S) between the pinion and the bearing, subtract the value (V), stamped on the pinion head (V = requested distance), from the measured value (X).

Fig. 119

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

SHIMS RANGE Thickness - mm Quantity

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

3.3

3.4

--

--

--

--

--

--

--

--

--

--

– Select the shim (2) of thickness value (S) among the range of available shims.

Fig. 120

– Remove the special tool 00 1142 444 0 to the differential group supports (7).

– Remove the ring nut (10), the false pinion 00 1142 443 0 (a1) and the bearing cones (3) and (8).

Fig. 121

– Once you have chosen the suitable shim (2), insert it on the pinion shaft with the chamfer against the pinion head, as shown in figure.

Fig. 122

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Force the bearing (3) into the pinion shaft (1) with the special tool 00 1131 410 0 under a press, making sure that it is well set.

– Insert the shims (4) and (6) and a new collapsible spacer (5).

Note: use always a new collapsible spacer (5).

Fig. 123

Note: check the right assembly sequence.

Fig. 124

– Insert the bevel pinion (1) unit into the differential support housing (7) and the bearing cone (8) on the pinion shaft, as shown in figure.

– Use the special tool 00 1131 410 0 and a hammer to drive the bearing (8).

Fig. 125

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Insert the ring nut washer (9) and screw a new lock ring nut (10) on the pinion end.

Fig. 126

– Screw the ring nut (10) in, using the wrench for ring nut 00 1131 407 0 and for pinion retainer 00 1142 439 0.

Warning: the torque setting is given by the preloading measurement on bearings (3) and (8); tighten the ring nut (10) gradually.

Note: if the tightening is excessive, the elastic spacer (5) must be replaced and the procedure repeated. When you check the preloading, it is advisable to beat slightly both pinion ends (1) with a soft hammer, so as to help setting the bearings (3) and (8).

Fig. 127

– If the bearings have been not replaced, to measure the preloading FPm of the pinion taper roller bearings (3) and (8), use a dynamometer whose cord is wound on the end of pinion shaft (1).

Warning: do not use this method with new bearings, if the bearings have been replaced see next step.

– The measured value should be within the following range (see : Desassembly - Fig. 107): FPm= FP0 ÷ (FP0 + 10) N follow the operating procedures in Fig. 131.

Fig. 128

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– If the pinion taper roller bearings (3) and (8) are new, to measure the preloading FPm of the bearings, use a dynamometer whose cord is wound on the special tool 00 1142 438 0 inserted on the end of pinion shaft.

Fig. 129

– The effectively preloading FPm is measured on the special tool 00 1142 438 0 (gauge diameter Dm = 89.25 mm) – The measured value should be within the following range: FPm = 36.0 ÷ 53.6 N Warning: values for new bearings.

Fig. 130

– The adjustment is carried out by increasing the ring nut (10) torque gradually, being careful not to exceed.

Warning: all preloadings must be measured without the seal rings.

– Once the requested preloading value is achieved, caulk the ring nut (10), using a hammer and a chisel.

Fig. 131

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

Toe-in / steering angle

Fig. 132

Toe-in adjustment – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Put two equal one-meter-long linear bars on the wheel sides and lock them with two nuts on the wheel hub stud bolt.

Warning: the two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft axis; align the two bars.

Fig. 133

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Measure the distance in mm M between the bars ends with a tapeline.

Note: keep the minimum value, swinging the measurement point.

Fig. 134

– Check that the difference of the measurements between the wheel hubs diameters ends is within the requested tolerance range.

– See: “Toe-in” in sec: Technical features.

– The nominal toe-in value (A) is referred to the external diameter of the wheel hubs flange, therefore the measured value (M) at the bars ends must be related to the ratio between length of the bar and flange diameter 0

nominal toe-in = A -2

0

measured toe-in = M -5

Fig. 135

– If toe-in is incorrect, operate with two wrenches on the guide rods (1) screwing in and out the two joint tie rods (3) equally till the toe-in is within the requested tolerance.

Fig. 136

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– After adjusting, screw in the lock nuts (2) of the guide rods (1) to the requested tightening torque.

– See: Adhesives and tightening torques.

Fig. 137

Steering angle adjustment – Some of the following pictures may not show exactly your axle, but the indicated operations are correct anyway.

– Use the same bars assembled for the toe-in adjustment and a long bar perfectly leaned over the machined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.

Fig. 138

– For the steering angle adjustment, set a protractor to the following calculated angle C: C= 90°-S – Where S is the prescribed adjustment steering angle.

– See: Technical Features.

– Position the protractor on the long bar.

– Move a wheel side till it forms, with the two bars, the calculated angle C.

Fig. 139

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

– Adjust the mechanical steering stop, screwing in or out the stop bolts (4), locking them with the nuts (5) to the requested tightening torque.

– See: Adhesives and tightening torques.

– Steer completely towards the other side and repeat the same operations.

Fig. 140

Nexos Elios 240-210 – EN

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03 CHASSIS - ELIOS 4 WHEEL DRIVE Disassembly and Assembly

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Nexos Elios 240-210 – EN