CLAAS RABA 579 Series GENERAL WORKSHOP MANUAL - PDF DOWNLOAD

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RABA 579 Series GENERAL WORKSHOP MANUAL

Abstract: This type of GENERAL WORKSHOP MANUAL was prepared for RABA 579.07/579.17 running gear system.

This is a second manuscript therefore further changes are expected!

RIGHTS FOR ALTERATIONS RESERVED!

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CONTENTS 1.

2.

2.1.

3.

3.1.

3.2.

3.3.

3.4.

3.5.

4.

5.

5.1.

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 6.

6.1.

6.2.

6.3.

7.

7.1.

7.2.

7.3.

8.

8.1.

8.2.

8.3.

9.

9.1.

9.2.

9.3.

10.

10.1.

10.2.

10.3.

11.

11.1.

11.2.

11.3.

12.

12.1.

12.2.

12.3.

13.

13.1.

13.2.

13.3.

14.

14.1.

14.2.

14.3.

15.

15.1.

15.2.

15.3.

Preface ................................................................................................................................................................... 4 Technical data ........................................................................................................................................................ 4 The systems of the axle ......................................................................................................................................... 4 General Safety Instructions .................................................................................................................................... 5 Before start the work .............................................................................................................................................. 5 Installing and uninstalling process ......................................................................................................................... 5 Working with the uninstalled axles ......................................................................................................................... 6 Save the environment! ........................................................................................................................................... 6 Termination of the warranty conditions and damage to property disposed ........................................................... 6 Special tools and equipments ................................................................................................................................ 7 Maintenance ......................................................................................................................................................... 12 Controlled features and values ............................................................................................................................ 12 Visual controlled features ................................................................................................................................ 13 Oil change and level control in the wheel hubs ............................................................................................... 13 Oil change and level control in the gear box ................................................................................................... 13 King-pin lubrication with grease ....................................................................................................................... 13 Service brake wearing control ......................................................................................................................... 13 Parking brake control ....................................................................................................................................... 13 Input gear corrective maintenance ....................................................................................................................... 13 Assembly.............................................................................................................................................................. 16 Disassembly ......................................................................................................................................................... 22 Corrective tasks ................................................................................................................................................... 33 Differential corrective maintenance ...................................................................................................................... 34 Assembly.............................................................................................................................................................. 37 Disassembly ......................................................................................................................................................... 43 Corrective tasks ................................................................................................................................................... 52 Oil pump corrective maintenance ........................................................................................................................ 53 Assembly.............................................................................................................................................................. 54 Disassembly ......................................................................................................................................................... 55 Corrective tasks ................................................................................................................................................... 56 Steering piston corrective maintenance ............................................................................................................... 56 Assembly.............................................................................................................................................................. 59 Disassembly ......................................................................................................................................................... 60 Corrective tasks ................................................................................................................................................... 60 Differential Carrier Housing Assy. corrective maintenance ................................................................................. 60 Assembly.............................................................................................................................................................. 64 Disassembly ......................................................................................................................................................... 83 Corrective tasks ................................................................................................................................................... 89 Bearing of the driver shaft ( double joint ) corrective maintenance ..................................................................... 89 Assembly.............................................................................................................................................................. 92 Disassembly ......................................................................................................................................................... 95 Corrective tasks ................................................................................................................................................... 98 Axle housing corrective maintenance .................................................................................................................. 98 Assembly............................................................................................................................................................ 101 Disassembly ....................................................................................................................................................... 109 Corrective tasks ................................................................................................................................................. 115 Axle incomplete (diff housing, axle housing) corrective maintenance ......... 115Hiba! A könyvjelző nem létezik.

Assembly............................................................................................................................................................ 118 Disassembly ....................................................................................................................................................... 120 Corrective tasks ................................................................................................................................................. 121 Wheel hub unit (5) corrective maintenance ....................................................................................................... 121 Assembly............................................................................................................................................................ 124 Disassembly ....................................................................................................................................................... 129 Corrective tasks ................................................................................................................................................. 135 Inner planetary carrier (7) corrective maintenance ............................................................................................ 135 Assembly............................................................................................................................................................ 137 Disassembly ....................................................................................................................................................... 139 Corrective tasks ................................................................................................................................................. 140

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16.1.

16.2.

16.3.

17.

17.1.

17.2.

17.3.

18.

18.1.

18.2.

19.

19.1.

19.2.

19.3.

20.

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Outer planetary carrier (8) corrective maintenance ........................................................................................... 141 Assembly............................................................................................................................................................ 143 Disassembly ....................................................................................................................................................... 146 Corrective tasks ................................................................................................................................................. 148 Wheel-hub, tie rods mounting on the incomplete axle corrective maintenance ................................................ 149 Assembly............................................................................................................................................................ 152 Disassembly ....................................................................................................................................................... 154 Corrective tasks ................................................................................................................................................. 160 Toe angle settings .............................................................................................................................................. 160 Toe angle setting................................................................................................................................................ 163 Corrective tasks ................................................................................................................................................. 164 Parking brake corrective maintenance............................................................................................................... 165 Assembly............................................................................................................................................................ 166 Disassembly ....................................................................................................................................................... 167 Corrective tasks ................................................................................................................................................. 168 Attachments ....................................................................................................................................................... 168

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1. Preface This publication "GENERAL WORKSHOP MANUAL" was prepared for workshops and contains all the necessary assembly instructions as well as data to be checked and adjusted during repair, with the knowledge of which repair and adjustment of the “RABA 579” series running gear system can properly be performed.

This manual based on 579.07/579.17 axles due to the small amount of difference from 05-06 and 15-16 versions of axles. Hence we will discuss a difference between them in locally at the chapters.

The technical data of the specific type versions of the RABA 579 type axles are indicated in the publication "TECHNICAL DATA", while the spare parts are listed in that "PARTS CATALOG" grouped according to the customers.

This "GENERAL WORKSHOP MANUAL" contains divided into sections the technical data and the service instructions of the axle. The sections of the service instructions contain the disassembly and reassembly operations of the individual assembly unit, stating the special tools to be used.

The order of the sections is determining the order of the mounting. The serial numbers of the figures are started from the beginning in each section. The item numbers of the figures for an assembly unit are referred to in the sections dealing with the assembly procedures.

For service operations it is recommended to use the tools shown in the figures in order to assure proper assembly of the individual units. The figures show each essential service operation stating the designation of the tool and its service position. The tools are partly available from commerce and partly can be fabricated in the workshop according to the tool blueprints ordered on basis of tool list supplemented to the "GENERAL WORKSHOP MANUAL" or can be ordered from RÁBA. The manufacturer shall not be liable for warranty claims on damages resulting from negligence of the general service practice required for normal service operations but not contained in this WORKSHOP MANUAL. For replacing assembly units or individual parts use ONLY genuine RÁBA made products.

RIGHTS FOR ALTERATIONS RESERVED!

2. Technical data 2.1. The systems of the axle This 579 running gear system have been designed by Raba in order to meet the modern agricultural tractors posed by more power and increased manoeuvrability requirements simultaneously. These axels have pumped lubrication system and spreading lubrication with dynamic oil level control at the same time. These lubrication characteristic and the dynamic oil cooling system provide the maximal mechanical efficiency and long oil and axle life also. This driveline was built with 3-stage which is producing enough torque for the heaviest agriculture works. And the multiple disc wet brake system can cope with the recent challenges of the agricultural transport tasks.

Driveline Service brake system Parking brake Lube system Front axle suspensions Rear axle suspensions

3-stage with double stage planetary gear wheel drive Hydraulic operated multiple disc wet brake Hydraulic opened single disc brake on the rear axle Combined: Pumped / spreading lubrication with dynamic oil level changing With oscillation axis Rigid and flat plate mounted

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Definition

Units

Data

Wheel track with single wheel Wheel track with double wheel Overall width Spring center distance in rear axle Applicable wheel disc Overall gear ratio Weight of front axle without oil fill Weight of rear axle without oil fill Max input torque of front axle Max input torque of rear axle Max. input rpm Permitted total rolling mass Max. latching slope angle with fixing brake operation

mm mm mm mm

1960 3112 2543 960

kg kg Nm Nm 1/min kg deg

3900 40000 18

3. General Safety Instructions 3.1. Before start the work Before start the work keep the local and standard safety regulations!

During the work use the CE-standard and the General Workshop Manual listed special tools only!

If you differ from the General Workshop Manual instruction the guarantee must be avoid automatically!

Keep the tidy up in the workplace to prevent the accidents and failures. These axles may contain flammable oils and components please keep the local fire safety instructions!

3.2. Installing and uninstalling process

During the un-installation and the installation process you must wearing the personal protection equipment according to the local craning safety standards and CE – safety standards.

Before start the craning the axle out of the machine you make sure about you uninstalled the all hydraulic and electric connections!

After the installing processes you must sure about you connected the hydraulic and electric connections!

Before start the machine you must sure about you filled with the axles the required quality and quantity of oil!

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3.3. Working with the uninstalled axles

Before star the work with uninstalled axles you must sure about you fixed the axle in a right way, and you use the required equipment for this process!

Before start un-mounting the parts of the axles you mast sure about the lubricant oils have been drained!

During the repairmen processes save your hands and eyes! These axles may contain shaped parts and tight gaps witch are able to hurt your hands in order to prevent your hand wear the hand protective gloves! During the maintenance and repair may brake of the small spices of the tools or parts in order to save your eyes wear the protection glasses!

The parts of the axles may contain small amount of lubricant oil after you have drained them! If the oils get into the floor may case the slip hazard and environmental pollution. Use the salvage containers to prevent effuse the oil left over!

3.4. Save the environment!



These axels filled with lubricant oils which are can cause environmental pollution and fire and sleep hazard!

In order to prevent these effects please keep the instructions above!  Do not use an open flame during the repair!  Collect the used oils and oil containers and handled them according to the referring safety instructions.

Absorb with the spilled oil and collect and handled it the same way as we noticed it the point before.

3.5. Termination of the warranty conditions and damage to property disposed

Our company disclaims any and compensation for damage resulting from improper uses or install of axles!

The improper repairs may void the warranty automatically!

The axles mast repair in the special trained and equipped workshop otherwise the warranty will automatically terminate!

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4. Special tools and equipments Description Brake disc lamellas fixing clamp for mounting Alignment rod for pinion gear unit Alignment rod for axle housing unit Rollover torque control equipment pinion gear unit Differential piston mounting tool kit Gear box bearings mounting tool kit Special wrench kit for gearbox bearing nuts Bearing installer for differential gear unit (left side ) Bearing installer for differential gear unit (right side ) Oil deflector collar installer tool for differential gear unit Wheel hub uninstalling kit Wheel hub installing kit King pin bush and sealing installer Wheel hub face seal mounting ring Wheel hub cover centering screw King pin uninstaller / installer kit Service brake wearing checking tool

Tool No.

Figure No.

9035-00162-00 9035-00156-00 9035-00145-00 9035-00140-00 9035-00282-00 9035-00146-01 9035-00277-00 9035-00278-00 9035-00279-00 9035-00265-00 9035-00246-01 9035-00247-01 9035-00280-00 8931-00425-00 9035-00235-00 9035-00168-02 AU -11908_00

1.

2.

3.

4a ;4b 5a – 5e 6a ; 6b 7a ; 7b 8.

9.

10a ; 10b 11a – 11g 12a – 12d 13.

14.

15.

16a ;16b 17

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Ordering Code 451088 451537 451526 451521 451863 451527 451856 451854 451855 451809 451774 451775 451857 402915 451724 451548 169289

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5. Maintenance This chapter of the manual will refer the normal operations. This chapter contains the values and main features which have to check and occasionally adjust according to this manual.

5.1.

Controlled features and values

Definition group Grease lubricated parts

Oil level control

Working hourly task

Part name

Conditions

500

King pin

Over +5Cº temperature!

Unloaded axle!

100

Oil level control sticks.

In normal oil temperature ( 0-25Cº)

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5.1.1 Visual controlled features 5.1.2 Oil change and level control in the wheel hubs 5.1.3 Oil change and level control in the gear box 5.1.4 King-pin lubrication with grease 5.1.5 Service brake wearing control 5.1.6 Parking brake control

6. Input gear corrective maintenance

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Figure 1 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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6.1. Assembly Assembly steps

Picture

Bearing cage sub assy Step 1 Place the bearing cage (5) with the larger bevel position upright and mount two orifices (6) and tighten to 10 Nm Step 2 Check the cleanliness of the orifices (6) hole visually Step 3 Place the taper roller bearing outer ring 3 32315B to a table Step 4 Apply gently oil on bearing cage bevel bearing positions Step 5 Press fit the bearing cage (5) with the 2 different taper bearing (3,8) Step 6 Check the clearance between taper roller bearing outer ring the bearing cage position if there is any clearance, press fit again.

Step 7 External and internal ring shall be assembled together from the same box Step 8 External and internal ring shall not be exchanged even they are from the same manufacturer Pinion (1) sub assy

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Step 9 Place the pinion (1) on to a flat table, apply gently assy oil to the bevel place and mount and press fit the taper bevel gear inner ring w/o any clearance, if there is any, press it again.

Step 10 Already mounted bearing cage (5) sub assy to place to the pinion (1) Step 11 Place shim (4) from the historical data set to the shaft of the pinion

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Step 12 Place the spacer ring (7) to the pinion (1) shaft then the bevel gear inner ring, and press fit the ring

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Step 13 Mount the spacer (9), yoke (12), washer (14) and the flange castle nut (15). With the pneumatic torque wrench 3/4" fix the flange castle nut. Torque the flange castle nut to 650 Nm with special torque wrench 9035-00139+

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Step 14 Set the pinion assy torque with torque wrench. If the drag torque is 2-7 Nm press fit the pinion sub assy

Step 15 Before tighten the yoke, the yoke and the spacer position must be marked and shall be mounted back to the same position, otherwise the drag torque will change Fig 4 Pinion subassy final assembly Step 16

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Press fit the inner ring of the bevel gear (8) to the shaft of the pinion then place spacer ring (8) Step 17 Press fit the V-ring (10) to the bearing cage to place the spacer ring (9)

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Step 18 Place then fit firmly the yoke with V ring to the pinion rib

Step 19 Washer (14), flange castle nut (15) fit to the stop then tighten to 650 Nm

Step 20 Align the cotter pin (16) hole on the pinion shaft (1) with the flange castle nut (15) hole.If the holes are not aligned the flange castle nut shall be tightened to the next hole. Insert the cotter pin to secure the joint.

Maximum torque 780 Nm.

6.2. Disassembly Disassembly steps

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Step 1 Remove the cotter pin (16) from the flange castle nut (15).

Step 2 Remove the flange castle nut (15) and the washer (14) from the end of the pinion gear (1).

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Step 3 Pull down the yoke assy (12) with the V-ring (11) from the ribs of the pinion gear (1).

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Step 4 Remove the seal (10) from the bearing cage (5).

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Step 5 Place the input gear into a special sleeve.

Step 6 Push the pinion gear (1) from its bearings (3,8) and the bearing cage (5). You can’t push it (1) helping with your hand ,so you have to use a special hydraulic presser.

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Step 7 After pushing the pinion gear (1) you can remove the spacer ring (9) and the inner ring of the tapered roller bearing (8).

Remove the bearing cage from the pinion gear.

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Step 8 Remove the spacer ring (7) and the shim kit (4). The inner ring and its rollers of the other bearing (3) stay on the pinion gear (1).

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Step 9 You can pull down the inner ring with its rollers of the bearing (3) from the pinion gear by a special bearing remover / puller. You have to put an other outer ring of the same typed tapered roller bearing in order to use this special bearing puller.

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Step 10 Place the pinion gear with the special bearing remover onto a special holder. Put them under a hydraulic presser and push the pinion gear from its bearing (3).

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Step 11 Remove the special bearing remover and the inner ring of the bearing (3) from the pinion gear.

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Step 12 Remove the outer rings of the bearings from the bearing cage (5).

Step 13 Screw out the orifices (6) from their hole from the bearing cage (5).

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7. Differential corrective maintenance

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Figure 3

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Figure 4

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7.1. Assembly Assembly steps Flanged differential part sub-assy

Picture

Step 1 Dismount the differential housing (1) to two pieces, please check and mark the positioning of the housing parts (1/1,1/2,1/3).

Step 2 Place 12 cylinder head bolts to the bevel gear (2) holes and fix them with O-ring.

Step 3 Place the bevel gear (2) to a fixture.

Step 4 Mount the flanged differential housing (1) to the bevel gear (2) in this position Step 5 Apply Loctite 277 to the first two threads of the bolt , and tighten the nuts by 390 Nm

Central section sub-assy of the differential

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Step 6 Change the position of the flanged differential sub-assy (1) and place one large Torlon sliding washer (7) and one large differential gear (8) as displayed on the figure.

Step 7 Mount 24 pcs of needle rollers (23) to the shaft of the differential spider (9). Fix the needle rollers with some rubber ring then mount one small differential bevel gear (10) and spherical washer (11)

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Step 8 Repeat this operation on all four shaft of the differential spider (9) Step 9 The pre assembled the differential spider (9) then placed to the half bore of the flanged differential housing. Over mount one large differential bevel gear.

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Step 10 Place the central differential housing(1/2) on the flanged differential housing (1/1).

Step 11 Apply Loctite 243 to the first two-three threads of the bolt M14x70 (9), and tighten them by 180 Nm, those bolts are supplied with the pre-assembled differential housing.

Step 12 Check the easy running of the differential bevel gears Step 13 Mounting of the diff lock and flattening of the diff lock disk (Figure 3) Step 14 Place the ribbed hub (12) over the large differential bevel gear (8) with the ribbed positioning shaft

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Select 11 pcs of separator plate (13) and 10 diff lock disk (14) and mount them to the splined hub (12), start always with external rib disk. Flatten the disk with 10 ton press (if available) Step 16 Place the thrust disk (15) over the set of disk. Place one thrust washer (7) to the splined hub (12)

Step 17 The third differential housing (1/3) shall be placed to the central differential housing (1/2)

Step 18 Apply Loctite 243 to the first two-three threads of the bolt M12x60 , and tighten them by 100 Nm, those bolts are supply with the pre-assembled differential housing

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Step 19 Remove the ribbed positioning shaft and place aside.

Axial bearing mounting Step 20 Place 6 pcs. of cylindrical rollers (16) into the third differential housing holes.

Step 21 Check the position of the cylindrical roller (16) comparing to the differential housing (1/3) with depth measurer Step 22 If the position is largely differ from the reference (5 mm), check the components, use other diff lock disk set.

Step 23 Please 6 pcs. of springs (17) into the holes of the third differential housing (1/3). Then the internal bearing raceway (18), axial bearing cage (19) and the external bearing raceway (24), fix the axial bearing with a snap ring (20)

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Step 24 Apply gently oil on the third differential housing bearing surface, then press fit the oil dam (21) and smaller taper roller bearing (22) Step 25 Turn the differential upside down and apply gently oil on the bearing surface and mount the larger tapered roller bearing (6) Step 26 There shall be no clearance between bearing ring??? and the differential housing

7.2. Disassembly Disassembly steps Step 1

Picture

Remove the snap ring (20) from the differential housing.

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Step 2 After removal the snap ring (20) you can pull down the group of parts at the same time such as the tapered roller bearing (22) , the oil dam (21) and the bearing raceway external (24) helping with a general bearing remover.

Step 3 Remove the axial cylindrical bearing cage (19) and the bearing raceway internal (18).

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Step 4 Take out the springs (17) and the rollers (16) from the holes of the third part (1/3) of the differential housing .

Step 5 Unscrew the bolts to remove the third part (1/3) of the differential housing from its second part (1/2) .

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Step 6 Separate the third (1/3) and the second part (1/2) of the bearing housing by a rubber mallet.

Step 7 Remove the splined hub (12) with the torlon plate.

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Step 7 Remove the separator plates (13) , the friction plates (14) and the lock plate (15) from the second (1/2) part of the differential housing.

Step 8 Remove the larger differential gear (8) from the differential housing.

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Step 9 Put the differential housing onto the torque support to loosen the bolts what connect the first and the second part of it to each other.

Step 10 Loosen and remove the bolts from the housing what connect the first and the second part of it to each other..

Step 11 Separate the first and the second part of the housing.

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Step 12 After separating the elements of the housing you can remove the differential gears (10) , the differential spider (9) and the thrust washers (11) of the gears.

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Step 13 Remove the other larger differential gear (8) and its thrust washer (7) from the house.

Step 14 Turn around the differential housing to loosen the nuts (5) at the end of the bolts (4) what connect the ring gear (2) to the first part of the differential housing (1/1).

Step 15 Loosen and remove the nuts (5).

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Step 16 You have to knock out the bolts (4) from the housing.

Step 17 Remove the gear ring (2) from the flanged differential housing part (1/1) by a hammer and a pin.

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Step 18 Remove the inner ring of the tapered roller bearing with its rollers by three crowbars.

7.3. Corrective tasks

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8. Oil pump corrective maintenance

Figure 5

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8.1. Assembly Assembly steps Step 1

Picture

Installing the intake valve guide sleeve into the pump housing Step 2 Installing the intake valve guide sleeve snap rings Step 3 Installing the intake valves and springs . Mounting the intake valve guide sleeve retainer ring Step 4 Installing the internal valves and springs onto the end cap nuts. Mounting the end cap nuts into the pump housing Step 5 Pushing the ball bearing onto the shaft Step 6 Mounting the external snap ring onto the shaft Step 7 Pushing the needle basket into the pump cover Step 8 Installing the shaft and the ball bearing into the pump housing Step 9 Installing the internal snap ring to hole Step 10 Mounting the central section onto the pump housing Step 11 Inserting the Ø8x40 dowel pins Step 12 Mounting the cavity latch onto the shaft Step 13 Pushing the internal Gerotor gear onto the shaft Step 14 Inserting the external Gerotor gear between the internal gear and the central section Step 15 Installing the pump cover onto the shaft and the dowel pins Step 16 Installing the M8 hex bolts, and tightening them with torque spanner Step 17 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Mounting the curved latch onto the shaft Step 18 Installing the gear onto the shaft Step 19 Pulling the washer onto the shaft Step 20 Mounting the castle nut, and tightening it with torque spanner Step 21 Installing the pressure relief valve

8.2. Disassembly Disassembly steps Step 1

Picture

Removing the cotter pin Step 2 Removing of the castle nut Step 3 Removing of the washer Step 4 Pulling the gear from the shaft Step 5 Removing the internal snap ring to hole Step 6 Removing the curved latch from the shaft Step 7 Removing the M8 hex bolts Step 8 Removing the pump cover Step 9 Removing the central section Step 10 Pulling the Gerotor gears from the shaft Step 11 Removing the cavity latch from the shaft Step 12 Removing the needle basket from the pump cover Step 13 Unmounting the pressure relief valve Step 14 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Unmounting the pump shaft and the ball bearing from the pump housing.

Step 15 Removing the external snap ring from the shaft Step 16 Pulling the ball bearing from the shaft Step 17 Unmounting the end cap nuts from the internal valves Step 18 Removing the valves and the springs Step 19 Removing the end cap nuts from the intake valve Step 20

Removing the intake valves and springs Step 21 Unmounting the intake valve guide sleeve retainer ring Step 22 Removing the guide sleeves

8.3. Corrective tasks

9. Steering piston corrective maintenance

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Figure 6

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Figure 7 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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9.1. Assembly Assembly steps Step 1

Picture

Apply grease or mineral oil at gland #3 and piston #2 grooves Step 2 Assemble piston guiding ring #7 into piston groove Step 3 Assemble piston-seal-Oring #8, into empty piston groove do NOT scratch O-ring surface(tool: screw driver, oiled or greased) Step 4 Assemble piston-seal #8. onto O-ring. It is recommended to pre-heat the ring at 50 .. 60 Celsius (120 .. 140 F). then overlap to piston OD until it reaches the groove.

Step 5 Resize the seal #8 to piston Nominal Outside Diameter +0,5 .. 0,8 mm (0,02 .. O,03\M+18168) approximately (tool: piston ring compressor) Step 6 Assemble static seal #9 and backup-ring #1O into gland #3 outer groove - do NOT scratch seal lips - IMPORTANT: respective position of these two parts is critical to function! (tool: screw driver, oiled or greased) Step 7 Assemble rod seals #6 into glands inner grooves (tool: three-prong installation tool) Step 8 Press-fit he rod wipers #5 into glands outer open grooves (tool: hammer + plastic plunger with OD: 75,0 to 75,5 mm) Step 9 Gently slide gland #3 over rod assembly #2. IMPORTANT: rod is NOT symmetrical: gland to be fitted at he rod end where it will face he ‘protrusion’ with smaller diameter, of he piston Step 10 Gentlyfit piston into housing #1 and push until rod comes out of opposite gland, and gland also sits on tube end (tool: plastic hammer) Step 11 Fit he retaining ring #4 into its hole in he housing tube OD. It shall enter by its ‘elbow’ and he elbow shall fit into he corresponding hole D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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available in he gland #3 Step 12

Fully engage the ring #4 by turning he gland #3 COUNTER clockwise until named ring is fully ‘pulled-in’ - turn 90 more for safety (tool: above mentioned adjustable pin-type face wrench) Cylinder should be now ready for reassembly on duty.

9.2. Disassembly Disassembly steps Step 1

Picture

Release he retaining ring #4 by turning he gland #3 clockwise until named ring is ejected out of hole in he tube (tool: adjustable pin-type face wrench, with round pins, to engage holes dia 8,25 mm provided in face ofgland #3) Step 2 Gently pull gland #3 out of he main housing #1 and slide it off he rod to set it completely free Step 3 Gently pull rod assembly #2 out ofthe cylinder housing (do NOT damage rod chromed diameter) Step 4 Remove wipers #5 from both ends by deforming he metal cage, and SCRAP them (tool: screw driver) Step 5 Remove seals #6, #7, #8, #9, #1O from grooves (tool: screw driver) and SCRAP them Step 6 Piston cannot be removed from rod: subassembly #2 is non-serviceable Cylinder should be now completely tier down.

9.3. Corrective tasks

10. Differential Carrier Housing Assy. corrective maintenance

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Figure 8

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Figure 9 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Figure 10 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Figure 11

10.1. Assembly Assembly steps Step 1

Picture

Lubricate the surface of the cylinder in the differential carrier housing (1) with Claas Agrihid 46 oil.

Step 2 Place the X-ring (15) and the backup ring (17) into the smaller groove of the cylinder.The backup ring must be placed on the outer side of the X-ring.

Step 3 Place the X-ring (16) and the backup ring (18) into the bigger groove of the cylinder.

The backup ring must be placed on the outer side of the X-ring.

Step 4 Lubricate the surface of the piston (14) with D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Claas Agrihid 46 oil.

Step 5 Push the piston (14) into the cylinder by special tool ( nr.… ). You have to screw the nut of the tool until the piston is not in its cylinder fully. Then unscrew the nut a half turning back. Let the tool be in this position for the pressure test of the differential lock.

Pressure test of the differential lock Step 6 For the pressure test it is necessary to let the special piston pusher tool be at the same position as in the earlier step (Step5).

Step 7 Pipes of the pressure tester appliance have to be connected to the ends of the oil channels in the differential carrier housing .

Differencial gear operator oil flows in these oil channels.

Step 8 Oil system of the differential lock have to be air bleeded and pressed by 30 bar air D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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pressure.

Step 9 If the pressure decrease under 25 bar after 5 minutes you have to increase it until it become 30 bar again for 10 minutes.After 10 minutes the pressure decreasing can not be more than 1,5 bar. If the pressure decreasing less than 1,5 bar you can continue the assembly.

Installing the input gear to the differential carrier housing Step 10 Turn the differential carrier housing to vertical position of the input gear.

Step 11 Put the O-ring (31) to the grooves of the input gear (3).

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Step 12 Place two special tools ( nr …. ) into the holes of the housing (1) what help the placing of the input gear (3) onto it.

Step 13 Place the shim kit (42) onto the housing and the special tools.

Step 14 Pull up the input gear (3) onto the housing and the special tools.

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Step 15 Screw 3 bolts of 11 (28) to fix the input gear (3) in the differential carrier housing (1) by 100 Nm torque.

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Installing of the differential into the differential carrier housing Step 16 Push the outer ring of the smaller bearing of differential (5) into the housing (1) helping with the special tool ( nr … ). Screw the bearing nut (20) into the housing after pushing the outer ring of the bearing , but you mustn’t fix it by the bearing nut (20).

Step 17 Turn the housing (1) to vertical position of the axis of the differential (5) and put it into the housing.

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Step 18 Push the outer ring of the bigger bearing of differential (5) into the bearing carrier (11) helping with special tool ( nr ).

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Step 19 Screw the bearing nut (19 ) into the bearing carrier (11). You mustn’t fix the bearing with the bearing nut (19).

Turn the bearing carrier to the opposite side.

Assemble the oil baffle plate parts (50) (51) to the opposite side of the bearing carrier and fix them with the six bolts.

Step 20 Place the O-ring (12 ) on the bearing carrier (11).

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Step 21 Put the bearing carrier (11) onto the housing (1) and cover the differential (5).

Step 22 Fix the bearing carrier (11) by two bolts (23) and tighten them with 40 Nm torque.

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Step 23 Screw four service bolts (these bolts are only placed because of helping the assembly ) into the holes of the bearing carrier (11) to fix the bearing carrier (11) to the housing (1).

Setting the contact of the pinion gear and the differential gear Step 24 Turn the housing (1) to vertical position of the input gear (3) and connect a torque measurer to it. Measure the natural input torque.

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Step 25 Turn around the input gear (3) continuously by the torque measurer and during turning around it, measure the input torque and screw the bearing nut (19) until the input torque becomes 3-6 Nm torque.

Step 26 If the input torque is OK , you have to remove the torque measurer from the input gear (3).

Screw the bearing nut (20) on the other side to set the clearance between the teeth of the pinion gear and the differential gear.

CAUTION ! You have to set the clearance without changing the input torque. Not to change it you have to unscrew the bearing nut (19) in the bearing carrier (11) during screw the other bearing nut (20). You have to turn in the bearing nut (20) one tooth and turn out the other bearing nut (19) one tooth.

You have to do that until the clearance between the pinion gear and the differential gear become 0,25-0,53 mm.

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Step 27 If the value of the input torque and the clearance are required you have to secure the bearing nuts by adjuster lock plates (21 , 22 ). Fix them to the housing (1) by helping with bolts (23).

Step 28 Check the input torque again.

Installing the oil pump

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Step 29 The differential carrier housing (1) shall be aligned into position for mounting the oil pump with filter (7). The small O-ring shall be glued into its place with oil, then the oil pump with filter (7) shall be placed into the differential carrier housing by aligning the guide pin and the threaded bores.

The differential carrier housing /1/ and the oil pump's (7) contact surface, the hydraulic bores shall be free from dirt and burr!

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Step 30 The oil pump with the filter (7) shall be fastened to the differential carrier housing (1) with three pieces of hexagonal bolt (33), the bolts shall be tightened with 125Nm torque.

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Installing the oil sump Step 31 The differential carrier housing (1) shall be aligned into position for mounting the oil sump, then the contact surface with the oil sump shall be wiped clean with alcohol soaked cloth. The contact surfaces have to be clean and grease free.

Step 32 Loctite 515 shall be applied uniformly on the differential carrier housing /1/ contact surface with the oil sump.

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Step 33 The oil sump (40) shall be affixed by aligning the bores, and fastened by installing 22 pieces of hexagonal bolt (38), tightening them with 40Nm torque.

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Step 34 The O-ring (13) shall be fitted to the oil drain plug (41), and the plug shall be screwed into place in the oil sump, and tightened with 70Nm torque.

Installing the steering cylinder Step 35 The differential carrier housing (1) shall be aligned into position for mounting the steering cylinder (8). Before installing the steering cylinder (8), the symmetricity of the steering rod shall be checked with the tool.

The rod shall be centered, if necessary. The plastic plug shall be removed, and the differential carrier housing (1) 's contact surface with the steering cylinder shall be smeared with Amblygon grease.

Step 36 The steering cylinder shall be plugged in through the bores in the differential carrier housing (1), by aligning the bores. The cylinder shall be fastened to the differential carrier housing with seven pieces of M20 bolt (36), tightening them with 490Nm torque.

Step 37 The steering cylinder's (8) position shall be secured with a lock plate (37).

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The cylinder head shall be aligned with a castle nut spanner, if necessary.

Step 39 Loctite 243 shall be applied on three pieces of M8 bolt , then the lock plate shall be installed using the bolt. The bolts shall be tightened with 40Nm torque.

Step 40 The plastic plugs removed shall be reinstalled.

10.2. Disassembly Disassembly steps Step 1

Picture

Remove the lock plate (37) what secure the steering cylinder (8).

Step 2 Remove the bolts (36) of the steering cylinder (8) and pull out it from the differential carrier housing (1).

Step 3 Remove the bolts (38) of the oil sump (40) and remove the oil sump (40) itself.

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Step 4 Remove the three bolts (33) of the oil pump and remove the oil pump (7) itself.

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Step 5 Unscrew the bolts (23) of the lock plates (21,22) to remove the bearing nuts (19,20)

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Step 6 Unscrew the bearing nuts (19,20).

Step 7 Unscrew the three bolts of the bearing nut carrier (11) and remove it.

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Step 8 After removal the bearing nut carrier (11) you can pull out the differential (5). Remove it from the housing (1).

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Step 9 Unscrew the bolts (28) of the input gear (3) and remove it from the housing (1).

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Step 10 Remove the shim kit (42)

10.3. Corrective tasks

11. Bearing of the driver shaft ( double joint ) corrective maintenance

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Figure 12

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Figure 13

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11.1. Assembly Assembly steps Preparing the bearing sleeve Step 1

Picture

Seal (5) shall be pressed into the bearing sleeve (4) until it butts on.

Step 2 One bearing (6) (6311 /C3 SKF) shall be pressed into the bearing sleeve (4) until it butts on.

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Step 3 The lock ring (7) (120 MSZ 231) shall be mounted into the bearing sleeve (4).

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Pressing the double joint Step 4 The sensor ring shall be pushed onto the longer shaft.

Step 5 The dust shield ring shall be pushed onto the shorter shaft.

Step 6 The prepared bearing sleeve (4) shall be pushed on the longer shaft until butts on, and secured in position with a lock ring (8) (55 MSZ 232).

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Step 8 Snap ring (8) shall be mounted into the groove on the longer driver shaft.

Step 7 The lock ring (3) (RW 50 DIN6993) shall be mounted on the longer and the shorter shaft.

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Remove the snap ring ( to shaft ) (8) .

Step 2 Knock down the bearing housing (4) , the oil-seal (5) and the ball bearing (6) at the same time. The ball bearing and the oil seal stay in the housing. Use two hammer to removal the bearing housing.

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Step 3 Remove the snap ring ( to hole ) (7).

Step 4 Knock out the ball bearing (6) from the bearing housing (4) helping with hammer and crowbar.

Removal of the ball bearing (6) from the bearing housing (4) can only be done by pushing the inner ring of it. So after removal it , you can’t use it again , you have to change the bearing.

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Step 5 Remove the oil seal (5) from the bearing housing (4) helping with a screwdriver.

11.3. Corrective tasks

12. Axle housing corrective maintenance

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Figure 14

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12.1. Assembly Assembly steps Step 1

Picture

The thrust washer (2) shall be glued with Loctite 9466 onto the axle housing (1), and shall be griped with a clamp.

The assembly of the axle housing shall be continued only after expiration of the adhesive during time of 24 hours. Warning! Assembly shall be continued only after 24 hours.

Step 2 The clearness of the brake piston bores shall be inspected, and they shall be blown through with high pressure air. Porous, dirty, burred brake bores are not allowed! Every bore shall be inspected manually!

Step 3 The contact surface between the axle housing and the brake piston cylinder shall be smeared slightly with CLAAS Agrihid 46 oil, then the X-ring shall be pushed into the groove with hand guided. The untwisted state of the X-ring shall be checked. The backup ring (5) shall be pushed into the X-ring (6) groove. The X-ring shall be situated on the side to the brake fluid line! The backup ring shall be situated on the opposite side to the brake fluid line!

Step 4 Into the other groove an other X-ring (7) and an other backup ring (8) shall be installed.

The X-ring shall be situated on the side to the brake fluid line! The backup ring shall be situated on the opposite side to the brake fluid line!

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Step 5

Step 6 The brake piston side shall be smeared slightly with CLAAS Agrihid 46 oil, and pushed into the axle housing (1) nest as it can be seen on the figure. The piston shall be secured with two pieces of assembly bolt (11).

The brake piston (9) installation tool screw shall be rotated until stop and then rotated half a turn back.

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Step 7 The hand pump shall be attached, the brake system shall be deaerated, and a brake pressure of 90-100 bar shall be applied for 5 minutes. (brake formatting). If the pressure falls under 90 bars after 5 minutes, then the pressure shall be reset to between 90-100 bars again. The pressure drop is appropriate if it is under 5% (5 bars). After a successful pressure, check the lines used for applying pressure and shall be sealed with caps.

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Step 8 Put into the stroke monitoring bore one bolt.

Screw shall be installed, and fastened with 40Nm torque.

Step 9 The assembly allen bolts (11) used for securing the piston (9) shall be removed.

Springs (10) shall be fitted onto 6 pieces of allen bolt (11). On the first 2 or 3 threads of the allen bolts (11) Loctite 277 shall be applied, and screw into the axle housing tapped holes. The allen bolts (11) shall be tightened with 40Nm torque.

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Step 10 King pin bushing (20) shall be placed on the press ring ( on the press tool ), then the king pin bushing (20) shall be forced into the bore.

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Step 11 The seal ring (21) shall be placed on the seal ring setter, then the seal ring shall be forced into the bore. The seal ring is not allowed to stick out from the surface, the split is not allowed to deviate from the horizontal position more than 10° in any direction.

Step 12 Press the king pin bushing (3) into the bore on the other side (bottom side).

Step 13 The O-ring (18) shall be placed into the groove of the bearing sleeves cylindrical surface of the preassembled driver shaft ( double joint ). The untwisted state of the Oring shall be checked.

Step 14 The driver shaft ( double joint ) (16) shall be fitted into the axle housing, making sure that the ribs of the shaft do not damage the oil dam of the brake piston (9). The sensor bore on the bearing sleeve (or its fillings) shall be situated upwards relative to the axle housings install position.

Step 15 The double joints bearing sleeve shall be attached to the axle housing (1) with six pieces of flanged bolt (19). The flanged bolts shall be tightened with 40 Nm torque.

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Step 17 Put the lock ring and after this the brake hub onto the driver shaft and then another lock ring into its groove. Following this put the separator plates and the brake discs on the double joint shaft.

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12.2. Disassembly Disassembly steps Step 1

Picture

Remove the separator plates ( 12 , 13 ) and the brake discs (14) at the same time from the axle housing.

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Step 2 Remove the lock ring, pull out the brake hub (15) and remove the another lock ring from the driver shaft (16) .

Step 3 Unscrew the flanged bolts (19) what connect the bearing house of the driver shaft (16) to the axle housing (1) and pull out the shaft with its bearing housing from the axle housing.

Step 4 Unscrew the allen bolts (11) with their springs (10) what connect the brake piston to the axle housing.

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Step 5 You can only push the brake piston from the axle housing helping with a plastic rod from the other side of the axle housing.. Caution ! During pushing the brake piston, the piston can jump suddenly from the axle housing so you have to hold it by hand.

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Step 6 Remove the X-rings (67) and the backup rings (5,8) from the groove of the housing.

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Step 7 Remove the seal (21) and the king pin bushings (3,20) from the housing helping with a crowbar. You can only remove them with shattering so you can’t re-assemble them into the axle housing again. After removal them you have to change them.

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12.3. Corrective tasks

13. Axle incomplete (diff housing, axle housing) corrective maintenance

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Figure 16

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Figure 17

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13.1. Assembly Assembly steps Step 1

Picture

The brake discs shall be secured on both side with clips.

Step 2 One piece of the big O-rings (8) shall be fitted slightly oiled into the bearing carriers groove untwisted. One piece of the small O-rings (9) shall be glued with oil into the bore of the bearing carrier, according to the figure.

Step 3 Special tool ( nr. …. ) has to be put into the differential housing to help placing of the axle housing on it.

Step 4 Axle housing (2) shall be pushed onto the differential carrier housing, properly aligning the double joint assemblies and the differential ribs. Before contact the brake disc securing clips shall be removed.

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Step 5 14 pieces of M20x100 bolts (10) shall be fitted with M20 washers (11), and using the bolts the axle housing shall be fastened to the differential carrier housing.

The bolts shall be tightened with 490Nm torque diagonally.

Step 6 On the other side repeat the operation steps above.

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13.2. Disassembly Disassembly steps Step 1

Picture

Remove two bolts (10) from the differential carrier housing (1).

Step 2 Put two special tool (nr …. ) into the holes of the two removed bolts (10).

Step 3 Remove all of the bolts (10) what fix the axle housing (2) to the differential carrier housing (1).

Step 4 Pull the axle housing (2) from the differential housing (1) a little bit to put the special tools ( nr … ) between them. It is necessary not to drop out the brake discs and the separator plates from the axle housing.

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Step 5 Pull down the axle housing (2) from the differential housing (1) . The two special tools help during the disassembly. They direct and hold the axle housing during pulling down it. CAUTION ! The brake hub (4) has to be on the driver shaft. Lack of lock ring it can remove from the shaft during pulling down the axle housing. If it happens the brake discs and the separator plates would drop out . So, be careful!

Remove the axle housing slowly.

Step 6 After removing the axle housing (2) from the differential housing (1) unscrew the two special tools ( nr… )

13.3. Corrective tasks

14. Wheel hub unit (5) corrective maintenance

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Figure 18

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14.1. Assembly Assembly steps

Picture

Step 1: Sticking the friction plate to the knuckle Stick the friction plate (11) to the knuckle (5) with Loctite 9466.Press the

friction plate with a clamp. You are allowed to continue the assembly after 24 hours because of drying of the glue.

Step 2: Pre-assembly of the wheel hub Take the wheel hub (1) onto the table of the presser machine.Push the outer ring (2) of the wheel bearing (tapered roller bearing) into the housing of the hub. Turn the hub and repeat it with the another wheel bearing outer ring (2).Before pushing the bearing outer rings you have to lubricate the place of them.

Step 3: Assembly of the wheel hub and the knuckle 1 Lubricate the place of the wheel bearings on the shaft of the knuckle.

Put the collar ring (3) on the shaft.Put the inner ring(with rollers) of the wheel bearings (2) on the shaft to the collar ring.Put the wheel hub (1) to the knuckle (5) and after that put the inner ring of the another wheel bearing (2) onto the shaft of the knuckle helping with special tools number 12a-12d

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Step 4: Set the clearance between the two wheel bearings Place the two dowel bushings (13) into the holes on the knuckle.Put the shim kit (15) to the dowel bushings.Screw the gear rim hub (21) to the knuckle.Ten bolts (23) have to be tightened by 490Nm torque.Torque checker equipment have to be put on the wheel hub and check the roller torque of the wheel bearings.If the roller torque isn’t between 15-30Nm you have to change the shim kit thinner or thicker.If the value of the roller torque is between 15-30Nm take off the gear rim hub helping with two bolts and then remove the wheel hub from the knuckle helping with the special tools number 11a-11g You have to measure the rolling torque of the bearings only without the rolling torque of the seal rings (4).So you have to remove the wheel hub to put the seal rings into at the next step.

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Step 5: Pre-assembly of the gear rim Put the planetary ring gear (24) to the service table.Let the snap ring groove be at the top.Place the gear rim hub (21) into the planetary ring gear (24).Let the holes of the dowel bushings be at the top.Put the snap ring (14) into the snap ring groove.Let the two holes of securer bolts (12) be between the two ears of the snap ring.The securer bolts (12) have to be smeared by Loctite 243 and put them into the holes in the gear rim hub and screw them with 50Nm torque.

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Step 6: Assembly of the seal rings into the wheel hub and the knuckle Smear the seal rings (4) and the place of them in the hub (1) and the knuckle with alcohol because of easier sliding.Put the fitter ring on the hub and place the seal ring cross the fitter ring into the wheel hub (1).Then remove the fitter ring.

Step 7: Assembly of the wheel hub and the knuckle 2 After putting the seal rings into the wheel hub (1), you have to assemble the wheel hub (1) and the knuckle (5) again.The method of the assembly is the same as at step 3.

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Step 8: Putting the assembled gear rim unit to the knuckle The method of the assembly is the same as at step 4.Put the correct width shim kit (15) what has been choosen earlier to the knuckle (5).To the shim kit put the earlier assembled gear rim unit. Ten bolts (23) have to be tightened with 490Nm torque. You don’t have to measure the rolling torque again.

Step 9: Assembly of the bearing and the oil seal for the driver shaft into the knuckle Push the oil seal (9) into the sealholder (10).Put the O-ring (11) on the seal holder.Push the cylindric roller bearing (7) into the knuckle (5).Put the lock ring (8) into the groove in the knuckle after the bearing (7). After that push the seal-holder (10) with the oil seal (9) into the knuckle.

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14.2. Disassembly Disassembly steps

Picture

Step 1: Gear oil flowing out Unscrew the allen bolt at the front of the outer planetary carrier (8) to let the gear oil flow out.

Step 2: Outer planetary carrier fixing Fix the outer planetary carrier (8) to an outer point with an endless sling.

Step 3: Bolts of the outer planetary carrier removing Unscrew the three bolts of the outer planetary carrier (8), but don’t remove them.With a hammer hit the head of them to remove the outer planetary carrier (8) from the wheel hub unit (5).

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Step 4: Outer planetary carrier removing Take off the outer planetary carrier (8).The outer sun gear (11) and the thrust washer (12) stay in it.

Step 5: Inner planetary carrier removing Pull out the inner planetary carrier (7) from the gear rim (12).

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Step 6: Inner sun gear removing Remove the thrust washer (9), the snap ring (15), the washer (14) and the inner sun gear (13).

Step 7: Bolts of gear rim unit removing Unscrew the bolts of the gear rim hub (6).You mustn’t remove all of the bolts.You have to let one of them in its hole because of bypass the falling down of the gear rim.

Step 8: Wheel hub fixing to the axle housing and gear rim unit fixing to outer point Put two special tools (11d) into the holes of the wheel hub (1).Put two endless slings onto them and fix the hub to the axle housing, because of bypass the falling down of the hub after removing the gear rim unit (planetary ring gear (12) and gear rim hub (6)).Put another endless sling around the gear rim unit and fix it to an outer point.

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Step 9: Gear rim unit removing Remove the tenth bolt what holded the gear rim unit.Screw two other bolts into the two other smaller holes in the gear rim hub (6) to pull the gear rim unit from the wheel hub (2).

Step 10: Special tools (11a-11g) putting up and fixing to outer point Put the special tools (11a-11g) onto the wheel hub (1) and fix it to outer point with the endless slings what holded the hub in the correct position to the axle housing before.

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Step 11: Wheel hub removing Screw the center bolt of the special tools (11a-11g) to pull the wheel hub (1) and the outer wheel bearing (4) from the knuckle (2).The inner wheel bearing (3) stays on the knuckle (2).

Step 12: Cotter pin and flanged castle nut removing Remove the cotter pin and the flanged castle nut from the end of the conical ball joint of the tie rod end.

Step 13: Tapered ball joint of tie rod end pushing Push the tapered ball joint of the tie rod end from the knuckle by the special tool ( ).

Step 14: Position holder putting Put the special tool ( ) onto the axle housing and the knuckle to hold the correct position between them.

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Step 15: Upper king pin removing Unscrew the bolts of the upper king pin and remove the upper king pin.

Step 16: Lower king pin removing Unscrew the bolts of the lower king pin and remove the lower king pin.

Step 17: Special tool (…) putting on the driver shaft Put the special tool (…) on the driver shaft at the end to cover the lock ring and save the oil seal (17) from the driver shaft.

Step 18: Knuckle removing Pull the knuckle from the driver shaft and the axle housing.

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14.3. Corrective tasks

15. Inner planetary carrier (7) corrective maintenance

Figure 20

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Figure 21

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15.1. Assembly Assembly steps

Picture

Step 1: Lubrication Lubricate the five pins of the inner planetary carrier (1).

Step 2: Bearing pushing Push the cylindric roller bearing (3) to one of the pins.

Step 3: Thrust washer putting Put the thrust washer (2) to one side of the planet gear (4).

Step 4: Planet gear pushing Push the planet gear (4) onto the cylindric roller bearing (3).

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Step 5: Thrust washer placing Place the other thrust washer (2) onto the other side of the planet gear (4).

Step 6: Lubrication Lubricate the thrust washer (2).

Step 6: Repeating steps Repeat step 2-6 to each pin of the planetary carrier (1).

Step 7: Backing plate assembly Put the backing plate (5) to the planetary carrier (1)

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Step 8: Bolts screwing Put thread locker ( Loctite 243 ) to the bolts (6).

Put the five bolts (6) into the holes of the backing plate (5) and planetary carrier (1) and tighten them with 125 Nm torque.

Step 9: Operation checking Check the operation all of the planet gears.

15.2. Disassembly Disassembly steps

Picture

Step 1 Remove the five bolts (6) from the backing plate (5).

Step 2 Remove the backing plate (5).

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Step 3 Remove the thrust washer (2).

Step 4 Remove the planet gear ( 4) and the thrust washer(2) at the other side of the planet gear.

Step 5 Remove all of the rollers of the bearing and the bearing basket from the inner bearing ring.

Step 6 Remove the inner ring of the bearing helping with general bearing remover.

Step 7 Repeat the steps 3-6 for each planetary gear and bearing.

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16. Outer planetary carrier (8) corrective maintenance

Figure 22

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Figure 23 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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16.1. Assembly Assembly steps

Picture

Step 1: Needle roller set placing into one side of the planet gear Place 28 pieces of needle roller (7) into one side of the planet gear (6) helping with special tool(...).Special tool is necessary because of putting the rollers to their correct place.Rollers must be placed around the inside perimeter of the planet gear (6).

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Step 2: Thrust washer assembly Place the thrust washer (5) next to one side of the planet gear that the needle rollers (7) can not fall out the planet gear.

Step 3: Spacer ring placing Put the spacer ring (8) into the planet gear (6).

Step 4: Needle roller set placing into the other side of the planet gear Place 28 pieces of needle roller (7) into the other side of the planet gear helping with special tool(…..).Rollers must be placed around the inside perimeter of the planet gear.The spacer ring (8) have to be between the first and the second set of the needle roller (7).

Step 5: Thrust washer assembly Place the other thrust washer (5) next to the other side of the planet gear (6) to cover the needle rollers (7).

Step 6: Planet gear placing into the planetary carrier The pre-assembled planet gear (6) have to be placed into the planetary carrier (1)

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Step 7: Special tool(…) taking on the planetary carrier Put the special tool(…) on the planetary carrier (1).

Step 8: Planet pin pre-assembly Put the steel ball (4) into the planet pin (3). Put the pin into the special tool (…).The ball (4) have to be put into the groove of the tool.

Step 9: Planet pin pushing Push the planet pin (3) through the tool into its correct place in the planetary carrier (1).The pin (3) have to push out the special tool (…) in front of itself from the planetary carrier (1).

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Step 10: O-ring assembly Put the O-ring (2) into its groove in the outer side of the planetary carrier(1).

Step 11: Lock ring assembly Put the lock ring to hole (9) into its groove in the inner side of the planetary carrier (1).

Step 12 Repeat the above steps for the other planetary gears.

16.2. Disassembly Disassembly steps

Picture

Step 1 Remove the lock ring to hole (9) from the inner side of the planetary carrier (1).

Step 2 Push the planet pin (3) from the outer D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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side of the planetary carrier until the O-ring will be free.

Step 3 Remove the O-ring (2) from the groove of the planetary carrier (1).

Step 4 Push the planet pin (3) further until the steel ball (4) can fall out from the hole of it.

Step 5 Then you have to place the special tool ( nr….. ) into the hole of the pin following the pin. It is necesarry not to fall out the needle rollers (7) when you push the pin. You have to push the pin by the special tool (nr…..)

Step 6 After removing the pin you can take out the planetary gear with all of the needle rollers and the two thrust washers.

Step 7 Remove the thrust washers and all of the needle rollers(7) and the spacer D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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ring (8) from the planetary gear (6).

Step 8 Repeat the above 1-7 step for all of the planetary gears.

16.3. Corrective tasks

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17. Wheel-hub, tie rod mounting on the incomplete axle, corrective maintenance

Figure 24

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Figure 25

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Figure 26

Figure 27

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17.1. Assembly Assembly steps Step 1

Picture

Before start the installation of the wheel hub unit, have to be masked the sharp edges and the snap ring in the hole.

Step 2 Pull the wheel hub unit onto the shaft /3/. During this operation please be careful , the sharp edges of the shaft may couse injury to the shaft sealing /4/!

Step 3 After you set the wheel hub king pin top hole position correctly, install the king pin /6/. Use the 16b tool for straight driving the holes and tapped holes of the bolts.

Step 4 Drive 4 pieces M20x55 bolts into the tapped holes /7/ and tightening them with 490Nm torque. Fixing the bolts with LOCTITE 243 bolt glue !

Step 5 Before start the mounting of the king pin installation on the bottom side, put 1 piece thrust bearing /8/ with /9/ seal into the gap between the knuckle and the axle housing. Then mount the bottom side king pin in the same way as you did it in case of the top side king pin. Fixing the bolts with LOCTITE 243 bolt glue !

Step 6 Mount the grease nipples into the central tapped hole of the king pins /10/. Tighten them with 20 Nm torque.

Step 7 Pull out the mask from the shaft-end. Put the lock ring onto the shaft. After this put the big axial thrust bearing with grease onto the face of the gear rim hub. Then mount the /13/ inner sun gear, put the /11/ washer onto the shaft. Be careful!

The inscription " OUT SIDE " - marking must face of out ! …

Fix the inner sun gear with snap ring to shaft. /14/

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Step 8 Insert the inner planetary gear carrier into the gear rim.

Step 9 You have to fix the small axial thrust bearing with grease on to the face of the outer sun gear.

Step 10 Put the outer sun gear with the thrust bearing into the outer planetary gear carrier. During the outer sun gear installation please be careful, this thrust bearing can getting a wrong position easily! Put the sealing into the groove of the outer planetary gear carrier paying special attention to the untwisting.

Step 11

Install the pre-mounted outer planetary gear carrier /19/.

Use the 15. tool for straight driving and position the holes.

Step 12 Drive the 3 pcs M12 bolts into the tapped holes.

Step 13 Caution! Before tighten the M22 bolts turn around 3 times the axle yoke! Have to be operated without any jam and noise! Tighten the 3 pieces M12 bolts with 70 Nm torque

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Step 14 After the wheel hub assembly have to be filled with 9,4 litre oil the planetary. Install the 2 pieces M22 locking bolts into the oil filling and control holes - in the wheel hub planetary gear carrier - with O-rings. Tighten them with 70Nm torque.

17.2. Disassembly Disassembly steps

Picture

Step 1: Gear oil flowing out Unscrew the allen bolt at the front of the outer planetary carrier (8) to let the gear oil flow out.

Step 2: Outer planetary carrier fixing Fix the outer planetary gear carrier (8) to an outer point with an endless sling.

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Step 3: Bolts of the outer planetary carrier removing Unscrew the three bolts of the outer planetary carrier (8) but don’t remove them.With a hammer hit the head of them to remove the outer planetary carrier (8) from the wheel hub unit (5).

Step 4: Outer planetary carrier removing Take off the outer planetary carrier (8).The outer sun gear (11) and the thrust washer (12) stay in it.

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Step 5: Inner planetary carrier removing Pull out the inner planetary carrier (7) from the gear rim (12).

Step 6: Inner sun gear removing Remove the thrust washer (9), the snap ring (15), the washer (14) and the inner sun gear (13).

Step 7: Bolts of the gear rim unit removing Unscrew the bolts of the gear rim hub (6).You mustn’t remove all of the bolts.You have to let one of them in its hole because of bypass the falling down of the gear rim unit.

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Step 8: Wheel hub fixing to the axle housing and gear rim unit fixing to an outer point Put two special tools (11d) into the holes of the wheel hub (1).Put two endless slings onto them and fix the hub to the axle housing, because of bypass the falling down of the hub after removing the gear rim unit (gear rim (12) and gear rim hub (6)).Put another endless sling around the gear rim unit and fix it to an outer point.

Step 9: Gear rim unit removing Remove the tenth bolt what holded the gear rim unit.Screw two other bolts into the two other smaller holes in the gear rim hub (6) to pull the gear rim unit from the knuckle (2).

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Step 10: Special tools (11a-11g) putting up and fixing to an outer point Put the special tools (11a-11g) into the wheel hub (1) and fix it to an outer point with the endless slings what holded the hub in the correct position to the axle housing before.

Step 11: Wheel hub removing Screw the center bolt of the special tools (11a-11g) to pull the wheel hub (1) and the outer ring of the bearing (4) from the knuckle (2).The inner ring of the bearing (3) stays on the knuckle (2).

Step 12: The cotter pin and the flanged castle nut removing Remove the cotter pin and the flanged castle nut from the end of the conical ball joint of the tie rod end.

Step 13: Pushing out the conical ball joint of the tie rod end Push out the conical ball joint of the tie rod end from the knuckle by the special tool ( ).

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Step 14: Position holder putting Put the special tool ( ) onto the axle housing and the knuckle to hold the correct position between them.

Step 15: Upper king pin removing Unscrew the bolts of the upper king pin and remove the upper king pin.

Step 16: Lower king pin removing Unscrew the bolts of the lower king pin and remove the lower king pin.

Step 17: Special tool (…) putting on the driver shaft Put the special tool (…) on the driver shaft. To protect the lock ring and save the oil seal (17) from the driver shaft.

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Step 18: Knuckle removing Pull the knuckle from the driver shaft and the axle housing.

17.3. Corrective tasks

18. Toe angle setting

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Figure 28 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Figure 29 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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18.1. Toe angle setting Toe angle setting steps Step 1

Picture

Control the steering cylinder’s /1/ rod, because have to set out equally on each side with 138 mm.

Step 2 Tighten the tie rod /10/ with 900 Nm torque into the steering cylinder's rod.

Step 3 Tighten the flanged castle nut /4/ on the conical ball joint with 730 Nm torque in one step. If the cross hole position is exact between the flanged castle nut and the conical ball joint hole apply the cotter pin to fix the flanged castle nut.

Step 4 If the position of the cross hole and the flanged castle nut is incorrect tighten over the flanged castle nut until reaches the exact position of the cross hole.

Please be careful! Do not step over the 800 Nm torque limit! Loosen the flanged castle nut during this operation is prohibited! In the end of the tie rod mounting fix the flanged castle nut with the cotter pin.

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Step 5 Repeat the previous steps on the other side of the axle.

Step 6 Put onto each tie rod one piece steering bumper from the I/6/ ; II /6/ ; III /7/ type . After put between I. and II. steering bumpers a few pieces of shim /8/ and tighten the allen bolts /9/ with 40 Nm torque. Check the operation distance with the special tool between the steering bumpers and the steering cylinder contact face. The operation distance must be 91+/-0,5 mm , and the difference between the right and left side in shim pieces can be maximum one piece!

Step 7

Unmount the allen bolts from the steering bumpers and use LOCTITE 243 fixing gel to lock the allen bolts and tighten them with 40 Nm torque.

Step 8 After the toe angle adjusted tighten the M38 lock nut /10/ with 610-680 Nm torque on both side.

18.2. Corrective tasks

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19. Parking brake corrective maintenance

Figure 30

Figure 31

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19.1. Assembly Assembly steps Step 1

Picture

Apply a Ibm coat of rnineral oil based fluid (suggested product: UCON L8285). 10 the new seals (3, 5, 6. 9, 13. 14, 20) und back-up rings (4, 7). 1)0 NOl’ OIL SEALS (16) Step 2 Install seal (9) in seal groove in piston (8).

Step 3 Siide the adjustmenL piston (10) mb the horc located in the hydraulic piston (8) undl it is flusli with the bottom of the hydraulic piston.

Step 4 Install seal (3) in the small bore of the torque plate (1).

Install seal (5) aud back-up ring (4) in the other groove located in 11w small hore of the torque plate (1) iii the order shown in illustration 3.0 Step 5 Install seal (6) and back-up ring (7) in the larger groove oí torque plate (1). Instal I in the order shown in illustration 3.0 Step 6 Install piston assembly into torque plate (1).

Step 7 AppIy a liberal coating of high grade lithium grease, (suggested product; Chemtool Inc. Alpha 2000) to all surfaces of the five dise springs (11) and stack them into the piston (8)111 an alternating cupped face to cupped face (series) orientation per illustration 3.0 Step 8 InstalI seal (14) into the internal groove on threaded cap (1 2), and seal (13) on (1w 01) of 11w cap (12) as show the illustration 3.0 Step 9 Thread the threaded cap (12) into the torque plate (1) until it bottoms out on tiw ti’om face und torque to 60-80 fl-Ibs (8l.3108i N-n».

Step 10 Install o-rings(16) into the grooves of adjustment screw (IS).

Step 11 Tlircad adjustment screw (1 5) into the hydraulic piston (8) until both o-rings are inside the horc of the piston, but not so far (hat the small piston (10) protrudes GUI past the nose of the hydraulic piston (8). Press on cap (28). See illustration 3.0 Step 12 Install o-rings (20)111 grooves in tbe back counterbores of the torque-plate (1). See iliustration 2.0 Step 13 D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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Assemble washer (22) and uretilane spring (23) 01110 (the mounting bolt (21) then slide the rnounting bolis through the bolt holes in (1w torque plute (1). The adjusment nutJsIece(24) onto 11w niotmting bolt. The cylindrical part of the jamnutisleeve should extend into the torque plate past the o-rings (20).

Step 14 Ínstall lining 8 carrier assemblies (25) into the cavity on the torque plate (1). Install the socket head cap screw (26) into the torque plate (1) and thread it mb the Lwo lwx nuts (27) located in ilw slo( in 11w haek side ortiic torque plate. Torque the two hex nuts (27) against each other to 30-35 fl-Ibs (40.7-47.5 N-rn).

(See illustration 2.0) Step 15

Install the bleeder (17) in the port located on the top side of the torque plate (1% and torque to 200-250 inIbs (22.6- 28.2 N-m).

19.2. Disassembly Disassembly steps REMOVAL FROM VEHICLE Step 1

Picture

Block vehícle in position to preven movement.

Step 2 Apply hydraulic pressure to the brake. Loosen hex nuts (27) and rernove socket head cap screw (26).

Step 3 With pressure applied. remove cap (28). (ben loosen adjustment screw (15) until the end of piston (10) that contacts the íront lining carrier Is Ilush ith the exposed end of piston (8).

Step 4 Release hydraulic pressure Írom the brake and remove lining carrier assemblies (25).

Step 5 Loosen brake line and cap inlet port.

Step 6 Loosen jam-nuu sleeves (24) and back mounting bolts (21) out of mounting holes.

DISASSEMBLY Step 7 Lise a spanner wrench to remove threaded cap (12), the disc springs (11) wiII be accessible when iBe threaded cap Is removed. (See illustration 3.0) NOTE: ONLY REMOVE THE THREADED CAP (12) IF THE BRAKE IS NOT PRESSURIZED. D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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ANOTHER ADJUSTR1ENTSCIWW(l5) IS BACKE» 0FF UNTIL THERE IS NO L0A»ON THE DISC SPRINCS (11).

Step 8

The preÍerred method Íor removaI oíthe pistons (8 8.

10) Is to press the pistons out Írom the lining t carrier (25) side ofthe torque plate (1). Remove piston (10) Itom piston (8) by pressing through the threaded hole.

CAUTION: New senls must be installed whenever the brake is disassembled.

19.3. Corrective tasks

20. Attachments

D:\munka\45916\Service_documents\579_service_manual\test_1\GE NERAL WORKSHOP MANUAL_XXL_17.doc

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