TM-21591-1

TABLE OF CONTENTS
1.1 Introduction 2
1.2 Ordering Spare Parts 2
1.3 Parts Liability and Guarantees for safety related components 2
1.4 Working Conditions and Tools 2
1.5 Service Work 5
1.5.1 Lubrication Table 5
1.5.2 Service Interval 6

2 REPAIR MANUAL 13
2.1 Exchange of the Complete Differential 13
2.1 Repairs on the Differential 14
2.2.1 Exchange of Crown Gear / Pinion 14
2.2.3 Exchange of Differential Cage (Compensating Gearbox) 27
2.2.4 Differential Lock 28
2.2 Axle Beam and Bogie Bearings 29
2.2.1 Exchange of Seal 29
2.2.2 Disassembly of Shaft and Seal Rings 29
2.2.3 Assembly of Seal Rings and Shaft 29
2.2.4 Exchange of Axle Beam 31
2.2.5 Adjustment of the gap between Sun Gear Shafts 32
2.3 Multi-Disk Brake with Brake / Spring Loaded Cylinder 35
2.3.1 Controlling the Release Gap of the Disks (Disks‘ Wear) 35
2.3.2 Controlling Cylinder Stroke and Adjustment 35
2.3.3 Exchange of Spring Loaded Cylinder 37
2.3.4 Prime Adjustment of Cylinder Stroke 39
2.3.5 Exchange of Brake Cylinder 40
2.3.6 Exchange of Disks and the Ball ramp actuator 41
2.4 Bogie Housing and Slewing Ring 43
2.4.1 Disassembly of the Bogie Housing 43
2.4.2 Reassembly of the Bogie Housing 43
2.5 Exchange of the Slewing Ring 46
2.6 Gear Drive inside the Bogie Housing 47
2.6.1 Exchange of the Studs 47
2.6.2 Exchange of the Gears and Needle bearings 47
2.7 Planetary Drive 48
2.7.1 Complete Exchange of Planetary Cage 50
2.7.2 Exchange of Sun gear shaft 50
2.7.3 Exchange of Planetary Gears 52
2.7.4 Exchange of Planetary Pins 53
2.7.5 Exchange of Crown Gear Carrier 53
2.8 Wheel Bearings 54
2.8.1 Wheel Bearing Exchange 54
2.8.2 Wheel Bearing Adjustment 55
2.8.3 Exchange of Axial Face Seal 57
1
2.8.4 Exchange of Axle Stub 57
 TM-21591-1

1 GENERAL AND SERVICE WORK

1.1 Introduction
The series production of VL 89 began in July 2012. This model contains a multi disc
differential lock which is actuated via hydraulic. The four planetary drives are driven by
spur gears. Both Bogie housings are mounted with pendulum bearings. The axle is not
steerable and is constructed for direct frame mounting with mounting surfaces for a lift
cylinder. The main drive is achieved over a Mechanics 8.5.C flange. Two hydraulically
operated multi-disk brakes used as operating brake and as parking brake are sufficient
for the installation.
1.2 Ordering Spare Parts
Spare parts for these NAF Axles should best be bought direct from an official KOMATSU
/ supplier whereby many of the important parts are conveniently stored and available.
Even when parts are not immediately available, it is recommended to order from the
supplier and not from the factory. The supplier can usually describe the necessary part
more accurately and give the part number more precisely and therefore avoid errors and
mistaken shipments.
For every spare part delivery, it is important to give the full exact type name with factory
number and year of fabrication. The type sign is located on the Diff.-housing near the oil
fill plug (refer to Fig. 1).
Use only original NAF spare parts
Using parts from other manufacturers voids every warranty and may lead to impaired
function such as service life.

1.3 Parts Liability and Guarantees for safety related components

We strongly recommend changing complete components in the case of safety related
components such as (control cylinders, steering cylinders, brake cylinders, spring
housing cylinders, etc.).
Once a safety related component has been disassembled or opened, all guarantees and
liabilities will be void and therefore NAF will not assume product liability for the drive unit.
This also applies, even if the complete drive unit is still under guarantee.

1.4 Working Conditions and Tools

A clean and well-lit work environment is necessary for an orderly proper repair. There
should also be enough room available to lay out the various parts and sub-assemblies
and to put them in order.
Furthermore, a complete as possible quality tool set of all important tools and basic
hardware is needed. Additionally, certain special tools are also necessary, which usually
prove to be of invaluable help, especially, when one must perform certain repairs
frequently. One spares oneself a lot of time and frustration. The speciality tools will be
described in the subsequent sections, i.e. marked (e.g. with WZ No.). Furthermore, a
certain expertise, and for some repairs, even specific training is necessary.

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Fig. 1

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Fig. 1a

Fig. 1b

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 TM-21591-1

1.5 Service Work

1.5.1 Lubrication Table
Lubrication Table for VL 89
Lubricating No. Fill Quantity Lubricant
Location
Differential 40/41/42/42a approx. 18.0 Litre LS-Gear-Oil SAE 90 / GL 5
Bogie Housing 60/62/63 each approx. 55.0 Litre EP Plus SAE 80W-90 / GL 4
Planetary Drive 50/51 each approx. 5.0 Litre EP Plus SAE 80W-90 / GL 4
Slewing Ring 90/92 as needed Brand EP Grease
Description of the Lubricating Location Numbers:
No.: 40 ⇒ Oil fill plug for Differential
No.: 41 ⇒ Oil dip stick for Differential
No.: 42 ⇒ Oil drain plug with magnet for Differential
No.: 42a ⇒Oil drain plug for rest oil in Differential and axle housing
No.: 50 ⇒ Oil drain plug with magnet for Planetary drive
No.: 51 ⇒ Oil fill plug with magnet for Planetary drive
No.: 60 ⇒ Oil fill plug for Bogie housing
No.: 61 ⇒ Oil control plug for Bogie housing
No.: 62 ⇒ Oil drain plug with magnet for Bogie housing
No.: 90 ⇒ Grease nipple to the Slewing ring
No.: 92 ⇒ Output plug when grease the buffer chamber of the Slewing ring
(refer to Fig. 1/2/3)
Examples for Brand-EP-Transmission oil SAE 90 specification: API-GL 5 or MIL-L-2105 B / LS
Fuchs (Renogear LS 90), (Renogear HLS 90)
DEA (Deagear LS SAE 85 W-90), (Dearon BHS SAE 90)
Aral (Degol 3216)
Mobil (Mobilube SHC-LS)
Esso (Gear oil LSA 85 W-90)
Shell (Gear oil 90 LS)
BP (Energear LS 90)
ELF (Tranself BM-LS 90)
Examples for Brand-EP-Transmission oil SAE 80W-90 specification: API-GL 4 or MIL-L-2105
BP (Gear Oil EP SAE 80W)
ELF (Tranself EP SAE 80W)
Mobil (Mobilube GX 80-A)
Shell (HSG 80-90)
Texaco (Geartex EP SAE 80W)
Examples for Brand-EP-Standard grease, lithium base saponified , water resistant (DIN 51825)
Klüber (Microlube GL 261) (Klüberplex BE 31-502)
Tripol (Tribol 3020 / 1000 -1)
Please refer to the legend of the Lubrication Plan concerning the fill quantity.

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 TM-21591-1

1.5.2 Service Interval

NAF axles are designed and built from long term experience and knowledge of work
machines. Proper functioning and constant work readiness is only achieved if the axle is
well cared for, properly handled and regularly serviced. This includes compliance to the
service interval, the use of appropriate lubricants corresponding to the Lubrication Table
and checking various service points. Special tools for maintenance work are not
necessary.

Service Interval Table for VL 89

Operating Hours 0 / After -250 500 2000 (every)
Initiation 1 day (every) or 1x year

Service Location (No.)

Differential (40/41/42/42a) 1 2 3 2
Planetary drive (50/51) 1 2 2
Bogie Housing (60/61/62) 1 2 3 2
Wheel nuts 4 4 4 4
Multi-Disk Operating Brake 4
(53/148)
Slewing Ring (90/92) 5 5
Various visible nuts and bolts 4

1 = First filling (see section 1.5.2.1)

2 = Oil change (see section 1.5.2.2)
3 = Checking oil level (see section 1.5.2.3)
4 = Inspection (see section 1.5.2.4)
5 = Grease (see section 1.5.2.5)

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 TM-21591-1

1.5.2.1 First Filling

Caution! The axle is delivered from NAF without oil.
Explanation: The differential gearbox and axle beam have a common oil chamber further
has every bogie housing and every the planetary drive a separate oil chamber. Therefore
the oil must be filled separately into each chamber.
• Differential
Remove oil fill plug (No.40) and fill oil corresponding to the Lubrication Table until the
oil reaches the upper control mark of the oil dip stick (No.41). Check after approx. 5
minutes and if need be, refill. Tightening moment for the fill plug (No.40) 70+10 Nm /
(No.42a) is 18+2 Nm. (Fig. 1)
• Planetary-Drive
First of all, turn the wheel hub until the oil drain plug (Nr.50) is perpendicular at the
bottom of the axle middle. Remove oil fill plugs (Nr.51) and fill oil corresponding to the
Lubrication Table until the bottom edge of the thread. Tightening moment for oil fill
plug (Nr.51) is 45+5 Nm. (Fig. 2)
• Bogie-Housing
The Bogie housing must be placed horizontally. The oil fill plugs (No.60) should be
perpendicular to the axle middle, and remove to open. Fill oil corresponding to the
Lubrication Table until the oil level reach the control opening (No.61). Tightening
moment of the fill plugs (No.60) and (No.61) is 80+10 Nm. (Fig. 3)
1.5.2.2 Oil Change
Note: Clean the area around the screw plugs (No.40/42) and the oil dipstick (No.41)
beforehand.
• Differential
Perform oil change when oil is warm. Remove oil fill plug (No.40) then open oil drain
plug (No.42) and drain oil, additional open the oil drain plug (No.42a) to let off the rest
oil Clean off the magnet of the oil drain plug (No.42) of any grime and of any existing
filings, before threading in. Fill new oil corresponding to the Lubrication Table, until the
oil level reaches the upper control mark of the dipstick (No.41). Tightening moment for
the oil fill plug (No.40) and oil drain plug (No.42) is 70+10 Nm. (Fig. 1) ) / (No.42a) is
18+2 Nm. (Fig. 1)

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• Planetary-Drive
Perform oil change when oil is warm, simultaneously with Differential. Therefore turn
the wheel hubs such that the oil drain plugs (Nr.50) are down. (Fig. 2) Clean the oil fill
plugs (Nr.51) and oil drain plugs (Nr.50) and the area around them of dirt. Remove oil
drain plugs (Nr.50) and drain oil. Clean off the magnet of the oil drain plugs (Nr.50) of
any grime and of any existing filings before threading in. Fill new oil corresponding to
the Lubrication Table, into the upper opening until the oil level reaches the bottom
edge of the horizontal threaded hole (Nr.51). Tightening moment for the screw plugs
(Nr.50/51) is 45+5 Nm.
• Bogie-Housing
Perform oil change when oil is warm, simultaneously with planetary drive. The Bogie
housing must be placed horizontally. Clean the oil fill plugs (No.60), oil drain plug
(No.62) and the area around them of dirt. Before draining the oil, the axle should sit
still for at least 30 minutes, so that any contaminates in the oil can come to rest in the
oil pan. Then open oil drain plugs (No.62), 2 per Bogie housing, and drain the
contaminated oil in a suitable container. Clean the magnet of the contaminated oil
drain plugs (No.62) of any grime and of any existing filings before set in. Fill oil as per
the Lubrication Table until oil exits from the control opening (No.61). Tightening
moment for the oil fill plugs (No.60); oil control plug (No.61)and oil drain plugs (No.62)
is 70+10 Nm. (Fig. 2)

Position for oil filling and oil controling Position to drain the oil
Fig. 2

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1.5.2.3 Checking Oil Level

Note: Clean the area around the screw plugs of dirt beforehand.
• Differential
The oil level should be on the upper control mark of the oil dipstick (No.41), topping up
oil to max. level if necessary. (Fig. 1)
• Planetary-Drive
Turn the wheel hub until the oil drain plug (Nr.50) is perpendicular at the bottom of the
axle middle. Remove oil fill plugs (Nr.51) and control the oil level. If necessary fill oil
corresponding to the Lubrication Table until the bottom edge of the thread. Tightening
moment for oil fill plug (Nr.51) is 45+5 Nm. (Fig. 2)
• Bogie-Housing
The Bogie housing must be placed horizontally, remove oil control plugs (No.61) and
check the oil level. The oil level should be on the bottom edge of the control opening
(No.61), topping-up oil at the oil fill plugs (No.60) to this level if necessary. Tightening
moment of the oil fill- and oil control plugs (No.60/61) is 70+10 Nm. (Fig. 3)

Fig. 3

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1.5.2.4 Inspection
• Various visible bolts and nuts
Due to stresses and vibrations exerted, it is possible for various bolts and nuts to set
or give way. Timely tightening of these will prevent any leaks or other greater
damages.
The adhered nut for the cardan flange attachment (pinion nut) may not be tightened.
• Wheel Nuts
Due to stresses of vehicle motion, the wheel nuts may set or loosen. Timely tightening
will prevent a deflection of the centre to the rim.
Tightening moment for wheel nuts is 550 Nm.
• Multi-Disk Operating Brake / Parking Brake
Check disk set and release gap, if necessary, adjust or replace disk set.
After having removed the screw plug (No.53) and the breather (No.148), the release
gap can be measured with a feeler gauge when brake is loosened (distance between
both actuator disks at unapplied and applied brake). (Fig. 14)
Release gap: min. 2.0 – 2.5 mm necessary. (Difference of the measured values)
Adjust and replace, see Repair Manual.

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1.5.2.5 Grease
- Slewing ring:
Note: The slewing has two areas. The bearing raceway area (1) has lifetime lubrication in
the grease chamber and needs no service. Only the buffer chamber (2) needs a scheduled
service. The service is the replacement of soiled grease.

After every 2000 operating hours

or once a year
First clean the areas around
the grease nipples (90) and
output plugs (92). Remove
the white plastic caps and
open at first one output
screw plug (92). Then start
the refill at both grease
nipples (90) for two sections
per half-circle, with standard
grease. Lubricate with hand
grease gun until grease
squeezes out with thumb
width from the output
opening (92) for every
lubricating process.
Clean this output and close
the opening with screw plug
and plastic cap.
Then open the opposite
output plug (92) and repeat
the procedure on the other
half-circle.

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TM-21591-1

step 1:

step 2:

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 TM-21591-1

2 Repair Manual
2.1 Exchange of the Complete Differential
(see Fig. 4)
Note! For large damages to the differential it may be more advantageous to exchange
the complete differential instead of repairing it. Therefore it would be advantageous to
remove the whole axle from the undercarriage.
• Drain oil from the differential and remove cardan shaft.
• Dismantle axle from the vehicle.
• During disassembly of the axle beam, loosen parking brake.
(Open parking brake connection at spring loader cylinder with pressure)
Release pressure : min. 18 bar max 35 bar
• Screw out hex. bolts (No.39) on both sides of the differential and take off axle beam
(No.22) with complete side parts that is pull out.
• If possible, leave straight pins (No.30) in the axle beams.
(Hold the disk pack (No.29) in position.)
Note! Original NAF spare and repaired differentials are properly set and adjusted
from the factory. Differentials not from NAF should be inspected for proper bearing
and contact pattern adjustment before installation.
• Remove rust protective coating from locating surfaces.
• Replace o-rings (size OR 265 x 4 / part no. 1170.716).
• Reinstall complete side parts, with this lead the external spline of the axle shaft into
the compensating gears by light turn at the cardan flange.
• Then push together axle beam up to flange location, paying attention to the straight pins.
• Insert hex. nuts (No.39). Tightening moment is 455 Nm.
• Install axle into vehicle, (connect brakes and cardan shaft).
• Fill oil into differential.
• Do not forget to vent brakes!
• Test-drive and retighten axle-mounting bolts.

Fig. 4

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2.1 Repairs on the Differential

2.2.1 Exchange of Crown Gear / Pinion
(see Fig. 5)
Note!
The crown gear and pinion (No.13) can only be exchanged as a matched set and not
separately, since the gears have been mated to one another. The same numbers marked
on the crown gear and pinion identifies the matched sets. (With etching pen engraved). It
is advisable to replace various bearings with this sort of repair.
• Remove differential. (section 2.1).
• Remove pinion nut (No.50), to ease disassembly, heat to approx. 150°.
Support cardan flange (No.51) with a brace.
(The loosening moment may reach up to 1500 Nm.)
• Loosen allen bolts (No.4) and remove flange on the crown gear side (No.6).
• Remove differential cage (No.11) with crown gear (No.13).
• Pull off cardan flange (No.51) and remove pinion (No.13) inward.
• Loosen all 4 hex. screws (No.58) and remove the cover (No.55) then extract the circlip
ring (No.90) Now, three radial shaft seals (No.91/89) can be pulled out.
• Inspect tapered roller bearing (No.8/24) for differential cage and (No.43/48) for pinion
and replace if need be.
• Loosen hex. bolts (No.9) and press crown gear (No.13) off of differential cage (No.11).
• Slide new crown gear onto differential cage (No.11) and during which insert both
straight pins (No.12). Tighten new hex. bolts (No.9) (coating on thread) cross wise with
a torque wrench. Tightening moment is 290+ 10 Nm.
• Determine thickness of the adjusting washer (No.45) (see section 2.2.1.2).
• If replacing, press selected adjusting washer (No.45) and bearing outer ring from
(No.43 and No.48) into differential housing (No.42).
• Install bearing inner ring from (No.8 and 24) with supporting washer (No.23), onto
differential cage (No.11).
Assembly temperature for bearing inner ring from (No.8 and 24) max. 80°.
• Install bearing inner ring (from No.43) with roller cage, onto pinion (No.13).
Assembly temperature for bearing inner ring (No.43) max. 80°.
• Determine thickness of the adjusting washer (No.44) (see section 2.2.1.1).
• Feed in pinion (No.13) from the inside of the housing (No.42) and support.
• Select a combination of two spacer sleeves (No.46/47) and between them adjusting
washer(s) (No.44), onto the shaft of pinion (No.13).
• Press bearing inner ring (from No.48) with roller cage, onto pinion (No.13).
Assembly temperature for bearing inner ring (No.48) max. 80°.
• Assemble cover (No.55) with installed seals (No.88/89) (see section 2.2.1.6).
• Clean pinion (No.13) and pinion nut (No.50), of dirt, oil and inhibitors.
• Coat entire diameter and length of thread of pinion (No.13) and nut (No.50), with
Loctite® 639.
• Apply wear and seizing inhibiting paste to the contact surface of the nut (No.50).

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TM-21591-1

(i.e. Wolfracote SSP from Klüber)

• Install cardan flange (No.51) and thread pinion nut (No.50) onto pinion (No.13) and
tighten with 800 Nm. The final position must be achieved within 3 to 5 minutes in order
for the Loctite® to achieve its full potential.
• Check pinion bearing preload with a torque wrench and if need be, change adjusting
washer (No.44). (Preload: 0.5 - 6 Nm).
Document measured pinion bearing preload (see section 2.2.1.3).
• Thread on nut (No.25) approx. 1 turn, thread out nut (No.3) approx. 2 turns.
• Insert differential cage (No.11) complete, hold flange (No.6) and new o-ring (No.7) with
allen bolts (No.4).
Fasten flange (No.6) additionally with for temporary assembly bolts M 18x2x50.
• Adjust backlash and crown gear bearing (0.15 – 0.25 play) (see section 2.2.1.4).
• Install differential (see section 2.1).

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Fig. 5

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1. Screw for locking plate 41. Allen screw

2. Locking plate for groove nut 42. Differential housing
3. Groove nut Crown gear side 43. Pinion head bearing
4. Allen screw for Diff.-flange 44. Print pattern adjusting washer Diff.-housing
5. O-ring, axle beam - Diff. 45. Pinion bearing adjusting washer
6. Diff.-flange Crown gear side 46. Spacer sleeve Pinion bearing
7. O-ring Diff.-flange 47. Spacer sleeve Pinion bearing
8. Diff.-cage bearing Crown gear side 48. Outer Pinion bearing
9. Crown wheel screw 49. O-ring Drive shaft flange
10. HV washer crown wheel 50. Drive shaft flange nut
11. Diff.-cage 51. Drive shaft flange
12. Dowel pin for crown wheel 52. Washer
13. Crown wheel / pinion 53. O-ring in Drive shaft flange cover
14. Butting ring for compensating gear 54. Gasket
15. Compensating gear 55. Drive shaft flange cover
16. Cross bolt 56. Grease nipple
17. Bushing 57. Lock washer
18. Differential gear 58. Screw for cover
19. Thrust washer for Differential gear 59. V-ring
20. Screw for compression spring by MDDL 60. Flange
21. Compression spring 61. Butting ring
22. Allen screw Diff.-cage 62. Driven disk
23. Multi disc support 63. Screw
24. Diff.-cage bearing (at lock) 64. Washer
25. Shaft seal for piston 65. Oil drain plug Diff
26. Driven disc 66. Axial bearing
27. Piston Diff.-lock 67. Butting ring
28. Axial bearing
29. Adjusting washers for Diff.-cage (gear gap)
30. Drive disc 89. Seal ring for Drive shaft flange
31. Piston Diff.-lock 90. Lock ring
32. Butting ring 91. Seal ring for Drive shaft flange
33. Multi disc support 106. Split spring for axle housing
34. Allen screw
35. Piston seal Diff.-lock
36. Diff. flange (lock)
37. Seal ring to control plug
38. Oil control plug Diff.
39.-
40. Butting ring

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TM-21591-1

2.2.2.1 Determining Thickness of the Adjusting Washer (44)

(see Fig. 5)
• Press in new bearing outer ring from (No.43) and (No.48) into differential housing
(No.42) until stop.
• Install bearing inner ring (from No.43) with roller cage onto pinion (No.13).
Assembly temperature for bearing inner ring (No.43) max. 80°.
• Select a combination of two spacer sleeves (No.46 / 47) and between them one or two
adjusting washers (No.44).
Assemble with a combine measure in the range of 36.55 mm to 38.55 mm.
Note: First check working selected combination if usable.
Adjusting washer thickness: 0.96 to 1.44 (with 0.04 steps)
Spacer sleeve (No.46): 24.0 ±0.02 mm
Spacer sleeve (No.47): available 11.51 mm; 11.99 mm and 12.47 mm
• Feed in pinion (No.13) from the inside of housing (No.42) and support.
• First insert selected spacer sleeve (No.46), then adjusting washer(s) (No.44) and then
spacer sleeve (No.47) onto the pinion (No.13). (see Fig. 5).
Tip: Start with a select combination with a total width approximately of 34,05 (it is a
empirical value)
• Press bearing inner ring (from No.48) with roller cage, onto pinion (No.13).
Assembly temperature for bearing inner ring (No.48) max. 80°.
• Apply wear and seizing inhibiting paste to the contact surface of the nut (No.50).
(i.e. Wolfracote SSP from Klüber)
• Install cardan flange (No.51) and thread pinion nut (No.50) onto pinion (No.13) and
tighten with 800 Nm.
• Check pinion bearing preload with a torque wrench and if need be, change adjusting
washer (No.44).
The pinion bearing may not have any axial play but should let itself turn with 5 to 11
Nm. For used bearings, an adjustment value of 1 to 9.0 Nm may apply.
(Pinion bearing preload for new bearings: 5 – 11 Nm).
Document measured pinion bearing preload (see section 2.2.1.3).
• Upon correct bearing preload, secure pinion bearing (No.50) with Loctite®.
(see section 2.2.1)

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2.2.2.2 Determining Thickness of the Adjusting Washer (45)

Note! By selecting the adjusting washer (No.45) the contact pattern adjustment is carried-
out.

Fig. 6

• Calculating thickness (Se) of the adjusting washer (No.45)

Se = L2 - Le - Lr -L1
A washer thickness between 2.5 and 3.5 mm must be achieved.
Select the nearest available washer thickness. Maximum allowable deviation of the
washer thickness from the calculated thickness Se is 0.1 mm.
„L2“ = distance between bearing seat (No.43) and middle of the differential
(approx. 235+0,1 mm).
„Le“ = mounting distance (engraved on pinion face approx. 120.88 mm).
„Lr“ = measure and document pinion gear head height (approx. 62.12 mm).
„L1“ = measure actual thickness of the new bearing (No.43).
The measurement „L1“ can vary near 49.212.
(Vernier calliper with at least 120 mm jaw length).

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2.2.2.3 Pinion Bearing Adjustment

• Clean pinion (No.13) and pinion nut (No.50), of dirt, oil, and inhibitors.
• Coat entire diameter and length of thread of pinion (No.13) and nut (No.50), with
Loctite® 639.
• Apply wear and seizing inhibiting paste to the contact surface of the nut (No.50).
(i.e. Wolfracote SSP from Klüber)
• Thread nut (No.50) onto pinion (No.13) and tighten with 800 Nm, while supporting
cardan flange (No.51). After some tap hammering on the outside of the housing in the
area of the pinion bearing to align the tapered rollers. The final location must be
achieved within 3 to 5 minutes in order for the Loctite® to achieve its full potential.
• Check pinion bearing preload with a torque wrench and if need be, correct the
adjustment.
The pinion bearing may not have any axial play but should let itself turn with 5 to 11
Nm. For used bearings an adjustment value of 1 to 9 Nm may apply.
• Document adjusted bearing preload for later crown gear bearing adjustment.
2.2.2.4 Backlash and Crown Gear Bearing Adjustment
• Exchange flange (No.36) complete with „MDDL“ components again the orifice flange
WZ 637 only for adjusting. Fix the orifice flange WZ 637 with four temporary assembly
bolts M 18x2x50. (see picture below)

• Loosen bolt (No.1) and remove locking plate (No.2) and turn back the nut (No.3)
approx 2 rotary.
• Insert differential cage (No.11) complete.
• Mount flange (No.6) with new o-ring (No.7)and fix it with allen bolts (No.4).
Fasten flange (No.6) additionally with four temporary assembly bolts M 18x2x50.
• Now turn nut (No.3) until a backlash of 0.15 to 0.25 mm is achieved turn nut (No.3) til
the necessary bearing preload of 1.0 – 3.0 Nm is achieved
Once the correct backlash and the adjust bearing preload is achieved, secure nut

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(No.3) with locking plate (No. 2) and hex. bolt (No.1).

• Measure on the original MDDL-flange (No.36) the measurement “X1”.
(see procedure picture blow)

set the dig.-depth gauge on zero determine the measurement “X1”

• Through the drill hole in orifice flange WZ 637 determine now the exact distance „X2“
from flange surface to outer bearing ring. (see procedure picture blow)

set the dig.-depth gauge on zero determine the measurement “X2”

Calculation of the adjusting washer:

Washer size „S“ = X2 – X1
(experimental value of the adjusting washer for new installation is 1.6mm for 2 Nm
bearing preload )

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• Adjust the initial stressing for diff.-cage bearing (No.8) and (No.24).
Turn therefore the nut (No.3) so long till the suitable bearing preload of 1.0 – 3.0 Nm is
reached. (see picture below)

• This value is determined on the pinion nut (No.50) with a torque meter, in that to the
pinion bearing preload (documented value from section 2.2.1.3) a moment of 0.5 to 1.5
is added.

22
TM-21591-1

• Remove the inner part from the orifice flange WZ 637 and insert the definite adjusting
washer for an test. (see picture below)

• After the installation of the definite adjusting washer and the cover, control the bearing
preload with dial gauge
Note: Trough tightening of the centre screw is no additional effect force of pressure
spring onto the bearing support.
• When the correct bearing preload is reached, exchange the orifice flange WZ 637
again flange (No.36) with include complete „MDDL“ components. Install with it the
definite adjusting washer into the original „MDDL“ flange (No.36) and renew the o-ring
(No.7/ see fig.6).
• Document adjusted bearing friction moment.

23
 TM-21591-1

2.2.2.5 Checking Contact Pattern

• Loosen temporary assembly bolts and allen bolts (No.4) at the flange (No.6) and
remove flange.
• Take out differential cage (No.11) and coat flanks from 2 teeth (= 4 tooth flanks) of
the crown gear (No.13) with thin yellow oil based paint and reinstall differential cage
(No.11), flange (No.6) with temporary assembly bolts.
• Turn pinion, so that the contact pattern is marked by the paint.
• Remove flange (No.6), take out differential cage (No.11) with crown gear and
assess contact pattern. With proper adjusting washer thickness a contact pattern as
per Fig. 9 should be achieved, otherwise select a new adjusting washer (No.45)
(see section 2.2.1.2).

Fig. 7 Fig. 8

If there is a contact pattern as per Fig. 7 or 8, by shifting the pinion with help from a
change in the adjusting washer (45) thickness, a contact pattern as per Fig. 9 is
achieved. By turning the nut (No.3) and exchange adjusting washer (No.29) can a adjust
sliding for the crown gear likewise to Fig. 7 or 8 be done.

Caution: During the adjustment process, always pay

attention to the proper preload for the bearings (8)
and (24). Likewise, when turning the nut (3) and
exchange washer (29) pay attention to the correct
backlash. Wipe oil paint from previous adjustment
attempts.

Fig. 9
Once the backlash and bearing preload has been adjusted, secure nut (No.3) with
locking plate (No.2) and new hex. bolts (No.1).

24
TM-21591-1

2.2.2.6 Exchange of Shaft Seals

• Drain the oil from the differential and remove the drive shaft from the input cardan
flange (51)
• The hex nut (50) in the cardan flange is locked with Loctite®, the loosening torque may
exceed 1000 Nm. Therefore preheating the nut to 120°-160°C with a blow lamp is
recommended. Loosen the nut (WS 50) and pull the cardan flange from the spline end
of the pinion shaft.
• Loosen all 4 hex. screws (58) and remove the cover (55) then extract the circlip ring
(90). Now, three radial shaft seals (88/89) can be pulled out.
• It is also recommended to exchange the O-ring (49), extract it from the groove in the
shaft. Check the sealing surface of the cardan flange (51) for any marks of wear and
replace it if necessary.
• Cover preparing: First put in the washer (52). Then press three new shaft seals (first
two 89) with special tools (WZ 335 deep distance and WZ 334 short distance) then
shaft seal (91) with WZ 334 into the cover (55) and fill 50% of the volume between the
seals with grease. It should be noted that the lips of the seals are installed in the
proper orientation as illustrated and correct distances as shown, which there are given
by installing the with special tools (WZ 335/334).
• After that install the circlip ring (90) to the grove in the cover (55) and renew O-ring
(53) and gasket (54).
• Then mount the complete cover (55) into the housing (42) and fix it with 4 hex. screws
(58) with locking washers (57) on it. When assembling the cover (55) it should be
noted that the lip of seals does not become damaged.
• With a steel brush remove rests of old hardened glue from the threads of shaft and nut
and clean from any dirt and grease.
• Install new O-ring (49), and shift the cardan flange (51) onto the spline of the shaft.
• Now cover the threads of shaft and nut with Loctite® 639.
• The applying and tightening of the nut must not take any longer than 3-5 minutes to
avoid any hardening of the adhesive.
• The nut cannot be applied using an impact wrench since this will promote early
hardening and the adhesive will be spun off the threads. Tighten the nut with 800 Nm
torque

25
TM-21591-1

Fig. 10

26
 TM-21591-1

2.2.3 Exchange of Differential Cage (Compensating Gearbox)

(see Fig. 5)
Note!
The both halves of the differential cage (No.11) can only be exchanged together, note
orientation markings and identification.
• Remove differential. (see section 2.1)
• Detach flange (No.6).
• Take out differential cage (No.11) with crown gear (No.13).
• Pull off bearing inner rings from (No.8 / No.24) and supporting washer (No.23).
Check both tapered roller bearing (No.8 / No.24) and replace if need be.
• Loosen hex. bolts (No.9) and pull crown gear (No.13) from differential cage (No.11).
• Remove allen bolts (No.22) and open differential cage (No.11).
• Take out crossbolt (No.16) with differential gear (No.18) and thrust washer (No.19) as
one unit. Check components and replace if need be.
• Remove compensating gears (No.15) with thrust washers (No.14). Check components
and replace if need be.
• Perform adjustment of the differential cage by selecting thickness „s“ of the thrust
washer (No.14).
Thickness „s“ of the thrust washers (No.14) to select from is 1.5; 1,7; 2,0; to 2.2 mm.
1. For testing purposes, screw together both differential cage halves with the selected
parts with four uncoated temporary assembly bolts M 12 x 80.
2. With the use of a profiled shaft end, turn the compensating transmission through.
There can be no noticeable resistance or no ascertainable jerking. The axial play at
the compensating gear (No.15) must be less than 0.2 mm.
3. For a wrong thrust washer adjustment, appropriately change and repeat test
method.
• At the correct adjustment, remove the four uncoated temporary assembly bolts and
finally bolt together with twelve new coated allen bolts (No.22).
Tightening moment for allen bolts (No.22) is 115+10 Nm.
• Press on both tapered roller bearings (No.8 / No.24) and during replacement also
press bearing shells in both flanges (No.6 / 36).
• Insert differential cage (No.11) and flange (No.6).
• For test purposes, fasten flange side with four temporary assembly bolts M 18x2x50.
• Adjust backlash and crown gear bearing (refer to section 2.2.1.4).
• Check contact pattern (refer to section 2.2.1.5).
• Remove temporary assembly bolts M 18x2x50.
• Install differential (see section 2.1).

27
 TM-21591-1

2.2.4 Differential Lock

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

28
 TM-21591-1

2.2 Axle Beam and Bogie Bearings

Note!
The bogie housing is mounted with a slewing ring onto the axle beam. For proper operation,
regular servicing as per a service plan is extremely necessary. To work on the bogie bearing it
is not required to remove the axle from the vehicle. It is sufficient when the side of the axle that
is being worked on is jacked up and the bogie swing is removed. During assembly and
disassembly, proceed with great care, so that the sealing surfaces of the slewing ring (No.172)
for the seal (No.61) are not damaged.
2.2.1 Exchange of Seal
(see chapter 2.3.4)
2.2.2 Disassembly of Shaft and Seal Rings
Disassemble the bogie housing (31) as per 2.5.1. Release the parking brake by hydraulic
pressure or by the emergency release bolt (see Chapter 2.4.), and turn back and forth either
the cardan flange at the differential or one of the output shafts (34), to be sure that the
backlash of the splines in the brake disks is aligned. Then activate the parking brake to hold
the brake disks in this position. Remove the sun gear shaft (140) sideways. Extract the
outer seal ring (176) in the axle beam. Then remove the auxiliary washer (142) and the
second inner seal ring (174).
2.2.3 Assembly of Seal Rings and Shaft
Use special insert punch WZ 592 and install first one new seal ring (174) with the lip in
direction pointing to the axle centre. Then lay in the washer (142) and then the second seal
ring (176) also with the lip in direction pointing to the axle centre. Insert the sun gear shaft
(140), fit the sun gear shaft splines into the splines of the inner disks (120), shifting sleeve
and compensating gear. The brake disks (120) are still fixed in their original position by the
activated parking brake. The shaft will be centred by the auxiliary washer between the two
seal rings (142), nevertheless be careful not to hurt the seal lips with the edges of the spline
shaft. Continue assembly as per 2.5.2.

29
TM-21591-1

Fig. 11

30
 TM-21591-1

2.2.4 Exchange of Axle Beam

(see Fig. 11)
Note! For the exchange of the axle beam, it would be advantageous to remove the entire
axle from the undercarriage.
• Drain oil from differential and the bogie swing and loosen cardan shaft.
• Remove axle from the vehicle.
• Before disassembly of the axle beam, remove spring-loaded cylinder. See section
2.8.1
• Remove hex. bolts (No.103) or (No.104) of differential and remove axle beam
(No.102) with complete bogie housing.
• If possible, let leave straight pins (No.122) in the axle beams during disassembly.
(There fixed the multi disk package (No.120) in position.)
• Loosen allen bolts M18 (No.125/126) and remove complete bogie housing.
Take precautions not to damage the sealing surfaces.
• Loosen allen bolts (No.124) and take off slewing ring (No.172).
• Insert new o-ring (No.173) onto the step of the new axle beam (No.102).
• Fasten new slewing ring (No.172) in the proper orientation (red marking on inner ring
to be placed upwards) with new hex. bolts M20x2 (No.124), with adhesive in thread,
„cross-wise“.
Tightening moment is 645 Nm.
• Open the output plugs and apply grease to both lubricating nipples of the new slewing
ring (No.172) until grease exits from output openings of the slewing ring. It is only for
the buffer chamber.
• Insert both straight pins (No.106) or (No.107) into the slewing ring.
• Replace the seal ring (No.61) with punch WZ 632 in bogie housing (No.31) and coat
sealing lips with grease.
• Fasten complete side component to the axle beam with new allen bolts M18
(No.125/126) with adhesive in thread „crosswise“. During assembly, pay attention to
the sealing lips of the seal (No.61). Insert washers (No.58) underneath the six top
allen bolts (No.126) which are screwed from outside direction of the bogie housing.
Tightening moment is 455 Nm.
• Insert new straight pins (No.122) into the axle beam (No.102).
• Install the multi disk brake complete onto the sun gear shaft (No.140) and into the axle
beam (No.102).
• Insert toothed ring (No.121) onto the four straight pins (No.122).
• Replace o-rings (No.5) and insert both straight pins.
• Reinstall complete side component, for this mesh the external spline of the sun gear
shaft into the compensating gears by light turning at the cardan flange.
• Then slide together axle beam until flange location, paying attention to the straight
pins.
• Screw on hex. nuts (No.103). Tightening moment is 455 Nm.
• Reassemble spring loaded cylinder see section 2.4.1.
• Install axle into vehicle, (connect brakes and cardan shaft).

31
 TM-21591-1

• Fill oil into differential and into bogie housing.

• Do not forget to vent brake!
• Test drive and retighten axle mounting bolt.
2.2.5 Adjustment of the gap between Sun Gear Shafts
Note:
The adjusting bolt is only in longest size available. For fitting is a lathe necessary.
The adjusting bolt is in the centre of the cross bolt placed and is with a split spring pin on a
sun gear shaft face side attached.

32
 TM-21591-1

Procedure steps:
• Place the complete bogie / axle housing with mounted sun gear shaft in a vertical
position.
Measure the projection end “a” from the sun gear shaft to the axle connecting
surface.
(see Photo. 1)

(Photo 1) Measure distance „a“

• Place the complete opposite bogie / axle housing with mounted sun gear shaft and
complete differential housing in a vertical position.
Measure depth distance “b” from the differential housing surface to the end surface
of the sun gear shaft inside the differential.
(see Photo. 2)

(Photo 2) Measure distance „b“

33
 TM-21591-1

• Place the complete opposite bogie / axle housing with mounted sun gear shaft and
complete differential housing in a vertical position.
Measure step distance “c” from the differential housing surface to the axle
connecting surface.
(see Photo. 3)

(Photo 3) Measure distance „c“

Determining of the size “s” for the adjustment bolt

Measurement “s” = “b” –“c” – “a” –1.0 mm (gap)
Select the washer package with ± 0.2 tolerance.

34
 TM-21591-1

2.3 Multi-Disk Brake with Brake / Spring Loaded Cylinder

Note:
To work on the brake cylinder it is not required to removed the axle from the vehicle.
2.3.1 Controlling the Release Gap of the Disks (Disks‘ Wear)
(See Fig. 11)
• Screw out screw plug (No.53) and breather (No.148) (Fig. 1).
• Loosen parking brake. (Open parking brake connection at spring loaded cylinder with
pressure)
Release pressure: min. 18 bar
max. 35 bar
• Measure and document distance „ X1 „ between both actuator discs with a feeler
gauge.
• Parking brake in brake position. (Spring loaded cylinder has no pressure)
• Measure and document distance „ X2 „ between both actuator discs with a feeler
gauge.
• „ X1 „ - „ X2 „ = Release gap
Release gap: min. 2.2 - 3 mm necessary
Adjust and renew see follow sections.
2.3.2 Controlling Cylinder Stroke and Adjustment
Controlling:
• Remove screw cap (No.154) with a wrench SW 24 and take out emergency bolt
(No.155).
• Parking brake in actuated position. (Spring loaded cylinder is without pressure)
Through the threaded hole of the piston (No.157), measure distance „ A1 „ and document.
(appropriate measuring instrument i.e. dial gauge or depth gauge)
„ A1 „ = Distance from the adjusting allen bolt (No.158) to the end face of the housing
(No.156).
• Release parking brake.
(To release parking brake, bring pressure to connection (I) at spring loaded cylinder)
Release pressure: min. 18 bar / max 35 bar
Through the threaded hole of the piston (No.157) measure distance „ A2 „ and document.
(appropriate measuring instrument i.e. dial gauge or depth gauge)
„ A2 „ = Distance from the adjusting allen bolt (No.158) to the end face of the housing
(No.156).
• „ A1 „ - „ A2 „ = Cylinder stroke
Cylinder stroke: min: 5.0 – 6.0 mm necessary.

35
 TM-21591-1

Adjustment:
Note: Adjust the cylinder stroke of the left and right brake separately.
The adjusting bolt (No.158) is secured with Loctite® 242 and fixed with a nut (No.159) and
has a pitch of 1.5 mm.
• Remove brake connection (I) at spring loaded cylinder (cyl. upper part / No.151).
• Loosen 4 allen bolts (No.152) and remove spring loaded cylinder (cyl. upper part /
No.151). Do not loosen both allen bolts (No.170).
• Loosen locking nut (No.159), for this secure at pressure piston (No.164) at the wrench
surfaces SW 16 from also turning.
• Remove adjusting allen bolt (No.158) complete. Clean thread of the adjusting allen bolt
(No.158) and locking nut (No.159) of oil and adhesive residue.
• Screw on locking nut (No.159) again up to the head of the adjusting allen bolt
(No.158).
• Coat entire diameter and length of thread of adjusting allen bolt (No.158) with Loctite®
242.
• Screw in adjusting allen bolt (No.158) with allen wrench SW 8 into the pressure piston
(No.164), until the screw-in moment of approx. 8 - 15 Nm is clearly reached. The brake
disks and the ball ramp actuator are now next to one another without Release gap.
• Turn back the adjusting allen bolt (No.158) again about 3½ revolutions (corresponding
to a travel of 5.25 mm) and lock in this position with the hex. nut (No.159). During this
adjustment, secure the pressure piston (No.164) at the wrench surfaces SW 16 from
also turning. With this adjustment is a disk release gap of 2.4 mm is achieved.
• Should the cylinder –bottom part (No.162) or the pressure piston (No.164) become
wetted with Loctite® residue, the residue must be removed.
• The release gap is again controlled by measuring of the piston stroke after the
adjustment. With an appropriate measuring instrument (i.e. dial gauge or depth gauge)
measure the stroke movement of the pressure piston (No.164) with activation of the
brake (connection II) and with release respectively. If the piston stroke exceeds a value
of 5.25 the adjustment must be performed again.
• Insert o-ring (No.176) into the groove of the cylinder-bottom part (No.162) and install
the spring loaded cylinder (No.151) onto the brake cylinder (No.150) and fasten with
four allen bolts (No.152) „cross-wise“.
Note: With these fastening bolts is simultaneously the disk spring pack (No.169) After
fastening the spring loaded cylinder (No.151), the multi-disk brake is in brake position.
• Insert hex. bolt (No.155) and o-ring (No.168) into the spring loaded cylinder (No.151)
and again tighten screw plug (No.154).

36
 TM-21591-1

Fig. 12 Fig. 13
2.3.3 Exchange of Spring Loaded Cylinder
• Secure vehicle with sufficient steps against rolling away.
• Have zero pressure at both connections I and II.
• Remove screw plug (No.154) and take out hex. bolt (No.155).
• Screw in emergency hex. bolt (No.155) clockwise until noticeably tight. Thereby the
spring pack is completely under tension and the brake is relieved.
• Loosen 4 allen bolts (No.152) and if possible, simultaneously remove, to prevent a
jamming of the cylinder housing.
• Remove screw plug (No.154) and take out hex. bolt (No.155) of new spring loaded
cylinder.
• Screw in emergency hex. bolt (No.155) of the new spring loaded cylinder clockwise
until noticeably tight. Thereby the spring pack is under tension.
• Insert o-ring (No.176) into the groove of the cylinder-bottom part (No.162) and install
the spring loaded cylinder (No.151) onto the brake cylinder (No.150) and fasten with
four allen bolts (No.152) „cross-wise“.
• Screw open emergency hex. bolt (No.155).
After loosen the emergency hex. bolt (No.155), the multi-disk brake is the brake
position.

37
TM-21591-1

• Measuring of the piston stroke after the assembly controls the release gap. With an
appropriate measuring instrument (i.e. dial gauge or depth gauge) measure the stroke
movement of the pressure piston (No.164) with activation of the brake (connection II)
and with release respectively. If the piston stroke exceeds a value of 5.25 the
adjustment must be performed again.
• Insert hex. bolt (No.155) and o-ring (No.168) into the spring loaded cylinder (No.151)
and screw on screw plug (No.154) again and hand tighten.
• At standstill both the operating- as well as the parking brake are to be activated
alternatively, to make possible the orientation of individual parts.
• Both pressure chambers of the cylinders are to be vented at the breather (III) after
assembly to ensure that there is no air in the lines.

38
 TM-21591-1

2.3.4 Prime Adjustment of Cylinder Stroke

(See Fig. 12/13)
Note: The cylinder stroke of the left and right brake must be adjusted separately.
The adjusting bolt (No.158) is secured with Loctite® 242 and fixed with a nut (No.159)
and has a pitch of 1.5 mm.
• Loosen brake connection (I) at spring loaded cylinder (cyl. upper part / No.151).
• Loosen 4 allen bolts (No.152) and remove spring loaded cylinder (cyl. upper part /
No.151). Do not loosen both allen bolts (No.170).
• Loosen locking nut (No.159), for this secure pressure piston (No.164) at the wrench
surfaces SW 16 from also turning.
• Remove adjusting allen bolt (No.158) complete. Clean thread of the adjusting allen bolt
(No.158) and locking nut (No.159) of oil and adhesive residue.
• Screw on locking nut (No.159) again up to the head of the adjusting allen bolt
(No.158).
• Coat entire diameter and length of thread of adjusting allen bolt (No.158) with Loctite®
242.
• Screw in adjusting allen bolt (No.158) with allen wrench SW 8 into the pressure piston
(No.164), until the screw-in moment of approx. 8 - 15 Nm is clearly reached. The brake
disks and the ball ramp actuator are now next to one another without release gap.
• Turn back the adjusting allen bolt (No.158) again about 3½ revolutions (corresponding
to a travel of 5.25 mm) and lock in this position with the hex. nut (No.159). During this
adjustment, secure the pressure piston (No.164) at the wrench surfaces SW 16 from
also turning. With this adjustment, a disk release gap of 2.4 mm is achieved.
• Should the cylinder –bottom part (No.162) or the pressure piston (No.164) become
wetted with Loctite® residue, the residue must be removed.
• Measuring of the piston stroke after the adjustment again controls the release gap.
With an appropriate measuring instrument (i.e. dial gauge or depth gauge) measure
the stroke movement of the pressure piston (No.164) with activation of the brake
(connection II) and with release respectively. If the piston stroke exceeds a value of
5.25 the adjustment must be performed again.
• Insert o-ring (No.176) into the groove of the cylinder-bottom part (No.162) and install
the spring loaded cylinder (No.151) onto the brake cylinder (No.150) and fasten with
four allen bolts (No.152) „cross-wise“.
Note: With these fastening bolts is simultaneously the disk spring pack (No.169) After
fastening the spring loaded cylinder (No.151), the multi-disk brake is in brake position.
• Insert hex. bolt (No.155) and o-ring (No.168) into the spring loaded cylinder (No.151)
and again tighten screw plug (No.154).
• At standstill both the operating- as well as the parking brake are to be activated
alternatively, to make possible the orientation of individual parts.
• Both pressure chambers of the cylinders are to be vented at the breather (III) after
assembly to ensure that there is no air in the lines.

39
 TM-21591-1

2.3.5 Exchange of Brake Cylinder

• Secure vehicle with sufficient steps against rolling away.
• Have zero pressure at both connections I and II.
• Remove screw plug (No.154) and take out hex. bolt (No.155).
• Screw in emergency hex. bolt (No.155) clockwise until noticeably tight. Thereby the
spring pack is completely under tension and the brake is relieved.
• Loosen 4 allen bolts (No.152) and if possible simultaneously remove, to prevent a
jamming of the cylinder housing and remove the spring loaded cylinder (No.151)
completely.
• Loosen three allen bolts (No.113) and if possible, remove simultaneously.
• Remove complete brake cylinder (No.150) assembly from axle beam (No.65).
• Place a new O-ring (No.178) in the groove of the cylinder housing (162) and apply the
area around the oil return bores with an fluid sealant (ex. Loctite® 518).
• Insert the complete lower part of the brake cylinder (No.150) into the hole of the axle
beam (No.65) and during this pay attention that the sides of the compression wedge
(No.181) lies parallel to pressure roller (No.182). Tighten allen bolts (No.113) with 45
Nm.
• Perform prime adjustment of the cylinder stroke as per section 2.3.4.
• Insert o-ring (No.176) into the groove of the cylinder-bottom component (No.162) and
install the spring-loaded cylinder (No.151) onto the brake cylinder (No.150) and fasten
the four allen bolts (No.152) with new spring washers (No.153) „cross-wise“.
Tightening moment for allen bolts (No.152) is 45 Nm.
• Screw open emergency hex. bolt (No.155).
After loosening the emergency hex. bolt (No.155), the multi-disk brake is the brake
position.
• Measuring of the piston stroke after the assembly controls the release gap. With an
appropriate measuring instrument (i.e. dial gauge or depth gauge) measure the stroke
movement of the pressure piston (No.164) with activation of the brake (connection II)
and with release respectively. If the piston stroke exceeds a value of 5.25 a new
adjustment must be performed.
• Insert hex. bolt (No.155) and o-ring (No.168) into the spring loaded cylinder (No.151)
and screw on screw plug (No.154) again and hand tighten.
• At standstill both the operating- as well as the parking brake are to be activated
alternatively, to make possible the orientation of individual parts.
• Both pressure chambers of the cylinders are to be vented at the breather (III) after
assembly to ensure that there is no air in the lines.

40
 TM-21591-1

2.3.6 Exchange of Disks and the Ball ramp actuator

Note:
For working on this part of the brake, the axle must be removed from the vehicle.
(See Figs. 5/11/14)
• Disassemble side component as per section 2.1.
• Disassemble brake cylinder as per section 2.3.5.
• Pull off toothed ring (No.121).
• Take out disk pack (No.119) / (No.120) complete with ball ramp actuator (No.118) from
the axle beam.

Note for assembly:

The principle components of the ball
ramp actuator (No.118) are only
exchangeable as an complete
assembled units. The tension springs
can be dismounted and exchanged.
The layer arrangement of the multi-disk
brake is put together as per the
following:
Three outer disks (No.119) and three
inner disks (No.120) of the disk pack
are assembled in the represented
manner (Fig. 20). First an outer disk
(No.119) is inserted, and then alternate Fig. 14
between an inner disk (No.120) and an
outer disk (No.119). At the ball ramp
actuator (No.118) would be an inner
disk (No.120) on both sides.

Important:
Place the first outer disks (steel) its next
to the actuator disks, with the eye
hooks into the pin nipples of the
actuator disks. To become the full Fig. 15 Fig. 16
brake power. Following outer disks
must be assembled into the straight
pins (No.122). (see Fig. 21 and 22)

• Both outer disks (No.119) of each brake side are to be assembled onto the straight
pins (No.122) „cross-wise“. Each inner most outer disk of each brake side is not
mounted to the straight pins (No.122) anymore, but into both coupler catches of the
ball ramp actuator (No.118). During assembly pay attention that the four cooling oil
openings of the inner disks line up.

41
TM-21591-1

• Align hub profile of the 6 inner disks (No.120) with a profiled mandrel (i.e. sun gear
shaft (No.140)).
• After all six outer disks (No.119) and six inner disks (No.120) and the ball ramp
actuator (No.118) have been assembled; a toothed ring (No.121) is slid onto all four
straight pins (No.122) to assist assembly.
• Replace o-rings (No.5).
• Reinstall complete side component, for this mesh the external spline of the axle shaft
into the compensating gears by light turning at the cardan flange.
• Then slide together axle beams until flange location, observing straight pins.
• Insert hex. bolts (No.39 / Fig. 5). Tightening moment is 400 +10 Nm.
• Install axle into vehicle, (connect brakes and cardan shaft).
• Fill oil into differential.
• Do not forget to vent brake!
• Test drive and retighten axle mounting bolt.

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 TM-21591-1

2.4 Bogie Housing and Slewing Ring

(See Fig. 11 and 17)
2.4.1 Disassembly of the Bogie Housing
First loosen all 8 hex bolts (1) at the bearing stud (33, centre cover), insert M10x40 long
extraction bolts and remove the bearing stud along with the mounted gear (38). Then loosen
16 Allen bolts (125) at the rear of the bogie housing and four Allen bolts (126) at the top
outside and remove the entire bogie housing (23) to the side.
The shaft (140) coming out of the differential is directly mounted to the bearing stud (33).
Before starting the disassembly with released parking brake turn back and forth either the
cardan flange at the differential or one of the output shafts (34), to be sure that the backlash
of the splines in the brake disks is aligned. Then activate the parking brake to hold the brake
disks in this position. Pull out the bearing stud (33) along with the mounted shaft (140).
Then dismount the bogie housing as described above.
2.4.2 Reassembly of the Bogie Housing
Set the seal ring (26) with punch WZ 632 onto the step of the bogie housing (23), the seal
lip pointing in the direction of the bogie housing. Put grease onto the sealing surface of the
slewing ring where the lip of the seal ring will be sliding.
To find the tooth gaps of the sun gear (140) and internal toothing of the slewing ring (172)
you can slightly turn each one of the planet gears (136). Now mount the complete
assembled bogie with new adhesive coated Allen bolts (125) and (126) and tighten in a
crosswise manner with 465 Nm. Use for the 4 upper Allen bolts (126), which are screwed in
from the outside of the bogie housing, hardened washers (58).
During the assembling of the bogie housing it should be noted that the lip of seal (26) does
not become damaged. During the assembly the tandem housing (23) initially centres itself
over the two dowel pins (128) at the slewing ring (172).
Prior to the reassembly of bearing stud (33) coat the flat face with a fluid sealant e.g.
“Loctite® 518”.
Mount the bearing stud along with the mounted gear (41). The brake disks (120) are still
fixed in their original position by the activated parking brake. By slightly turning the shaft
(140) the teeth of the spline have to find the gaps of the internal spline in brake disks,
shifting sleeve (56) and differential gear (15).]
Tighten the bearing stud (33) with adhesive coated hex bolts (1). Finally open output plug
(92) first one side. Then apply grease sequentially to the buffer chamber of slewing ring
(172) at grease nipples (90; 2x per slewing ring) until grease seeps out thump wide from the
output (92). Replace the greasing with the second output. Cover input grease nipples and
output plugs with white plastic caps (179).

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TM-21591-1

Fig. 17

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TM-21591-1

1 Hex. Screw for cover and middle bearing 21 Sheet-metal cover

bolt 22 Plug
2 Hex. Screw 23 Bogie housing
3 Allen screw 24 Cover
4 Allen screw 25 Cylinder roller bearings for intermediate
5 Allen screw gear
6 Plug 26 Seal ring for Slewing ring
7 Cylinder roller bearings for Drive shaft 27 Bushing
8 Cylinder roller bearing middle bearing bolt 28 Washer
9 Cylinder roller bearing for Drive shaft 29 Lock washer
10 Oil seal 30 Washer
11 O-ring for intermediate gear bolt 31 Thrust stud in BB
12 CU Seal ring 32 Interim gear bolt
13 Oil seal middle bearing bolt 33 Tandem housing – middle bearing bolt
14 Straight pin 34 Plug
15 Straight pin 35 Flange on Portal
16 Straight pin 36 BB -Gear ring
17 Straight pin 37 Portal - Pinion Shaft
18 Washer 38 Bogie – Interim gear wheel
19 Snap ring 39 Bogie – End gear wheel
20 Snap ring 40 Portal - Gear wheel
41 Bogie - Middle gear wheel

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 TM-21591-1

2.5 Exchange of the Slewing Ring

Dismount the bogie housing as per 2.5.1. Loosen hex bolts (124) to disassemble the
slewing ring (172).
Insert a new seal ring (175) into the new slewing ring (172) and fill the hollow space of the
seal ring with grease. Set a new O-ring (173) onto the step of the slewing ring.
The hardening gap of the slewing ring (area not hardened between begin and end of
hardened raceway) is marked on the inner ring with a red line. The slewing ring must be
mounted in such a manner that this area (red mark) is at the top; then this part of the
raceway will not be heavily stressed. With the new slewing ring (172) in the proper
orientation, mount it to the axle beam (101) and secure with new adhesive coated hex
bolts (124). Tighten the bolts "crosswise" with 465 Nm.
Reassemble the bogie housing as per 2.5.2.

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 TM-21591-1

2.6 Gear Drive inside the Bogie Housing

2.6.1 Exchange of the Studs
Start to remove the tin cover (21). Then can the snap ring (19) and the ring (18) be
removed. Further screw an impact puller into the M12 thread on the face of the stud (32)
and pull it out.
Apply a new O-ring (11) into the groove of the stud. Insert it into the hole of the bogie
housing (23), gear (38). Then lay in the spacer ring (18) and secure with the snap ring (19).
Close the opening with an new tin cover (21)
2.6.2 Exchange of the Gears and Needle bearings
First remove the complete bogie housing (23) as per 2.5.1 Further remove the inner BB-
Drive and the middle stud (33) with gear. Then pull out the interim studs as per 2.7.1. Now
can the gears (38) be removed through the large central opening of the bogie housing.
Needle bearing rings (25) can now be exchanged. Note: There is a circlip ring (17) for
position fixing, between needle bearing rings integrated. When disassembled, insert the
circlip ring (17) again. Insert the new needle bearing rings (25) into the gears (38). The new
gears (38) are inserted through the large opening (dia. approx. 200) into the tandem
housing beginning with outer most gear and assembled as per 2.7.1.
Finish assembly as per 2.5.2.

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 TM-21591-1

2.7 Planetary Drive

Note!
To work on the planetary drive it is not required to remove the axle from the vehicle. It is
sufficient when the side of the vehicle that is being worked on is jacked up and the wheel
removed.

Fig. 18

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 TM-21591-1

1. Gear rim 16. Plug 31. Tapered roller brg.

2. Hex. screw 17. Wheel nut 32. Hex. screw
3. washer 18. Limes ring 33. Wheel bolt
4. Planetary cage Inner p. 19. Washer package 34. Wheel hub
5. Shear pin 20. – 35. O-Ring
6. - 21 - 36. Tapered roller brg.
7. Planetary bolt 22 – 37. Circlip
8. Needle cage 23 - 38. Ring gear carrier
9. - 24. - 39. Groove nut
10. Planetary gear 25. - 40. Sun gear shaft
11. Butting ring 26. O-Ring 44. Bogie housing
12. - 27. Axle stub 49. O-Ring
13. Planetary cage Outer p. 28. Hex. nut 62. Adjusting washer
14. Seal ring 29. Slide ring
15. Plug 30. Axle stub ring

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 TM-21591-1

2.7.1 Complete Exchange of Planetary Cage

(see Fig. 18)
• Jack up and secure vehicle.
• Remove wheel.
• Drain oil (section 1.5.2.2).
• Remove hex. bolts (No.32).
• Pull off the complete planetary cage (No.13).
• Replace o-ring (No.35) and insert into the recess of the wheel hub (No.34).
• Assemble new complete planetary cage (No.13).
For this, bring the teeth of the sun gear shaft (No.40) and the four planetary gears
(No.10) to meshing location. Then under light turning, slide on planetary cage until the
planetary gears mesh into the crown gear (No.1). Afterwards, push on planetary cage
(No.13) till it closed.
• Insert hex. bolts (No.32). Tightening moment is 125 Nm.
• Adjust thrust stud. (see section 2.3.2.1)
Note: Thrust stud = Screw plug (No.16)
• Fill oil (section 1.5.2.2 –Planetary drive).
• Install wheel.
• Let down vehicle.
2.7.2 Exchange of Sun gear shaft
(see Fig. 18)
• Drain oil (section 1.5.2.2).
• Remove planetary cage (No.13) (see section 2.3.1).
• Pull out sun gear shaft (No.40) from the axle stub (No.27).
• Insert new sun gear shaft (No.40).
To ease meshing with the profile of gear (No.43), lightly turn the sun gear shaft back
and forth.
• With an exchange of the sun gear shaft (No.40), the adjustment of the thrust stud
(No.16) is to be checked and readjusted if need be, to prevent any axial pressing.
See section 2.3.2.1.
• Reassemble planetary cage (No.13). See section 2.8.1.
• Fill oil (section 1.5.2.2 –Planetary drive).

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 TM-21591-1

2.7.2.1 Check and Adjust the Thrust Stud Adjustment.

Note: Thrust stud = Screw plug (No.16)
(see Fig. 19)
• For this measure distance (l4) from the wheel hub flange surface (No.34) to the face of
the axle shaft (No. 40) and distance (l5) from the flange surface of the planetary cage
(No.13) to the stopping face of the thrust stud (No.16) with a depth gauge.
Axial play l5 - l4 must be at least 0.5 mm. (Max. allowable 2.0 mm)
• If the measured or calculated axial play is outside of these values, the thrust stub
(No.16) is to be adjusted with appropriate new washer packet (No.19).
• For this, the assembled thrust stud (No.16) should be completely threaded out.
To ease assembly, heat to approx. 80°.
• Then assemble the planetary cage (No.13) to the wheel hub (No.34) as per section
2.3.1. Insert sun gear shaft (No.40) inward through the threaded hole M 30 x 1.5 with
an approx. Ø 20 mm mandrel and light tap hammering until stop.
• Selection of the washer packet „ S “ (No.19)
„ S “min = 22 - „ A “ measured
„ S “max = 23 - „ A “ measured
„ A “ = distance from spot face of planetary cage to the face of the axle shaft.
• Clean thread M 30 x1.5 in planetary cage (No.13) of dirt, oil and inhibitors.
• Thread in thrust stud (No.16) with selected washer packet „ S “ (No.19) into planetary
cage and tighten with 200 to 240 Nm.
• Fill oil (section 1.5.2.3 –Planetary drive).

Fig. 19

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 TM-21591-1

2.7.3 Exchange of Planetary Gears

(see Fig. 18)
• Remove planetary cage (No.13) see section 2.8.1.
• Place planetary cage (No.13) with the opening upward.
• Loosen four hex. bolts (No.2).
• Evenly pull off planetary cage – inner part (No.4) with pulling washer WZ 190.
• Remove thrust washers (No.11) and pull off planetary gears (No.10).
• Insert thrust washers (No.11), with the lip showing towards the stopping diameter in
the planetary cage (No.13).
• Insert a needle cage (No.8) onto the new planetary bolt (No.7), and push the new
planetary gear (No.10) onto the planetary bolt (No.7).
• Insert shear sleeves (No.5) and check completeness respectively.
• Adjust thrust washer (No.11), with the lip showing toward the stopping diameter of the
inner part (No.4) of the planetary cage.
• Press on planetary cage (No.4) and screw on with new coated bolts (No.2) and
washers. Tightening moment is 290 Nm.
• Check the free floating of the planetary gears (No.10) and axial play (min. 0.3 mm).
• Reassemble planetary cage (No.13) complete.(see section 2.8.1).

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 TM-21591-1

2.7.4 Exchange of Planetary Pins

(see Fig. 18)
• Remove planetary cage (No.13). See section 2.8.1.
• Remove planetary gears (No.10). See section 2.8.3.
• Check parts and replace it if necessary.
• Fasten pulling plate WZ 190 with four temporary assembly bolts M 12 x 35 to the four
planetary pins (No.7) and pull out the planetary pins (No.7) with the centre bolt.
• Press in the new planetary pins (No.7).
• Insert thrust washers (No.11), with the lip showing towards the stopping diameter of
the planetary cage (No.13).
• Reassemble planetary gears (No.10) see section 2.3.3.
• Reassemble planetary cage (No.13) complete. See section 2.8.1.
2.7.5 Exchange of Crown Gear Carrier
(see Fig. 18)
• Remove planetary cage (No.13) see section 2.8.1.
• Remove snap ring (No.37).
• Replace crown gear (No.1).
• Reinsert snap ring (No.37).
Note: The ring gear should have a radial play of approx. +/- 0.4 mm on the ring gear
carrier (No.38).
• Assembly planetary cage (No.13). See section 2.8.1.

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 TM-21591-1

2.8 Wheel Bearings

(see Fig. 18)
2.8.1 Wheel Bearing Exchange
• Remove planetary cage (No.13) complete (section 2.8.1).
• Disassemble sun gear shaft (No.40) (section 2.8.2).
• Loosen groove nut (No.39).
For this, heat groove nut M 85 x 2 (No.39) to approx. 150°C, (i.e. with soldering torch)
and loosen with special socket wrench WZ 081. The loosening moment can reach up
to 2000 Nm.
• Remove crown gear carrier (No.38) with crown gear (No.1).
• Pull off wheel hub (No.34) and outer gear bearing (No.36), simultaneously from the
axle stub (No.27), with an appropriate extractor.
• Remove axial face seal (No.29) from the axle stub (No.27) and wheel hub (No.34) and
replace it if necessary.
• Press out bearing outer ring from the gear bearings (No.31 and No.36) from the wheel
hub.
• Press bearing inner ring (No.31) with an extractor from the axle stub (No.27) and press
a new bearing inner ring (No.31) onto the axle stub (No.27) again.
Assembly temperature for the bearing inner ring (No.31) max. 80°.
• Reinsert new bearing outer rings (No.31 u. No.36) into the wheel hub (No.34).
• Press new axial face seal (No.29) into wheel hub (No.34) and into axle stub (No.27)
with a special assembly tools (WZ 234); otherwise insert the face seal (No.29) into the
grooves of spindle ring and wheel hub by hand. The face seals are very brittle, be
careful not to break them.
• Clean thread M 85 x 2 of the axle stub (No.27) and nut (No.39) of dirt, oil, adhesive
residue, and inhibitors.
• Centrally insert wheel hub and assemble heated bearing inner ring from (No.36) onto
the axle stub (No.27) completely, use assembly sleeve if necessary.
• Coat end faces of the crown gear carrier (No.38) with Klüber-Paste Wolfracote SSP.
• Insert crown gear carrier (No.38) with crown gear (No.1).
• Adjust gear bearing (see section 2.4.2) and tighten groove nut (No.39) with special
socket wrench WZ 081.
• Insert axle shaft (No.40), to ease meshing with the profile of gear (No.43), turn lightly
the sun gear back and forth. (see section 2.3.2)
• Reassemble planetary cage (No.13). (see section 2.3.1).

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 TM-21591-1

2.8.2 Wheel Bearing Adjustment

• Measure distance „X1“ on axle stub (No.27). (theoretical = 22 ± 0,2)
„X1“ = Distance between end face on axle stub (No.39) and shoulder for adjusting
washers.

Fig. 20 reading value „X1“

• Coat end face of the ring gear carrier (No.38) with Klüber-Paste Wolfracote SSP.
• Screw on nut (No.39) and tighten until a bearing preload of approx. 20 to 40 Nm (with
seals) is achieved at the gear bearings. Align roller cage and gear bearing, during this
turn wheel hub 1-2 times in both directions and continuously tap hammer on the
outside of the wheel hub (No.31) and ring gear carrier (No.11).
• Measure distance „X2“. (theoretical „X2“ = 20 ± 0,75)
„X2“ = Distance between end face on axle stub (No.27) and end face of ring gear
carrier (No.11).

Fig. 21 reading value „X2“

55
TM-21591-1

• Select washer thickness „d“ (No.62) of the adjusting washers.

„d“ max = „X1“ - „X2“
„d“ min = („X1“ - „X2“) – 0.15 (see below Fig. )

Fig. 22
• Again loosen nut (No.39) and remove.
• Clean thread M 85 x 2 of axle stub (No.27) and groove nut (No.39) of oil, dirt,
inhibitors, and adhesive residue.
• Insert adjusting washer with calculate thickness „d“.
• Again coat end face of ring gear carrier with Klüber-Paste Wolfracote SSP (do not coat
groove nut No.39).
• Coat entire diameter and length of thread M 85 x 2 of axle stub (No.27) and groove nut
(No.39) with Loctite® 262.
• Thread on groove nut (No.17) with a special groove socket wrench WZ 081 and
tighten with 1900+100 Nm. With using of the torque amplifier Sk 3.91-1007 with 5:1
ratio, tighten with 390 Nm. The final bearing preload adjustment must be between 20
to 35 Nm.
• The final location of the axle stub nut (No.39) must be achieved within 2 -5 minutes, in
order for the Loctite® to achieve its full potential.

11. ring gear carrier

27. stub axle
39. groove nut
62. adjusting washer
Fig. 23

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 TM-21591-1

2.8.3 Exchange of Axial Face Seal

• For this, refer to section 2.9.1 and 2.9.2.
2.8.4 Exchange of Axle Stub
(see Fig. 18)
• First of all perform disassembly as per 2.9.1.
• After loosening the hex. bolts (No.28) remove the complete axle stub (No.27).
• Pull off axle stub ring (No.30).
• Insert new o-ring (No.49) into the grove of axle stub ring (No.30) and press onto the
axle stub (No.27).
• Insert both dowel pins (No.59) into the bogie housing (No.44).
• Add new o-ring (No.26) and preassemble axle stub (No.27) with tightening hex. bolts
(No.28) on the bogie housing (No.44).
Tightening moment is 290 Nm.
• Continue assembly as per section 2.9.1.
• Reinstall gear.

Revisions reserved
Neunkirchen on the November 30 2012

57
TM-21591-1

NAF Special tool table for VL 89 axle

Description: WZ number:

Insert punch WZ 199

to insert the seal rings 1160.223 / 116.224 by drive shaft
flange
(short distance)
(with ring for long distance)
Insert punch WZ 203
WZ 283
to insert the bearing 1110.186 on driving pinion
Mandrel and calibre socket WZ 509
for seal rings 1180.811 in diff. lock shifting
Groove socket wrench WZ 012
for diff. lock shifting cylinder 5263.061
Insert punch WZ 592
to insert the seal rings 1160.236/ 7308.063 into axle beam
Insert punch WZ 632
to insert the seal ring 7308.040 into bogie housing
Groove socket wrench WZ 081
for groove nut 7329.073 in wheel hub
Installer ring WZ 234
for slide ring 1180.325 in wheel hub
Extractor plate WZ 190
to pull off the inner part from the planetary cage in
planetary drive system

58