0-Text-e - Amazon S3 · ZF – AXLE MULTISTEER MS-E 3050/3060/3070 ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau Property of American Airlines. REPAIR MANUAL for ZF-axle MS-E 3050/3060/3070

Order no.: 5871 564 002

ZF – AXLE MULTISTEER

MS-E 3050/3060/3070

ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau

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REPAIR MANUAL for ZF-axle

MS-E 3050/3060/3070

I M P O R T A N T I N F O R M A T I O N: The great variety of ZF units compels a restriction of the Disassembly and Assembly Manuals to a standard ZF production unit. Continuous technical improvement of the ZF units as well as extensions concerning design possibilities might require differing work steps, which can be carried out by qualified specialists without any greater difficulties with the aid of the perspective illustrations included in the corresponding Spare Parts Lists. This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of preparation of the Repair Manual. ZF Passau GmbH reserves the right to replace this Disassembly and Assembly Manual by a subsequent edition at any time without prior notice. Upon request, ZF Passau GmbH shall advise which edition is currently valid. For maintenance work always observe the lubrication and maintenance instructions (ZF order no: 5871 564 902) as well as the ZF List of lubricants TE-ML 05.

The ZF List of lubricants is constantly updated and can be ordered or viewed: - At all ZF plants - At all ZF Service Centers - Internet http://www.zf.com/ - Service – Techn. Information – List of lubricants ..... ----------------------------------------------------------------------------------------------------------

ATTENTION:

Observe the vehicle manufacturer’s instructions and specifications for installation and commissioning of the unit!

ZF Passau GmbH Donaustr. 25 - 71 D - 94034 Passau Abt.: ASDM / Section : ASDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Copying even partially not permitted! Reproduction meme par extrait est interdite! Technische Änderungen vorbehalten! With the reserve of technical modifications! Sous reserve de modification techniques! Design level 2005/06 3. edition 2006/07

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C O N T E N T S Chapter/page

Preface General and important information on industrial safety Marking of type plate and information on spare parts order Examples of contact patterns for Gleason gear-tooth system Wear measurement – multi-disc brake Conversion table Denomination of standard dimensions Tightening torques for plugs

0/1

0/2 ... 3

0/4 … 5

0/6 ... 7

0/8 ... 9

0/10

0/11

0/12

LIST OF TOOLS (required special tools) ILLUSTRATED TABLES

W/01 ... 9

WB/01 ... 13

1. DISASSEMBLY

1.1 STEERING 1.2 OUTPUT 1.2.1 Planetary carrier 1.2.2 Brake/hub 1.2.3 Knuckle housing 1.3 DIFFERENTIAL – INPUT 1.3.1 Differential version „D-500“ and „D-750“ 1.3.2 Input 1.4 PIVOT BEARING

1/1 … 16

1/1 … 4

1/5 … 12 1/5 … 6 1/6 … 9

1/10 … 12

1/12 … 16 1/13 … 14 1/14 … 16

16

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C O N T E N S Chapter/page

2. REASSEMBLY

2.1 INPUT 2.1.1 Determine shim for pinion positioning (contact pattern – crown wheel /

pinion) 2.1.2 Adjust rolling moment of drive pinion bearing 2.2 DIFFERENTIAL Version „D-500“ and „D-750“

2.2.1 Adjust backlash of bevel gear set and bearing rolling moment of differential bearing

2.2.2 Backlash and contact pattern check 2.3 INPUT FLANGE 2.4 OUTPUT 2.4.1 Pre-assemble axle housing 2.4.2 Knuckle housing 2.4.3 Hub 2.4.4 Multi-disc brake 2.4.4.1 Leakage test of multi-disc brake 2.4.4.2 Adjust and check disc clearance/piston stroke 2.4.5 Planetary carrier 2.5 PIVOT BEARING 2.6 STEERING 2.6.1 Steering setting and checking 2.6.1.1 Basic track setting 2.6.1.2 Steering angle setting 2.6.2 Leakage test of steering 2.7 Oil drain-,oil filler and oil control plugs

2/1 … 36

2/1 … 4 2/1 … 3

2/3 … 4

2/4 … 11 2/7 … 9

2/9 … 11

2/11 … 12

2/13 … 27 2/13 … 14 2/15 … 18 2/19 … 21 2/21 … 25 2/23 … 24 2/24 … 25 2/26 … 27

28

2/29 … 35 2/34 … 35

2/34 2/35 2/35

2/36

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R e p a i r M a n u a l

Corporate Division Off-Road Driveline Technology

and Axle Systems

5871 564 002 0/1

PREFACE

This documentation has been developed for specialized staff trained by ZF Passau for Repair and Maintenance work to be made on ZF-units.

This documentation describes a ZF series product with a design level valid at the date of edition

Due to a continuous technical improvement of the product, however, the repair of the unit at your disposal might require both deviating work steps and differing setting and testing data. We would therefore recommend you to charge masters and servicemen with the work on your ZF product, whose practical and theoretical training is constantly updated in our training school. The Service Stations established by ZF Friedrichshafen all over the world offer you: 1. Permanently trained staff 2. Prescribed equipment, e.g. special tools 3. Genuine ZF spare parts at current state of the art

All work is done there with utmost care and reliability. In addition, repair work carried out by ZF-Service Stations is covered by the ZF-warranty within the terms of the currently applicable contractual conditions.

Any damage resulting from work which is done in an improper and unworkmanlike manner by third parties and consequential costs incurred are excluded from this contractual liability. This is also applicable if other than genuine ZF spare parts are used. ZF Passau GmbH Service Department

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GENERAL

The Service Manual covers all work required for disassembly and the pertaining reassembly. When repairing the transmission, ensure utmost cleanliness and that the work is done in a workmanlike manner. Dismantle the transmission only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar.

Carry out disassembly and reassembly work on a clean working place. Use special tools, which have been developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from residues of seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to a normal wear during operation, such as bearings, thrust washer etc., will be reinstalled. Parts such as sealing rings, lock plates, split pins etc. must generally be replaced. Radial sealing rings with worn or broken sealing lip must also be replaced. In particular, ensure that no chips nor other foreign bodies remain in the housing. Check lube oil bores and grooves regarding unhindered passage. Treat all bearings with operating oil prior to installation:

NOTE: Only a heating furnace (oil bath) or an electric drier is permitted to be used for heating up parts such as bearings, housings etc.!

Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.

CAUTION When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual. Tighten screws and nuts according to the enclosed standard table, unless otherwise specified. The use of fluid seals or Molykote is not permitted for the control part in the transmissions – due to a possible malfunction. Never wash clutch plates having organic friction linings (e.g. paper linings) (adverse effect on lining adhesion). Only dry-cleaning is permitted (leather cloth).

DANGER When using detergents, observe the manufacturer’s instructions regarding their handling.

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The structure of this repair manual reflects the sequence of the work steps for completely disassembling the dismantled unit. Please find special tools required to carry out the repair work in the current text as well as in chapters "W“(List of special tools) and "WB" (illustrated tables).

Important information on industrial safety

As a principle, the persons repairing ZF-units are responsible on their own for industrial safety.

Observing all valid safety regulations and legal requirements is a precondition for avoiding personal injury and damage to the product during maintenance and repair work. Persons performing repair work must make themselves familiar with these regulations before starting their work. A suitably trained and skilled staff is required for a proper repair of these ZF-products.

The repairer is obliged to perform the training. This manual uses the following safety notes:

CAUTION You will find this symbol in this repair manual where a reference note is made to special working procedures, methods, information, applications of auxiliaries, etc.

DANGER

This symbol refers to situations where lacking care might lead to personal injury or damage to the product.

____________________________________________

NOTE: Before starting the tests and repair work, thoroughly study this manual.

NOTE:

Illustrations, drawings and parts do not always represent the original; the working procedure is shown.

The illustrations, drawings, and parts are not drawn to scale; Do not draw conclusions on size and weight (not even within one and the same illustration). Carry out the work according to the description.

NOTE: After repair work and the tests, the expert staff must verify that the product is perfectly functioning again.

��

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MARKING OF TYPE PLATE FOR ZF-AXLES

VERSION "A"

1 = Axle type (model) 2 = Unit number 3 = ZF-parts list number 4 = Total ratio of axle 5 = Oil filling (oil specification) 6 = ZF-List of lubricants 7 = Oil filling capacity 8 = Customer number

INFORMATION ON SPARE PARTS ORDER:

When ordering genuine -ZF-spare parts consider the following data:

1. = Axle type 2. = Unit number 3. = ZF-parts list number 4. = Brand and type of spare part 5. = Denomination of spare part 6. = Spare part number 7. = Kind of shipment

Please complete the a.m. details to avoid mistakes in the delivery of the ordered spare parts!

1 2

7

3

6

4

5

8

These data can be taken from the type plate!

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MARKING OF TYPE PLATE FOR ZF-AXLES

VERSION "B"

1 = Customer name (vehicle manufacturer) 2 = Type 3 = ZF- parts list number 4 = Vehicle manufacturer’s parts list number 5 = Current series number 6 = Oil filling capacity (oil specification) KUNDE / CUSTOMER

TYPE SERIAL - NO.

PARTS LIST NO.

CUSTOMER PART NO.

LIST OFLUBRICANTS

TE-ML

MANUFACTURED BYZAHNRADFABRIK PASSAU GMBH

MADE IN GERMANY

INFORMATION ON SPARE PARTS ORDER:

When ordering genuine -ZF-spare parts consider the following data:

1. = Transmission type 2. = Unit number 3. = ZF- parts list number 4. = Brand and type of spare part 5. = Denomination of spare part 6. = Spare part number 7. = Kind of shipment

Please complete the a.m. details to avoid mistakes in the delivery of the ordered spare parts!

1

2

3

4

5

6

These data can be taken from the type plate! Prope

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TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM EXEMPLES POUR LA DENTURE GLESON Ideales Tragbild d.h. die Ritzeldistanz stimmt Ideal tooth-contact pattern i.e. pinion distance is correct L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte Bild / Figure 1/3/5 Schubflanke (Konkav) Coast side (concave) Côté poussé (concave)

Bild / Figure 1

Bild / Figure 2/4/6 Zugflanke (Konvex) Drive side (convex) Côté entraîné (convexe)

Bild / Figure 2

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5871 564 002 0/7

Ritzeldistanz muß größer werden Pinion distance must be increased La distance du pignon doit être augmentée

Ritzeldistanz muß kleiner werden Pinion distance must be decreased La distance du pignon doit être diminuée

Bild / Figure 3

Bild / Figure 5

Bild / Figure 4

Bild / Figure 6

(+) (-)

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BRAKE WEAR MEASUREMENT

ON ZF-AXLES OF MT/MS-E 3050/3060/3070 RANGE ATTENTION: The measurement of wear on the multi-disc brake only gives limited information on the total state of the plate pack – without disassembling the output. Make measurement of lining wear at least once per year, in particular, however, in case of a different braking behaviour, like:

• Brake noises • Reduced braking power • Different deceleration • Different brake oil level

• Different braking pressure

To avoid injury when opening the oil drain/oil filler plug (1), due to a possible pressure build-up in the planetary carrier bring drain hole to topmost position (12 o’clock) and carefully

unscrew oil drain and filler plug (1). Then turn output until oil filler/ oil drain hole (1) is on 9.00 o’clock position – see figure 1. Figure 1

Sketches in figure no. 2 and 3 are shown turned by 90° !

Figure 2 Figure 3 Legend to figure no 1, 2 and 3:

1 = Oil filler-/oil drain hole 2 = Gauge hole (Ø = 10 mm) in ring gear - 9 00 clock position 3 = Dial indicator with solenoid support 4 = Planetary carrier 5 = Ring gear 6 = Piston 7 = Plate pack X = Piston stroke

3

X 4 5 6 7

2

1

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Lining wear measurement of multi-disc brake: With unapplied brake, piston is in contact with ring gear by compression spring return – see figure no. 2 – get dial indicator (3) into touch with piston(6) through oil filler /oil drain hole (1) and gauge hole (2).

- Apply pressure on brake and determine piston stroke (X – see figure no. 3) by means of dial indicator - Take limit value of piston stroke (at max. wear) from the chart below!

Axle type Lined disks Piston stroke with new disks Limit value of piston stroke(X) at max. wear

MT-E 3050 8 pcs. 0.7 ... 1.3 mm 7.0 mm MT-E 3060 6 pcs. 0.7 ... 1.3 mm 6.0 mm MT-E 3060 7 pcs. 0.7 ... 1.3 mm 6.5 mm MS-E 3050 8 pcs. 0.7 ... 1.3 mm 7.0 mm MS-E 3060 6 pcs. 0.7 ... 1.3 mm 6.0 mm MS-E 3070 7 pcs. 0.7 ... 1.3 mm 6.5 mm

Make lining wear measurement on both outputs! (S) Solenoid support 5870 200 055 (S) Dial indicator 5870 200 057 (S) Extension 5870 200 091 Then provide oil drain/filler plug with new O-ring and install it! Tightening torque(M36x1.5) ............ MA = 50 Nm

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VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE

TABLEAU DE CONVERSION

25.40 mm 1 kg ( Kilogramm ) 9.81 Nm ( 1 kpm ) 1.356 Nm ( 0.138 kpm ) 1 kg / cm

1 bar ( 1.02 kp/cm2 )

0.070 bar ( 0.071 kp/cm2 ) 1 Liter 4.456 Liter 1 Liter 3.785 Liter 1609.344 m 0° C ( Celsius ) 0 ° C ( Celsius )

=

=

=

=

=

=

=

=

=

=

=

=

=

=

1 in ( inch)

2.205 lb ( pounds )

7.233 lbf x ft ( pound force foot)

1 lbf x ft ( pound force foot )

5.560 lb / in ( pound per inch )

14.5 psi (pound force per square inch lbf/in2 )

1 psi ( lbf/in2 )

0.264 Gallon ( Imp. )

1 Gallon ( Imp. )

0.220 Gallon ( US )

1 Gallon ( US )

1 Mile ( land mile )

+ 32° F ( Fahrenheit )

273.15 Kelvin

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BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS

DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Masse in kg/m; flächenbezogene Masse in t/m2 Note : linear density in kg/m; areal density in t/m2 Nota : Densité linéaire en kg/m; Densité superficielle en t/m2

Begriff Unit Unité

Formelzeichen Formula Sign Symbole

Neu Alt New Old Nouveau Vieux

Umrechnung Conversion Conversion

Bemerkungen Note Nota

Masse Mass Mass

m kg (Kilogramm) kg

Kraft Force Force

F N (Newton) kp 1 kp = 9.81 N

Arbeit Work Travail

A J (Joule) kpm 0.102kpm = 1J = 1Nm

Leistung Power Puissance

P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW 1 KW = 1.36 PS

Drehmoment Torque Couple

T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) = F (N) . r (m)

Kraftmoment Moment (Force) Moment (Force)

M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) = F (N) . r (m)

Druck (Über-) Pressure (Overpress) Pression (Sur-)

pü bar atü 1.02 atü = 1.02 kp/cm2

= 1 bar = 750 torr

Drehzahl Speed Nombre de Tours

n min -1

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TIGHTENING TORQUES FOR SCREWS (in Nm) ACCORDING TO ZF-STANDARD 148

Friction coefficient: µ tot.= 0.12 for screws and nuts without subsequent treatment, as well as for phosphated nuts. Tighten manually!

Unless otherwise specified, the tightening torques can be taken from the following chart :

Metric ISO-standard thread DIN 13, page 13

Dimension 8.8 10.9 12.9

M4 2.8 4.1 4.8

M5 5.5 8.1 9.5

M6 9.5 14 16.5

M7 15 23 28

M8 23 34 40

M10 46 68 79

M12 79 115 135

M14 125 185 215

M16 195 280 330

M18 280 390 460

M20 390 560 650

M22 530 750 880

M24 670 960 1100

M27 1000 1400 1650

M30 1350 1900 2250

M33 1850 2600 3000

M36 2350 3300 3900

M39 3000 4300 5100

Metric ISO fine thread DIN 13, page 13

Dimension 8.8 10.9 12.9 M 8 x 1 24 36 43

M 9 x 1 36 53 62

M 10 x 1 52 76 89

M 10 x 1.25 49 72 84

M 12 x 1.25 87 125 150

M 12 x 1.5 83 120 145

M 14 x 1.5 135 200 235

M 16 x 1.5 205 300 360

M 18 x 1.5 310 440 520

M 18 x 2 290 420 490

M 20 x 1.5 430 620 720

M 22 x 1.5 580 820 960

M 24 x 1.5 760 1100 1250

M 24 x 2 730 1050 1200

M 27 x 1.5 1100 1600 1850

M 27 x 2 1050 1500 1800

M 30 x 1.5 1550 2200 2550

M 30 x 2 1500 2100 2500

M33 x 1.5 2050 2900 3400

M 33 x 2 2000 2800 3300

M 36 x 1.5 2700 3800 4450

M 36 x 3 2500 3500 4100

M 39 x 1.5 3450 4900 5700

M 39 x 3 3200 4600 5300

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LIST OF TOOLS FOR DISASSEMBLY AND REASSEMBLY

ZF – MULTISTEER

MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003

Disassembly Chapter/Fig.

Reassembly Chapter/Fig Designation and Application

Part number

5871 564 002 / E W/01

1/1

Assembly truck cpl. with tilting device Supporting bracket 1 set = 2 pcs Universal use. For clamping the cpl. axle MT-E 3050/3060/3070 on the assembly truck.

5870 350 000 5870 350 106

1/05

Hot air blower 230 V Hot air blower 115 V Universal use. For heating-up bearings and parts assembled with LOCTITE.

5870 221 500 5870 221 501

1/09 1/15 1/59

Plastic hammer 60 mm Universal use. For a gentle disassembly and reassembly of single components.

5870 280 004

1/12 1/21 1/24

2/96 2/90 2/111

Set of external pliers A1-A2-A3-A4 Universal use. To unsnap and to snap-in externally clamped retaining rings.

5870 900 015

1/13

Plastic hammer 30 mm Universal use. For a gentle disassembly and reassembly of single components.

5870 280 003

1/19 1/33 1/46

2/43 2/68

Lifting bracket Universal use. For disassembly and reassembly of the hub or the cpl output.

5870 281 043

1/20 1/47 1/48

Lifting strap Universal use. For disassembly and reassembly of the cpl. output of the hub carrier and the cpl. HL transmission.

5870 281 026

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MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/02

1/22

Two-armed puller Universal use. For pulling off the planetary gears from the planetary carrier.

5870 970 002

1/26

2/71 2/82

Socket spanner # To loosen and tighten the Slotted nut M 85 x1.5 4472 347 002 on the hub carrier. Slotted nut M110 x1.5 4472 347 026 on the hub carrier.

5870 656 097

1/27

Assembly lever 1 set = 2 pcs Universal use. For installing and dismantling housings, flanges, and axle components.

5870 345 065

1/32

Adjusting device 2 pcs. required Universal use. Easier dismantling of disc carrier 4472 347 025; 4472 348 042 .

5870 400 001

1/33

Two-armed puller SPW 380 / SPT 250mm Pressure piece Universal use . For pulling off the hub 4472 347 024 / 4472 348 041 / 4472 399 033 from the hub carrier Also see : 5870 281 043

5870 970 028 5870 100 067

1/34

Pry bar Universal use. To separate flanges, bearings and shafts and to dismantle seal rings.

5870 345 071

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MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/03

1/36

Gripping insert # MS – E 3050 For pulling off the taper roller bearing inner ring 47431A = 0750 117 562 from the hub carrier. Can be used together with : Pressure piece Two-armed puller

5873 013 015

5870 100 067 5870 970 028

1/36

Gripping insert # MS – E 3060 / 3070 For pulling off the taper roller bearing inner ring JP12049A = 0750 117 570 from the hub carrier. Can be used together with : Pressure piece Two-armed puller

5873 004 026

5870 100 067 5870 970 028

1/39 1/42

2/53 2/58

Lifting chain 3-line Universal use. For various lifting operations. Together with: MS-E 3050 / 3060 2 ring bolts M16 DIN 580 0636 804 001 Together with: MS-E 3070 2 ring bolts M18 DIN 580

5870 281 047

1/40

Gripping insert # MS – E 3050 For pulling off the taper roller bearing inner ring HM801349 = 0750 117 357 from the bearing pin. Gripping insert # MS – E 3060 For pulling off the taper roller bearing inner ring HM804846 = 0750 117 469 from the bearing pin. Gripping insert # MS – E 3070 For pulling off the taper roller bearing inner ring HM807049 = 0750 117 179 from the bearing pin. Can be used together with : Back-off insert

5873 001 032

5873 011 015

5873 001 037

5870 026 100

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MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/04

1/43 1/44

Internal extractor MS – E 3050 Universal use ø 46 – ø 56 mm To remove seal ring 0734 309 430 and bushing 0730 260 633 from knuckle housing and axle housing hole. Internal extractor MS – E 3060 / 3070 Universal use ø 56 – ø 70 mm To remove seal ring 0734 309 429 and bushing 0730 260 621 from knuckle housing and axle housing hole. Can only be used together with: Counter support

5870 300 007

5870 300 017

5870 300 020

1/45 1/62

Internal extractor ø 56 – ø 110 mm Universal use To remove bearing outer ring 0750 117 357; 469; 179 and 0750 117 088 / 354 from knuckle housing and axle housing. Can only be used together with : Counter support

5870 300 019

5870 300 020

1/50

Striker Universal use. To remove bearing outer ring from axle housing.

5870 650 004

1/51

Gripping insert # MS – E 3050 / 3060 For pulling off the taper roller bearing inner ring 30210 / JLM506849 = 0750 117 802 / 795 from the differential carrier. Can be used together with : Pressure piece # Back-off insert # Gripping insert # MS – E 3070 For pulling off the taper roller bearing inner ring 28985 / 387A = 0750 117 177 / 346 from the differential carrier. Can be used together with: Pressure piece # Back-off insert #

5873 001 020

5870 100 009 5870 026 100

5873 001 034

5870 506 058 5870 026 100

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MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/05

1/56

2/11 2/37 2/41

Clamping fork # Universal use. To lock the input flange during loosening and tightening the threaded joint.

5870 240 025

1/61

Gripping insert For pulling off the bearing inner ring JM5049 = 0750 117 355 and HM807049 = 0737 117 179 from the bevel pinion.

5873 001 037

2/2

Digital depth gauge # 200 mm Gauge blocks# 1 set = 2 pcs For different measuring tasks.

5870 200 072 5870 200 066

2/6

Assembly fixture# Assembly ring # To mount the bearing outer rings JW5010 / HM807010 0750 117 355 / 179 in the axle hole.

5870 345 049 5870 345 056

2/12

Torque wrench # 0.6 – 6 Nm Reducing adapter # ¼“ – ½“ Reducing adapter # ½“ – ¾“ Universal use. To measure and check the rolling resistance in the pinion bearing.

5870 203 030 5870 656 056 5870 656 057

2/15

Adjusting screws M12x1.5 To align and position the crown wheel to the differential carrier.

5870 204 027

2/23 2/28

Driver MS – E 3050 / MS – E 3060 For driving the bearing outer ring 30210 = 0750 117 802 / JLM506849 = 0750 117 785 into the housing hole - axle housing. Can be used with : grip 5870 260 002

5870 058 061

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MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/06

2/23 2/28

Driver MS – E 3070 For driving the bearing outer ring 28921 = 0750 117 177 / 383A = 0750 117 346 into the housing hole - axle housing. Can be used with: grip 5870 260 002

5870 058 051

2/26 2/27

Measuring bar # 320 mm Digital depth gauge # 200 mm Straigtedges # (1 set = 2 pcs.) Universal use. For different measuring tasks.

5870 200 126 5870 200 072 5870 200 066

2/30 2/31

Magnetic stand # Dial indicator # Universal use. For determination of backlash crown wheel / pinion .

5870 200 055 5870 200 057

2/38 2/39

Driver # MS –E 3050 / 3060 To insert seal ring 60 x 90 10/14.5 = 0734 319 709 into axle housing – input flange .

5870 048 269

2/38 2/39

Driver # MS –E 3070 To insert seal ring 65 x 105 10/14.5 0734 319 745 into axle housing – input flange.

5870 048 286

2/45 2/46 2/51 2/52

Driver # MS-E 3050 To insert bushing 0730 260 633 into axle housing/knuckle housing – output. To insert seal ring 0734 309 430 into axle housing/knuckle housing – output. Can be used together with: grip

5870 055 081

5870 260 002

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ZF – MULTISTEER

MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/07

2/45 2/46 2/51 2/52

Driver # MS –E 3060 / 3070 To insert bushing 0730 260 621 into axle housing/knuckle housing – output. To insert seal ring 0750 110 138 / 0734 309 429 into axle housing/knuckle housing – output. Can be used together with : Grip

5870 055 090

5870 260 002

2/47

Driver # MS –E 3050 To insert bearing outer ring HM 801 310 = 0750 117 357 into axle housing – knuckle housing bearing Driver # MS –E 3060 To insert bearing outer ring HM 804 810 = 0750 117 469 into axle housing – knuckle housing bearing Driver # MS –E 3070 To insert bearing outer ring HM 807 010 = 0750 117 179 into axle housing – knuckle housing bearing Can be used together with : Grip

5870 058 058

5870 058 022

5870 058 078

5870 260 002

2/49

Lever riveting tongs # Universal use. For assembly of plugs 0631 405 058 / 074 into knuckle housing.

5870 320 016

2/63

Torque wrench # 10 – 90 Nm Universal use. To measure and check rolling resistance in the knuckle housing bearing.

5870 203 034

2/67

Driver # MS –E 3050 / MS -E 3060 To insert seal ring 0750 110 155 and 0734 309 401 into hub hole. Plane installation position. Can be used with: grip 5870 260 004

5870 051 035

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ZF – MULTISTEER

MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/08

2/07

Driver # MS – E3070 To insert seal ring 0734 319 425 into hub hole. Installation depth max. 6.2 mm Can be used with: Grip 5870 260 004

5870 051 023

2/83

HP - pump # Threaded coupling# M 14 x 1.5 Breather bottle # To breathe brake and to determine piston stroke. Leakage test of brake system.

5870 287 007 5870 950 102 5870 286 072

2/84 2/91

Digital depth gauge # 300 mm Straightedge # 580 mm Universal use. For different measuring operations. Determination of thrust washer thickness ecc.

5870 200 114 5870 200 022

2/93

Driver # MS – E 3050 For driving thrust washer 0769 120 746 into the planetary carrier.

5870 048 245

2/93

Driver # MS – E 3060 / MS – E 3070 For driving thrust washer 0769 120 870 into the planetary carrier.

5870 048 263

2/99

Hot air blower 230 V Hot air blower 115 V Universal use. To warm up housing and bearing parts.

5870 221 500 5870 221 501

2/102

Inner installer # MS – E 3050 / 3060 Inner installer # To install sealing elements in the steering 4472 134 002 = 0501 213 767 .

5870 651 086 5870 651 087

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ZF – MULTISTEER

MS – E 3050 / 3060 / 3070 4472 097 006 / 4472 098 007 + 009 / 4472 099 003



Part number

5871 564 002 / E W/09

2/102

Inner installer # MS – E 3070 Inner installer # To install sealing elements in the steering 4472 134 006 = 0501 213 857.

5870 651 088 5870 651 089

2/104

Calibration bushing # MS – E 3050 / 3060 For calibration of sealing elements in the steering 4472 134 002 = 0501 213 767 .

5870 651 090

2/104

Calibration bushing # MS – E 3070 For calibration of sealing elements in the steering 4472 134 006 = 0501 213 857.

5870 651 091

2/116

Socket spanner # MS – E 3050 / 3060 For a controlled tightening of tie rods 0501 007 631 / 632 on the piston rod. Wrench size 55 mm Socket spanner # MS – E 3070 For a controlled tightening of tie rods 0501 007 716 / 717 on the piston rod. Wrench size 75 mm

5870 656 100

5870 656 099

2/118

Measuring device # Straightedges # 1 set = 2 pcs To determine and set the steering angle.

5870 200 033 5870 200 029

2/120

HP - pump # Threaded joint # GE12PLM M 18 x 1.5 Measuring fitting# For a function test and for leakage test of steering cylinder.

5870 287 007 0662 561 931 5870 950 139

# Very important tools.

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5871 564 002

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B/09

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Corporate Division Off-Road DrivelineTechnology

and Axle Systems

5871 564 002 1/1

1. DISASSEMBLY

Total view – axle installed on assembly truck. Illustration shows version „MS-E 3060“. Secure axle by means of a support (arrow)! (S) Assembly truck 5870 350 000 (S) Support 5870 350 106

Figure 1

1.1 STEERING: View – Steering installed in axle.

Figure 2

Loosen hex nuts on both tie rods.

Figure 3

Drive out tie rod from bevel seat – use suitable mandrel (brass/aluminium)!

Figure 4

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5871 564 002 1/2

Warm up threaded joint area of piston rod /axial joint –disassembly is more difficult (thread/axial joint is installed with locking compound/Loctite no. 243). (S) Hot-air blower 230 V 5870 221 500 (S) Hot-air blower 115 V 5870 221 501

Figure 5

��

Separate both tie rods (assy) from piston rod. If work is just to be done on sealing elements and/or piston rod or guide, no disassembly of the steering cylinder assy is required and you may continue with figure no. 12!

Figure 6

Tie rod version: Tie rod with clamp fixing - version „A“ Tie rod with counter nut fixing - version „B“ – see illustration in the corresponding spare parts list

Figure 7

Loosen threaded joint of steering /axle drive housing.

Figure 8

Version „A“

Version „B“ Prope

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5871 564 002 1/3

Drive out steering cylinder assy by means of a plastic/aluminium hammer (S) Plastic hammer 5870 280 004

Figure 9

Take steering cylinder assy out of the axle drive housing.

Figure 10

Unsnap the circlip and remove flange.

Figure 11

Unsnap retaining ring. Set of external pliers 5870 900 015

Figure 12

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5871 564 002 1/4

Drive the guide into the cylinder tube (diretion of arrow) until the circlip can be removed (see figure no. 14). (S) Plastic hammer 5870 280 003

Figure 13

Unsnap circlip.

Figure 14

Drive out piston rod together with guide from cylinder tube. (S) Plastic hammer 5870 280 004

Figure 15

Pull off guide from piston rod. Remove all sealing elements from piston, guide and cylinder.

Figure 16

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5871 564 002 1/5

��

1.2 OUTPUT: Loosen screw plug and drain oil from the axle. Use suitable collecting basin – environmental protection !

Figure 17

��

To avoid injury due to a possible pressure build-up in the oil system of the planetary carrier, bring oil filler and control plug to 12 o’clock position and carefully unscrew! Then bring drain hole to 6 o’clock position and drain the oil! Use suitable collecting basin – environmental protection!

Figure 18

Figure 19

��

Following illustration shows the complete disassembly of the output (figure no. 20 …. no. 45) – if work is required on the differential and/or pinion, you may disassemble the output as one unit – as shown on the adjacent photo. Please take the required work steps (such as dismantling the tie rod-, bearing pins ecc. ...) from chapters - 1.1 STEERING, page 1/1 and - 1.2.3 KNUCKLE HOUSING, page 1/10. Pay attention to seal ring in the axle housing - risk of damage!

(S) Lifting bracket 5870 281 043

1.2.1 PLANETARY CARRIER: Loosen both cylinder screws and separate planetary carrier from hub. (S) Lifting strap 5870 281 026

Figure 20

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5871 564 002 1/6

Unsnap circlip. (S) Set of external pliers 5870 900 015

Figure 21

Pull off planetary gear by means of a two-armed puller. (S) Two-armed puller 5870 970 002

Figure 22

Unsnap circlip and remove washer. Then remove roller bearing, second circlip and washer from planetary gear.

Figure 23

1.2.2 BRAKE/HUB: Unsnap retaining ring and remove both thrust washers. (S) Set of external pliers 5870 900 015

Figure 24

Version MS-E 3060/3070

Version MS-E 3050

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5871 564 002 1/7

Remove slotted nut mount (cylinder screw).

Figure 25

Loosen slotted nut. (S) Slotted nut wrench 5870 656 097

Figure 26

Press off ring gear with piston. Pay attention to the releasing O-ring (arrow)!

(S) Assembly lever 5870 345 065

Figure 27

Loosen hex. screws, remove spring sleeves and compression springs.

Figure 28

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5871 564 002 1/8

Press off piston from ring gear.

Figure 29

Remove sealing elements (arrows) from ring gear.

Figure 30

Remove plate pack.

Figure 31

Remove O-ring (arrow) and lift-off disc carrier with lever, then remove releasing O-ring. (S) Adjusting device 5870 400 001 (2 pcs. required)

Figure 32

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5871 564 002 1/9

Figure 33

To ensure correct functioning, always fit a new cassette-type sealing (see figure no. 34) after any disassembly of hub! Pull hub from hub carrier by means of pressure piece and two-armed puller. Pay attention to the releasing bearing inner ring ! (S) Two-armed puller 5870 970 028 Pressure piece 5870 100 067 (S) Lifting bracket 5870 281 043

Lift-off shaft seal (arrow) with lever and remove both bearing outer rings from hub. (S) Pry bar 5870 345 071

Figure 34

Just for axle type MS-E 3060: Remove spacer bush.

Figure 35

Figure 36

Pull bearing inner ring from hub. MS-E 3050 (S) Gripping insert 5873 013 015 (S) Two-armed puller 5870 970 028 (S) Pressure piece 5870 100 067 MS-E 3050/3070 (S) Gripping insert 5873 004 026 (S) Two-armed puller 5870 970 028 (S) Pressure piece 5870 100 067

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5871 564 002 1/10

Figure 37

1.2.3 KNUCKLE HOUSING: Legend to the sketch: (Illustration shows lower bearing pin) 1 = Bearing pin 2 = Knuckle housing 3 = Axle housing 4 = Shim (only fitted on lower bearing pin) 5 = O-Ring 6 = Sealing cap 7 = Taper roller bearing 8 = lubrication nipple

Loosen threaded connection and remove upper bearing pin. Remove lower bearing pin – by means of lifting device / see figure no. 39 - not before securing the knuckle housing!

Figure 38

��

Secure knuckle housing by means of lifting device and dismantle lower bearing pin. Pay attention to releasing shim! (S) Lifting chain 5870 281 047 MS-E 3050/3060 2 Eyebolt M16 0636 804 001 MS-E 3070 2 Eyebolt M18 DIN 580

Figure 39

Figure 40

Remove bearing inner ring (7), O-ring (5) and sealing cap (6) from bearing pin (1). MS-E 3050 (S) Gripping insert 5873 001 032 MS-E 3050 (S) Gripping insert 5873 001 015 MS-E 3050 (S) Gripping insert 5873 001 037 in connection with back off insert 5870 026 100

1

7

6

5

1

7

2 3

6

5 4

8

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5871 564 002 1/11

Separate knuckle housing with double u-joint shaft from axle housing. Pay attention to seal ring in the axle housing – risk of damage!

Figure 41

Pull out double u-joint shaft from knuckle housing. Pay attention to seal ring in the axle housing – risk of damage!

Figure 42

Pull out seal ring and afterwards the bushing behind from the knuckle housing. MS-E 3050 (S) Internal extractor 5870 300 007 (S) Counter support 5870 300 020 MS-E 3060/3070 (S) Internal extractor 5870 300 017 (S) Counter support 5870 300 020

Figure 43

Pull out seal ring and afterwards the bushing behind from the axle housing. MS-E 3050 (S) Internal extractor 5870 300 007 (S) Counter support 5870 300 020 MS-E 3060/3070 (S) Internal extractor 5870 300 017 (S) Counter support 5870 300 020

Figure 44

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5871 564 002 1/12

Pull out both bearing outer rings from the swivel bearing holes. (S) Internal extractor 5870 300 019 (S) Counter support 5870 300 020

Figure 45

Figure 46

1.3 DIFFERENTIAL - INPUT: If work is required on the differential and/or pinion, you may disassemble the output(s) as one unit – as shown on the adjacent photo. Please take the required work steps (such as dismantling the tie rod-, bearing pins ecc. ...) from chapters - 1.1 STEERING, page 1/1 and - 1.2.3 KNUCKLE HOUSING, page 1/10. Pay attention to the seal ring in the axle housing - risk of damage!

(S) Lifting bracket 5870 281 043 Fix axle housing part /II by means of a lifting strap, loosen threaded joint of axle housing half on crown wheel side (differential) and separate axle housing half part /II from axle drive housing. Pay attention to the releasing differential ! (S) Lifting strap 5870 281 026

Figure 47

��

Remove bearing outer ring (arrow1) and the shim behind as well as O ring (arrow 2) from axle housing part /II. Mark shim (regarding position /bearing allocation) – assembly aid !

Figure 48

1

2

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5871 564 002 1/13

Lift off the differential from the axle drive housing.

Figure 49

��

Pull out bearing outer ring and the shim behind from the bearing hole of axle housing part /I. Mark shim (regarding position /bearing allocation) – assembly aid! (S) Striker 5870 650 004

Figure 50

Figure 51

��

Figure 52

1.3.1 DIFFERENTIAL Version „D-500“ und „D-750“: The illustration shows version „D-500“. Pull both taper roller bearings from differential carrier. MS-E 3050/3060 (S) Gripping insert „Super“ 5873 001 020 Back-off insert 5870 026 100 Pressure piece 5870 100 009 MS-E 3070 (S) Gripping insert „Super“ 5873 001 034 Back-off insert 5870 026 100 Pressure piece 5870 506 058 Loosen threaded joint (position „X“). In version „D-750“ the hex. screws are installed with locking compound (Loctite) - disassembly is more difficult - if required, warm up area of threaded joint (disassembly aid) !

Version „D-500“

Version „D-750“

X X

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5871 564 002 1/14

Separate differential carrier halves and remove the releasing single components.

Figure 53

Press off crown wheel from differential carrier half.

Figure 54

1.3.2 INPUT: Legend to sketch no. 55: 1 = Input pinion 6 = Seal ring 2 = Hex. nut 7 = Taper roller bearing 3 = Washer 8 = Spacer ring (bearing rolling moment) 4 = Input flange 9 = Shim (contact pattern) 5 = Screen sheet 10 = Input housing

Figure 55

Loosen hex. nut and remove the washer behind. Pay attention to support of axle housing (arrow) !

(S) Fixture 5870 240 025

Figure 56

1

2

4

5 6 3

7 8

9

10

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5871 564 002 1/15

Remove flange. If required – remove screen sheet from output flange.

Figure 57

Lift-off seal ring with lever.

Figure 58

��

Drive out input pinion. If taper roller bearings should not be replaced, pay attention that the outside bearing inner ring – with all its rolls – is in contact with bearing outer ring when driving out the input pinion ! (S) Plastic hammer 5870 280 004

Figure 59

Remove spacer ring.

Figure 60

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5871 564 002 1/16

Press off bearing inner ring from input pinion. (S) Gripping insert 5873 001 037

Figure 61

Extract outside bearing outer ring. (S) Internal extractor 5870 300 019 (S) Counter support 5870 300 020

Figure 62

��

Drive out bearing outer ring from the inner bearing hole – pay attention to the shim behind! Mark shim (reg. position/bearing allocation) – assembly aid !

Figure 63

1.4 PIVOT BEARING: If required: Provide bushings with a separating slot – see arrow - (bushings are destroyed by this). Then remove bushings from holes.

Figure 64

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5871 564 002 2/1

2. REASSEMBLY

Figure 1

2.1 INPUT : Comment on sketch: 1 = Drive pinion 2 = Differential (with crown wheel) 3 = Shim for contact pattern (Bevel gear set) 4 = Spacer ring (Bearing rolling moment/pinion bearing) 5 = Shim (bearing rolling moment/differential bearing) 6 = Shim for backlash 7 = Input flange 8 = Seal ring 9 = Axle drive housing 10 = Axle housing /part I (10a = O-ring) 11 = Axle housing/part II (crown wheel side) Just for „New part“ assembly or if disassembled: Install o-ring (10a) on axle housing/part I (10) and mount axle drive housing (9)– observe installation position ! Tightening torque: MS-E 3050/3060 (M 18/10.9).. MA = 390 Nm MS-E 3070 (M 18x1.5/10.9).... MA = 440 Nm

2.1.1 Determine shim for pinion positioning to obtain an optimum contact pattern of crown wheel/pinion - refer to contact pattern examples, page 0/06 and 0/07: Read dimension "I" (Position – see arrow) from axle drive housing. Dimension "I" e.g. ......................................... 149.09 mm

Figure 2

Read pinion dimension (basic distance) „X“ from pinion (see arrow) or measure it in case of a + or – deviation of the pinion dimension caused by the production (value concerned is marked by hand on the pinion, e.g.+ 0.1). Pinion dimen. “X“ (without + or –deviation) = 116.0 mm

Pinion dimen. „X“ with an indicated + 0.1

deviation = 116.1 mm

Pinion dimen. „X“ with an indicated – 0.1 deviation = 115.9 mm Dimension „II“ (Pinion basic distance) e.g. ……… 116.00 mm

Figure 3

1 3

8 7

4

2

5

6

9

11

10

116

+ 0,1

10a

149,09

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5871 564 002 2/2

��

Figure 4

Figure 5

Measure dimension „III“ bearing width, observing that the rollers are located without any play (rotate bearing inner ring in both directions several times – roller setting) ! Since the installed roller bearing is subject to a pre-load in installation position, consider an experience deduction

of – 0.1 mm ! Dimension „III“ = e.g. 32.00 mm – 0.1 mm → 31.90 mm (S) Digital depth gauge 5870 200 072 (S) Gauge blocks 5870 200 066 CALCULATION EXAMPLE: Dimension „I“ ………………………......... 149.09 mm Dimension „II + III“ (116.00 + 31.90) .... – 148.10 mm Result .................................................... = 1.01 mm Shim required “S” 1.00 mm Insert the determined shim (e.g. „S“ = 1.00 mm) into the inner bearing hole /pinion bearing.

Super-cool bearing outer ring (see arrow) and bring it into contact position in the inner bearing hole / pinion bearing by means of the fixture. (S) Assembly fixture 5870 345 049 (S) Assembly ring 5870 345 056

Figure 6

Instal outside bearing outer ring /pinion bearing

Figure 7

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5871 564 002 2/3

Mount heated bearing inner ring until contact is obtained and readjust after cooling-down.

Figure 8

Figure 9

��

2.1.2 Adjust rolling moment of drive pinion bearing 1.0 ... 3.0 Nm (without seal ring): Mount spacer ring (s = optional). We would recommend to re-install the spacer ring found during disassembly. If, however, the required rolling moment of 1.0 ... 3.0 Nm (without seal ring) is not achieved - see bearing rolling moment test - correct the bearing rolling moment by means of a corresponding spacer ring!

Insert the preassembled drive pinion, mount the heated bearing inner ring until contact is obtained.

Figure 10

��

Mount flange, fix with washer and hex. nut. During tightening, rotate pinion in both directions several times (roller setting) ! Tightening torque: MS-E 3050/MS-E 3060 (M27x1.5) ................. MA = 480 Nm MS-E 3070 (M30x1.5) ................................... MA = 600 Nm (S) clamping fork 5870 240 025

Figure 11

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5871 564 002 2/4

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Figure 12

Check rolling moment of pinion bearing ! Bearing rolling moment (without seal ring) 1.0 ... 3.0 Nm Try to achieve upper value. If the rolling moment differs from the required value, correct it with a suitable spacer ring (see figure no. 9/page 2/3)! (S) Torque wrench 5870 203 030 (S) Reduction ¼" to ½" 5870 656 056 (S) Reduction ½" to ¾" 5870 656 057

��

Reassemble seal ring – as shown in section 2.3 page 2/11…. 2/12 (after completed differential assembly and positive contact pattern check) !

2.2 DIFFERENTIAL Version „D-500“ and „D-750“: Illustration shows version „D-500“. Mount slotted pins (arrows) into differential carrier half, considering the assembly specification , see sketch no. 14.

Figure 13

Figure 14

Assembly specification: Bring slotted pin(s) in a position where slot shows into the direction of force (arrow)! In case of double slotted pins – bring the slots in a 180° degrees offset position to each other! To sketch: 1 = differential carrier 2 = slotted pin 3 = slotted pin (just for double slotted pin version) X = direction of force

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5871 564 002 2/5

Press differential carrier until contact is obtained.

Assembly aid - (just for version „D-500“) Insert two adjusting screws into crown wheel. (S) Adjusting screw (M12x1.5) 5870 204 027

Figure 15

��

Insert thrust washer and axle bevel gear. Put driving lugs of thrust washer into driving holes / differential carrier – do not locate in oil supply recesses !

Figure 16

��

Install differential bevel gears and thrust washers on differential spider and insert in differential carrier half I. Ensure radial installation position of thrust washers! Lug is looking vertically upward (see arrow)!

Figure 17

Insert second axle bevel gear.

Figure 18

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5871 564 002 2/6

Figure 19

��

��

Figure 20 ��

Stick thrust washer with grease (assembly aid) into differential carrier half II. Locate differential carrier half II on differential carrier half I. Put driving lugs of thrust washer into driving holes / differential carrier – do not locate in oil supply recesses! Fasten differential carrier halves with cylindr. screws and washers (D-500, Pos. X) and with hex. screws (D-750, Pos.X). Ensure radial installation position – designation (ZF-Nr. ….) at the same time corresponds to radial position marking! Just for version „D-750“, insert hex screws with locking agent (Loctite-no. 262)!

Version „D-500“ Tightening torque (M 12x1.5/12.9) ……… MA = 145 Nm Version „D-750“ Tightening torque (M 12x1.5/10.9) ……… MA = 122 Nm Tightening torque (M 16x1.5/10.9) ……… MA = 300 Nm Install both bearing inner rings (arrows).

Figure 21

Wet some tooth flanks of the crown wheel with marking ink (for contact pattern check – see figure no 32, page 2/9).

Figure 22

Version „D-500“

Version „D-750“

X X

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5871 564 002 2/7

��

��

Figure 23

Figure 24

2.2.1 Adjust backlash of bevel gear set and bearing rolling moment of differential bearing: Backlash (crown wheel/drive pinion) MS-E 3050/3060 = 0.12 ... 0.24 mm MS-E 3070 = 0.15 … 0.27 mm Differential bearing preload = 0.10 ... 0.15 mm (corresponds to a bearing rolling moment of 1 ... 4 Nm) Bring axle drive housing/axle housing into upright position! Insert shim (backlash) into hole of axle housing /part I and install bearing outer ring until contact is obtained. We would recommend to install the shim (experience value = approx. 1.25 mm) found during disassembly – also refer to disassembly instructions page 1/13, figure no. 50!

However, the required backlash is decisive for the shim(s) to be used! MS-E 3050/3060 (S) Driver 5870 058 061 (S) Grip 5870 260 002 MS-E 3070 (S) Driver 5870 058 051 (S) Grip 5870 260 002 Insert pre-assembled differential.

��

��

Place bearing outer ring. Locate the bearing outer ring on the bearing inner ring, until all rollers are located without any play. For this purpose rotate differential and bearing outer ring in both directions several times – roller setting! A correct positioning of bearing outer ring and differential is imperative for the following measuring operation!

Figure 25

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5871 564 002 2/8

Figure 26

Figure 27

��

�� Figure 28

Determine dimension "I", from mounting face of axle drive housing to bearing contact.

Dimension "I" e. g. ........................................ 18.10 mm

(S) Digital depth gauge 5870 200 072 (S) Gauge blocks 5870 200 066 (S) Measuring bar 5870 200 126 Make measurement on several points and calculate mean value! Determine dimension "II", from mounting face of axle housing /part II to contact face /bearing outer ring. Dimension "II" e. g. ................................. 17.20 mm CALCULATION EXAMPLE:

Dimension "I" e. g. ................................................... 18.10 mm Dimension "II" e. g. ............................................... – 17.20 mm Difference ............................................................. = 0.90 mm requ. bearing preload (0.10 ...0.15mm).................. + 0.13 mm Result… …………………………….………….… = 1.03 mm Required shim "S" ÷÷÷÷ = 1.05 mm Insert determined shim(s) e. g. „S“ = 1.05 mm into bearing hole of axle housing /part II and instal bearing outer ring so that contact is obtained. Instal (stick) bearing outer ring into hole with grease – assembly aid ! MS-E 3050/3060 (S) Driver 5870 058 061 (S) Grip 5870 260 002 MS-E 3070 (S) Driver 5870 058 051 (S) Grip 5870 260 002

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5871 564 002 2/9

Locate preassembled axle housing /part II (without O-ring) (observe radial installation position) and temporarily fix with hex. screws.

Figure 29

Figure 30

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��

2.2.2 Backlash and contact pattern check: Place dial indicator at right angles to a tooth flank of the crown wheel (within the outer diameter area) through oil filler hole and check backlash. Backlash MS-E 3050/3060 = 0.12 … 0.24 mm MS-E 3070 = 0.15 … 0.27 mm In case of a deviation from the specified backlash, correct it with a suitable shim (see figure. 23)! A correction of shim / backlash also requires a correction of shim/bearing rolling moment to the opposite direction (see figure no. 28)! (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 Rotate drive pinion in both directions several times over crown wheel/differential (contact pattern impression – in this connection see figure no. 32) !

Figure 31

��

Remove differential. Compare contact pattern (see arrow) with contact pattern examples on page 0/6 … 0/7. If the contact pattern differs considerably, an error was made when measuring the shim (see figure no. 23, page 2/7), which needs to be corrected by all means!

Figure 32

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5871 564 002 2/10

Oil O-ring and mount on collar (arrow) of axle housing half / part II.

Figure 33

Reinstal differential.

Figure 34

Instal pre-assembled axle housing half (observe radial installation position), fix with hex. screws and washers. Tightening torque: MS-E 3050/3060 (M 18/10.9)………………... MA = 390 Nm MS-E 3070 (M 18x1.5/10.9)............................. MA = 440 Nm

Figure 35

Bring axle into horizontal position and secure with a support (arrow) !

Figure 36

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5871 564 002 2/11

Disassemble flange. (S) Clamping fork 5870 240 025

Figure 37

Figure 38

��

2.3 INPUT FLANGE: Comment on sketch no. 38 … figure no. 41: 1 = drive pinion 6 = seal ring 2 = hex. nut 7 = bevel roller bearing 3 = washer 8 = spacer ring 4 = input flange 9 = input housing 5 = screen X = installation dimension MS-E 3050/3060 ÷ 13.0+0.2 mm MS-E 3070 ÷ 13.5+0,2 mm Illustration shows version – MS-E 3060

��

Figure 39

��

Figure 40

Place seal ring (6), considering the required installation position (dimension „X“) – see sketch no. 38.

Contact face (outer diameter) of seal ring: - wet it with spirit (assembly aid) if rubber-coated - apply sealing agent (Loctite no. 574) if made of metal Apply grease on seal and dust lip of the seal ring! (Grease e.g. "PETAMO GHY 133 N" ZF-order no. 0671 190 099) Ensure plane installation position of seal ring – use suitable driver! MS-E 3050/3060 (S) Driver 5870 048 269 MS-E 3070 (S) Driver 5870 048 286 Press screen /thrust plate (5) on the input flange until contact is obtained – also see sketch no. 38! Screen/thrust plate must not be deformed when mounted – use suitable driver!

1

2

4 3

5 6

7

9

7

X

8

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5871 564 002 2/12

Install pre-assembled input flange (4+5) and washer (3), fix with hex. nut (2). Secure hex. nut with locking agent (Loctite-no. 262)! Tightening torque: MS-E 3050/MS-E 3060 (M27x1.5) ................. MA = 480 Nm MS-E 3070 (M30x1.5) ................................... MA = 600 Nm (S) Clamping fork 5870 240 025

Figure 41

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Figure 42

Figure 43

Figure 44

Figure 45

2.4 Output: Comment on sketch no. 42: 1 = Axle housing 2 = Knuckle housing 3 = Hub 4 = Multi-disc brake 5 = Planetary carrier Mount just for cpl. output – figure no. 43: Locate the cpl. output on the axle – by installing the u-joint shaft in the differential toothing. Pay attention to seal ring in the axle housing – risk of damage! Other required work steps (bearing pin and tie rod assembly) can be taken in extracts from the complete assembly (Section 2.4.2 knuckle housing, page 2/15 … 2/18 and section 2.6 steering, page 2/29)! (S) Lifting bracket 5870 281 043

2.4.1 Pre-assemble axle housing:

Legend on sketch no. 44 … Figure no. 47: 1 = axle housing 2 = bushing (observe installation position) 3 = seal ring (observe installation position) 4 = bearing outer rings (pivot bearing) X = Lubrication groove outlet (V-point – oil chamber side) Bushing – lubrication groove outlet installed in 600 o’clock position (referred to the axle mounted in the vehicle)! Insert bushing into hole of axle housing – considering installation dimension „B“ and installation position „X“ / see detailed sketch. Detailed sketch – turned by 90 °: (S) Driver tool (MS-E 3050) 5870 055 081 Grip 5870 260 002 (S) Driver tool (MS-E 3060/3070) 5870 055 090 Grip 5870 260 002

1 2 3 4 5

X

2

3

1

4

4

2 1

X

1 = Achsbrücke 2 = Buchse B = Installation dim.1.0 +0.3 mm X = Observe installation position of bush - Lubrication groove outlet (V-point – oil chamber side) in 600 o’clock position – referred to the axle fitted into the vehicle !

B

B

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5871 564 002 2/14

Figure 46

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��

Figure 47

Flush-mount seal ring (item 3 – see sketch no. 44) into axle housing hole, with seal lip showing to oil chamber. Contact face (outer diameter) of seal ring: - wet it with spirit (assembly aid) if rubber-coated - apply sealing agent (Loctite no. 574) if made of metal Apply grease on seal and dust lip of the seal ring! (Grease e.g. "PETAMO GHY 133 N" ZF-order no. 0671 190 099) Ensure plane installation position of the shaft seal ring! (S) Driver tool (MS-E 3050) 5870 055 081 Grip 5870 260 002 (S) Driver tool (MS-E 3060/3070) 5870 055 090 Grip 5870 260 002 Mount both bearing outer rings (Item 4- see sketch no. 44) into pivot bearing holes of the axle housing. MS-E 3050 (S) Driver 5870 058 058 Grip 5870 260 002 MS-E 3060 (S) Driver 5870 058 022 Grip 5870 260 002 MS-E 3070 (S) Driver 5870 058 078 Grip 5870 260 002

Carefully install u-joint shaft (Risk of damage – seal ring) !

Figure 48

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2.4.2 Knuckle housing: Just for assembly of a new knuckle housing: (Figure no. 49) Shut machining openings (of oil supply holes – position 1 and 2 (only version MS-E 3060) with plugs. (S) Lever riveting tongs 5870 320 016

Figure 49

Figure 50

Figure 51

Figure 52

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��

Legend to sketch no. 50 … Figure no. 52: 1 = Knuckle housing 2 = Bushing (observe installation position) 3 = seal ring (observe installation position) W = Installation dimension – shaft seal ring MS-E 3050 ÷÷÷÷2.0 +/- 0.2 mm MS-E 3060/3070 ÷÷÷÷ 3.5 +/- 0.2 mm B = Installation dimension - bushing MS-E 3050 ÷÷÷÷1.0 +/- 0.2 mm MS-E 3060/3070 ÷÷÷÷ 2.0 +/- 0.2 mm X = Lubrication groove outlet (V- point – oil chamber side) Installation position of bushing Lubrication groove outlet in 600 o’clock position - referred to the axle fitted into the vehicle! Insert bushing into the hole of the knuckle housing – considering the installation dimension „B“ and installation position „X“ / see detailed sketch.

Detailed sketch:

(S) Driver tool (MS-E 3050) 5870 055 081 (S) Driver tool (MS-E 3060/3070) 5870 055 090

Mount seal ring (item 3 – see sketch no. 50) into knuckle housing hole – considering installation dimension „E“ (see sketch no. 50) and installation position (seal lip showing to oil chamber).

Contact face (outer diameter) of seal ring: - wet it with spirit (assembly aid) if rubber-coated - apply sealing agent (Loctite no. 574) if made of metal Apply grease on seal and dust lip of the seal ring! (Grease e.g. "PETAMO GHY 133 N" ZF-order no. 0671190099) Ensure plane installation position of the shaft seal ring!

(S) Driver tool (MS-E 3050) 5870 055 081 (S) Driver tool (MS-E 3060/3070) 5870 055 090

2

1

X

1 = Knuckle housing 2 = Bushing

X = Observe installation position of bushing – lubri-cation groove outlet (V-point – oil chamber side)in 600 o’clock position - referred to the axle fitted into the vehicle!

2

3

X

1

W

B

1

2

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Locate pre-assembled knuckle housing on axle housing, and carefully mount u-joint shaft (Seal ring – risk of damage) ! (S) Lifting chain 5870 281 047 MS-E 3050/3060 2 Eyebolt M16 0636 804 001 MS-E 3070 2 Eyebolt M18 DIN 580

Figure 53

Figure 54

Legend to sketch no. 54 …. Figure no. 57: (Illustration shows lower bearing pin) 1 = bearing pin 2 = sealing cap 3 = O-ring 4 = bevel roller bearing 5 = shim (just on lower bearing pin) 6 = lubrication nipple 7 = knuckle housing 8 = axle housing X = area/anti-corrosive agent

Mount sealing cap – observe installation position (see sketch no. 54) !

Figure 55

Instal O-ring (arrow - 1) and apply anti-corrosive agent, „Weicon Anti Seize“ (Never Seez) ZF-order no. 0671 196 001 on bearing pin collar (arrow-2) Mount bearing inner ring.

Figure 56

1

2

7 4

3

2

1 6 5

8

X

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Just on lower bearing pin : Instal shim for pivot bearing roller moment setting e.g. S = 0.80 mm (experience value) on lower bearing pin.

Figure 57

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Instal pre-assembled lower bearing pin and fix with hex. screws. Observe installation position – mount bearing pin with lubrication nipple showing to axle centre ! (S) Lifting chain 5870 281 047 MS-E 3050/3060 2 Eyebolt M16 0636 804 001 MS-E 3070 2 Eyebolt M18 DIN 580

Figure 58

Insert O-ring – see arrow (1pc /for version → brake breather valve integrated in the knuckle housing), or O rings (2 pcs. /for version → brake breather valve integrated in the bearing pin) into the countersink(s) of the knuckle housing.

Figure 59

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Instal pre-assembled upper bearing pin (figure no. 55 and 56). Observe installation position – oil supply holes for multi-disc brake!

Figure 60

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Fix both bearing pins definitively. MS-E 3050 Tightening torque (M 16/10.9) …………. MA = 280 Nm MS-E 3060 Tightening torque (M 18/10.9) …………. MA = 390 Nm MS-E 3070 Tightening torque (M 20/10.9) …………. MA = 560 Nm

Figure 61

Figure 62

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Figure 63

Mount lubrication nipple in both bearing pins (arrow-1, installation position at the upper bearing pin – showing to the axle center) and apply grease to the pivot bearing (grease acc. to ZF-list of lubricants „TE-ML 05“, e.g. RENOLIT 283 EP 2, ZF order no.: 0671 190 079). Tightening torque (M 10x1) …………. MA = 6 Nm Mount breather valve (arrow 2 , position depending on version: integrated in the knuckle housing or in the bearing lid,) and provide with dust cap. Tightening torque (M 14x1.5) …………. MA = 20Nm Just on upper bearing pin: Brake tube connection (arrow-3, M 14x1.5 / ISO 6149) Check rolling moment of pivot bearing. Required bearing rolling moment: MS-E 3050 ÷÷÷÷ 38 … 45 Nm MS-E 3050 ÷÷÷÷ 50 … 60 Nm MS-E 3050 ÷÷÷÷ 78 … 85 Nm For this purpose locate torque wrench on a hex. screw, align at bearing pin center and determine bearing rolling moment considering the following formula. Try to achieve the upper value of bearing roller moment! In case of a deviation from the specified bearing rolling moment, correct it with a suitable shim. (see figure no. 57)!

(S) Torque wrench 5870 203 034

TE = effective torque on the central swivel point (bearing pin center) L = Distance – from torque wrench point of attach (hex. screw center) to grip center (torque wrench) e.g. L = 300 mm (0.3 m) A = Distance – from torque wrench socket (hex. screw center) to bearing pin center (central swivel point) e.g. A = 55 mm → MS-E 3050 A = 61 mm → MS-E 3060 A = 70 mm → MS-E 3070 TS = Value of the torque to be read from the scale

Resulting: A value achieved on the torque wrench scale of e.g. 32 … 38 Nm ^ 38 … 45 Nm effective bearing rolling moment of pivot bearing. 41 … 50 Nm ^ 50 … 60 Nm effective bearing rolling moment of pivot bearing. 58 … 69 Nm ^ 70 … 85 Nm effective bearing rolling moment of pivot bearing.

TE =

TS =

TS x (L+A) L

TE x L

L + A

2

1

3

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2.4.3 Hub: Install heated bearing inner ring until contact is obtained.

Figure 64

Figure 65

Figure 66

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��

Figure 67

Just for axle type MS-E 3060: Install spacer bush. Mount wheel bolts(1). Install both bearing outer rings (2) of hub bearing until contact is obtained. Oil O-ring (3) and locate in annular groove of hub. Mount shaft seal, considering installation position (marking OUT-SIDE looking upward/outward) and installation dimension „X“ – see detailed sketch. To ensure correct functioning, fit the hub with a „new“ cassette-type sealing only – also refer to disassembly instructions page 1/5, figure no. 18 !

Legend to figure no. 7 and detailed sketches: 1 = Hub 2 = shaft seal X = installation dimension MS-E 3050/3060 MS-E 3070 X = 0.0 ... 0.3 mm X = 6.4

- 0,4 mm

Version MT-E 3050/3060 Version MT-E 3070

Apply sealing agent (Loctite-Nr. 574) to contact face shaft seal / hub. Wet contact face of shaft seal / hub carrier with spirit at the very beginning of the assembly – assembly aid.

(S) Driver MS-E 3050/3060 5870 051 035 MS-E 3070 5870 051 023

X 1 2

X 1 2

3

2

1

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Install preassembled hub until contact is obtained and fix with heated outer bearing inner ring. (S) Lifting bracket 5870 281 043

Figure 68

Oil O-rings and locate in annular groove (arrow) of knuckle housing. Then install disc carrier.

Figure 69

Bring hub bearing into contact position (figure-no. 70 ... 72): Install ring gear (without sealing elements).

Figure 70

��

Bring hub bearing into contact position – for this purpose tighten slotted nut with a tightening torque of max. 1400 Nm. Apply lubricant (e.g. MOLYCOTE PASTE 1000, ZF order no. 0671 195 042) to thread – knuckle housing/slotted nut ! While tightening the slotted nut rotate hub in both directions several times – roller setting ! (S) Socket spanner 5870 656 097

Figure 71

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Loosen slotted nut again and remove ring gear.

Figure 72

��

2.4.4 Multi-disc brake: Install disc pack alternately starting with an outer disc. Pay attention to installation position of inner discs – see figure no. 74 ! Take the actually required disc fitting from the corresponding spare parts list!

Figure 73

��

Installation position of inner discs: Bring inner clutch discs in a position where one of the tooth recesses (arrow) is in 6 00 o’clock position – with axle being installed in the vehicle! Inner clutch discs s = 2.5 mm (Standard) Install inner clutch discs with s = alternatively (2.0-2.5-3.0 mm) – required for disc clearance adjustment – on the outside of the disc pack !

Figure 74

��

Oil O-ring and locate in annular groove of disc carrier. Stick O-ring by means of grease – assembly aid.

Figure 75

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��

Figure 76

Oil sealing elements and locate in annular grooves (arrows) of the ring gear – as shown in the detailed sketch. Pay attention to installation position and arrangement of sealing elements! Legend to figure no. 76 and detailed sketch: 1 = Ring gear 2 = Support ring 3 = U-ring 4 = U-ring 5 = support ring

Just for „assembly of new parts“ or if disassembled: Mount cylindrical pins into piston, considering installation dimension „X“ MS-E 3050 = 18.00 mm MS-E 3060 = 16.00 mm MS-E 3070 = 16.00 mm

Figure 77

Install piston on preassembled ring gear.

Figure 78

Figure 79

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Detail „A“: Fix piston with spring sleeve (2), compression springs (3 and 4) and „new“ hex screws (1). Use hex. screws just once for assembly ! Tightening torque (M 6/8.8) ................. MA = 8 Nm

2

3 4

5

X

1 2

3

4

Legend to detail „A“: 1 = Hex. screw (secial version) 2 = spring sleeve 3 = compress. springs (outer) 4 = compr. springs (inner)

A

1

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��

Mount preassembled ring gear considering the installation position (markings O in 12 00 o’clock position – see arrows, detail „B“).

Figure 80

��

Oil o-ring and insert in recess (arrow) einsetzen. Apply lubricant (e.g. MOLYCOTE PASTE 1000, ZF order no. 0671 195 042) on thread - knuckle housing / slotted nut!

Figure 81

��

��

Figure 82

��

Figure 83

Fix ring gear with slotted nut.

First tighten slotted nut with 1400 Nm, then retighten slotted nut until a fixing hole overlaps a threaded hole in the knuckle housing – in this connection also refer to fig. no. 88 !

While tightening the slotted nut rotate hub in both directions several times – roller setting ! Tightening torque: MS-E 3050 (M 85 x 1.5) .............................. MA = 1400 + 200 Nm MS-E 3060/MS-E 3070 (M 110 x 1.5) ........ MA = 1400 + 600 Nm (S) Socket spanner 5870 656 097 2.4.4.1 Make leakage test of multi-disc brake:

Mount breather valve (arrow) and connect HP pump (to connection hole/bearing pin). (S) HP pump 5870 287 007 (S) Threaded coupling (M14x1.5) 5870 950 102 (S) Breather bottle 5870 286 072 Breathe brake completely before starting the test ! Test media: Motor oils SAE-10W ;MIL-L 2104 C; MIL-L 46152; API-CC, CD, SC, SD, SE, ATF-oils: type A; suffic A; Dexron of II D

B Ensure exact toothing position of oil supply holes – knuckle housing / ring gear (pressure oil supply to brake piston) !

Detail „B“:

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High-pressure test: Build up test pressure p = 100 bar and close locking valve of HP-pump. A pressure drop by max.3 bar is permissible during a 5-minute test duration. Low pressure test: Reduce test pressure to p = 5 bar and close locking valve. No pressure drop is allowed during a 5-minute testing duration !

Figure 84

2.4.4.2 Adjust and check disc clearance/piston stroke: Disc clearance/piston stroke „X“ = 0.7 ..... 1.3 mm Legend to fig. no. 84 and sketches no. 85 + 86: 1 = Ring gear 2 = Measuring hole 3 = Piston X = disc clearance / piston stroke (S) Straightedge 5870 200 022 (S) Digital depth gauge 5870 200 114

��

Figure 85

��

Figure 86

Breathe brake completely before starting the test ! Build up braking pressure (100 bar) and find dimension „A“, from face/ring gear (1) through measuring hole (2) – see Figure no. 84 and sketch no. 85 – to face / piston (3). Dimension „A“ e.g. ............................... = 83.10 mm Release pressure from brake – i.e. no pressure applied on brake, piston is in contact with ring gear (reset piston through compression springs) - and find dimension „B“ from face / ring gear (1) through measuring hole (2) ) – see fig. no. 84 and sketch no. 86 – to face/piston(3). Dimension „B“ e.g. ............................... = 82.10 mm CALCULATION EXAMPLE:

Dimension „A“ e.g. .................................. 83.10 mm Dimension „B“ e.g. ............................... - 82.10 mm Result → disc clearance …………........ = 1.00 mm If the required disc clearance / piston stroke (X = 0.7 ..... 1.3 mm) is not achieved, correct it with correspondng inner clutch disc(s) – see figure no. 74 !

X

A

1 3 2

B

1 3

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Dismantle HP pump. Just for transport protection, install screw plug with o-ring in oil supply hole. Tightening torque (M 14 x 1.5) …………… MA = 23 Nm

Figure 87

Figure 88

��

Figure 89

Secure slotted nut with cylinder screw – in this connection refer to comment on figure no. 82 ! Tightening torque (M 10/8.8) ................. MA = 32 Nm Install thrust washer. Observe installation position – ensure that both lugs of the thrust washer are engaged each in a spare fixing hole of the slotted nut!

Figure 90

Mount thrust washer (retaining ring fixing ) – with shoulder showing to retaining ring – then snap retaining ring. (S) Set of external pliers 5870 900 015

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5871 564 002 2/26

Figure 91

2.4.5 Planetary carrier: Adjust axial play of sun gear shaft

0.3 ... 1.0 mm (figure no. 91 ... no. 97) Determine dimension I from mounting face of planetary carrier to contact face of thrust washer. Dimension I, e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 260.65 mm (S) Straightedge 5870 200 022 (S) Digital depth gauge 5870 200 114

Figure 92

Determine dimension II, from face (arrow) of sun gear to mounting face of hub. Dimension II, e.g. . . . . . . . . . . . . . . . . . . . . . . . . 255.70 mm CALCULATION EXAMPLE: Dimension I e.g. . . . . . . . . . . . . . . . . . . . 260.65 mm Dimension II e.g. . . . . . . . . . . . . . . . . . - 255.70 mm Difference . . . . . . . . . . . . . . . . . . . . . . = 4.95 mm Required axial play (average) e.g. …… . . - 0.65 mm Result = requir.thrust washer(s) e.g. …… s = 4,30 mm

Insert thrust washer(s) (e.g. s = 4.30 mm) into planetary carrier and press into contact position. (S) Driver MS-E 3050/3060 5870 048 245 MS-E 3070 5870 048 263

Figure 93

Figure 94

Preassemble planetary gear – depending on version – as shown in the figure beside. Legend to figure no. 94 – version MS-E 3060/3070:

1 = Planetary gear 2 = Roller bearing 3 = washer 4 = circlip

Legend to figure no. 94 – version MS-E 3050: 1 = Planetary gear 2 = Bearing inner ring with cylinder rollers 3 = Plastic ring (assembly aid) 4 = angle ring

1 3

2

3 4

4

Version

MS-E 3060/3070

Version

MS-E 3050

3 4

1 2 4

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��

Warm up bearing inner ring and install pre-assembled planetary gear until contact is obtained. Mount planetary gear or bearing inner ring with large radius looking to planetary carrier (downwards)!

Figure 95

Fix planetary gear by means of retaining ring. (S) Set of external pliers 5870 900 015

Figure 96

Install preassembled planetary carrier and fix with cylinder screws. Tightening torque (M12/8.8) . . . . . . . . . . MA = 55 Nm

Figure 97

Install screw plug with new o-ring. Tightening torque (M 36 x 1.5) . . . . . . . . . . MA = 50 Nm

Figure 98

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Figure 99

2.5 Pivot bearing: Just for version „with“ bushings (figure-no.99): Heat pivot bearing hole by means of hot-air blower and insert super-cooled bushing(s). Observe installation position for bushing version with slot, insert bushings – with slot in 12 00 o’clock position! (S) Hot air blower 230 V 5870 221 500 (S) Hot air blower 115 V 5870 221 501

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2.6 STEERING

Figure 100

Legend to sketch no. 100 …. Figure no. 112: 1 = Steering cylinder (cylinder tube with brake head) 2 = brake head (loose part) 3 = piston rod 4a = O-ring 4b = Form seal ring 5 = guide ring 6 = U-ring 7 = Rod wiper

8 = Dual ring 9 = circlip 10 = O-ring 11 = retaining ring 12 = flange 13 = circlip 14 = wrench socket (piston rod)

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Figure 101

Mount U-ring (6) and wiper (7) in the steering cylinder(1). Observe installation position – see detailed sketch! detailed sketch:

Position inner installer (S1) on piston rod (3), install o-ring (4b) and press with inner installer (S2) into annular groove (arrow) of piston (3). MS –E 3050/3060 (S) inner installer (S1) 5870 651 086 (S) inner installer (S2) 5870 651 087 MS –E 3070 (S) inner installer (S1) 5870 651 088 (S) inner installer (S2) 5870 651 089

Figure 102

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3 1 5 4a 4b 2 8 6

Piston sealing

6 7

14

13 9 10 11

12

7

1 6 7

7 6

1

3

4b S1

S2

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Install form seal ring (4a) and press with inner installer (S2) into annular groove (arrow) of piston (3).

Figure 103

Calibrate form seal ring (4a) by means of calibration bush (S3). MS –E 3050/3060 (S) calibration bush (S3) 5870 651 090 MS –E 3070 (S) calibration bush (S3) 5870 651 091

Figure 104

Place both guide rings (5) into annular grooves of the piston rod.

Figure 105

3

4a S1

S2

3

4a

S3

5

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Insert preassembled piston rod in the preassembled steering cylinder. Observe installation position – insert piston rod (3) with wrench point of attach (14 – see sketch no. 100) showing in direction of arrow ! Slightly oil all sealing elements before installing the piston rod !

Figure 106

Figure 107

Insert u-ring(6), rod wiper (7) and dual ring (8) in brake head(2). Observe installation position – in this connection refer to detailed sketch ! Detailed sketch:

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Install preassembled brake head. Slightly oil all sealing elements before inserting the brake head !

Figure 108

Push brake head into the steering cylinder (arrow) so that the circlip (9) can be mounted

Figure 109

7 6 2 8

7 6

8 2

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Position the inserted brake head (8) on the engaged snap ring (9) until contact is obtained (arrow). Just for version „with“ O-ring – see illustration in the corresponding spare parts list: Oil O ring (10) and place it into the recess.

Bild 110

Fix brake head (8) with retaining ring (11). (S) Set of external pliers 5870900 015

Figure 111

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Install flange (12) and snap circlip (13). Observe installation position of flange – chamfer (circlip contact-arrow) to show towards circlip!

Figure 112

Apply anti-corrosive agent (e.g. WEICON ANTI-SIZE, ZF order no.: 0671 196 001) on both contact faces (steering cylinder/axle drive housing).

Figure 113

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Insert preassembled steering cylinder and fix with hex. screws. Fix hexagon screws with locking agent (Loctite-no. 243)! Tightening torque (M 12/8.8) ………….. MA = 79 Nm

Figure 114

Figure 115

Legend to figure no. 115: (tie rod–versions) A = tie rod with clamp fixing B = tie rod with counter nut fixing 1 = axial joint 2 = ball joint with tube 3 = clamp bzw. lock nut (hex. nut) Do not tighten counter nut or clamp/screw before setting the track. Tightening torque: Clamp/screw (M 12x1.5) ………….. MA = 75 Nm Counter nut MS-E 3050 / MS-E 3060 (M28x1.5) …… MA = 390 - 410 Nm MS-E 3070 (M30x1.5) ………………….. MA = 400 - 450 Nm

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Figure 116

Provide connection – axial joint/piston rod (appr. 3 threads) – with locking agent (Loctite-no. 243). Observe installation position of tie rods – offset to show towards axle housing (see arrow) ! Fix both tie rods on steering. MS-E 3050/3060 Tightening torque (M 30x1.5) ………….. MA = 450 Nm

(S) socket spanner (span 55) 5870 656 100 MS-E 3070 Tightening torque (M 30x1.5) ………….. MA = 600 Nm

(S) socket spanner (span 75) 5870 656 099 Mount tie rod and fix with „new“ locking nut. Use locking nut just once for assembly ! Tightening torque: MS-E 3050/3060 (M 27x1.5) ……………. MA = 600 Nm MS-E 3070 (M 30x1.5) …………………. MA = 800 Nm

Figure 117

2

1

3

1 3

2

„B“

„A“

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2.6.1 Steering setting and checking:

Figure 118 1 = Straightedge 5870 200 029 4 = Stop screw with stop washer (internal) 2 = Measuring device 5870 200 033 5 = Stop screw (outside) 3 = Depending on version – clamp/screw or counter nut

2.6.1.1 Basic track setting:

Bring piston rod in central position = Dimension "X" (e.g. MS-E 3050/MS-E 3060 = 119 mm, MS-E 3070 = 124 mm)

Determine dimension = „X“ (measured from front face/steering cylinder to contact face piston rod/axial joint).

Piston (rod) stop/on the left in cylinder „dimension I“ e.g. .................................. 215 mm Piston (rod) stop/on the right in cylinder „dimension II“ e.g. ................................ - 23 mm Result (piston stroke) ……...................................................................................... = 192 mm ÷ 2 Result (½ piston stroke) …………………………………………………………… = 96 mm

Dimension "X" e.g.( (½ piston stroke + dimension II) (96 + 23)............ = 119 mm Do not change axial position of piston rod any more during track setting!

Mount straightedges (1) in horizontal and central axis position. Fix measuring device (2) on input flange. Loosen clamp/screw or counter nut (3) and set length of tie rod (axial joint) until the measuring device (2) indicates 0° (corresponds to a track setting of "zero"mm).

Make setting on both sides!

(S) Measuring device 5870 200 033 (S) Straight edges 5870 200 029

Check track setting (0°):

Determine dimension „A1“. Rotate both outputs by 180° - dimension „A2“ must equal „dimension A1“. Dimension "Y" = distance – wheel center to rim flange.

For a toe-in and toe-out setting, which might be required, stick to the vehicle manufacturer’s specification.

Then fix both tie rods /axial joint again by means of clamp/screw or counter nut (3). Tightening torque – clamp/screw (M 12x1.5).................................MA = 75 Nm Tightening torque - counter nut MS-E 3050 / MS-E 3060 (M28x1.5) ……………………………. MA = 390 - 410 Nm MS-E 3070 (M30x1.5) …………………………………………... MA = 400 - 450 Nm

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2.6.1.2 Steering angle setting: Set steering angle – not before track setting is completed! Set steering angle always on the curve inner output side.

Figure 119

Slew output until the required steering angle is achieved on the measuring device (2/sketch no. 119) (Measuring device must have parallel contact with the straigtedge (1/sketch no. 119)). Take the value of the steering angle „L“ to be set (see sketch no. 118) from the vehicle manufacturer’s specification!

Fix outer stop (5) by means of setting screw and lock nut. (Lock nut version depends on the steering angle to be set) -

- if steering angle less than + equal to 31° → hex. nut/standard version (DIN 934)

tightening torque of lock nut (DIN 934 - M18/10.9) ............ MA = 390 Nm

- if steering angle greater than 31° → hex. nut/flat version (DIN 439)

tightening torque of lock nut (DIN 439 - M18/10.9) ............ MA = 300 Nm

Set inner stop (4) by means of setting screw and stop washer (s = optional). Tightening torque (M18/10.9) ............................... MA = 390 Nm Make setting on both output sides.

(s) Measuring device 5870 200 033

2.6.2 Check leakage of steering:

Test pressure: 250 bar

Test medium: motor oil SAE 10W MIL-L 2104 C / MIL-L 46152 Connect HP pump, Build up test pressure P = max. 250 bar (bleed pressure chamber). Close locking valve of HP pump. A 5 bar pressure drop is permissible during a test duration of 20 sec.! An outer leakage is not permissible!

Make leakage test of steering in both steering directions.

Figure 120

(S) HP pump 5870 287 007 (S) Threaded joint GE12 PLM 0662 561 931 (S) Measuring fitting 5870 950 139

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2.7 Oil drain-,oil filler and oil control plugs and grease lubrication points: Mount oil drain plug with solenoid insert (1) - fitted with „new“ O ring. Mount oil filler and oil control plug (2) - fitted with „new“ O ring. Tightening torque (M 36 x 1.5) . . . . . . . . . . MA = 50 Nm

Figure 121

Mount oil drain, oil filler and oil control plug with solenoid insert (3) - fitted with „new“ o-ring - in both outputs. Tightening torque (M 36 x 1.5) . . . . . . . . . . MA = 50 Nm

Figure 122

Prior to putting the axle into operation fill it with oil - for this purpose stick to the ZF-lubrication and maintenance instructions, ZF-order no.: 5871 564 902! In addition observe the vehicle manufacturer’s regulations and instructions!

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Documents

0-Text-e - Amazon S3 · ZF – AXLE MULTISTEER MS-E 3050/3060/3070 ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau Property of American Airlines. REPAIR MANUAL for ZF-axle MS-E 3050/3060/3070