R

WORKSHOP MANUAL
ZF RL-75
5871199002
0804 DW05082901
ZF RL-75
Disclamers 2008 VDL Bus & Coach bv, Eindhoven, The Netherlands. In the interest of continuous product development VDL Bus & Coach reserves the right to change specifications or products at any time without prior notice. No part of this publication may be reproduced and/or published by printing, by photocopying, in digital format or in any way whatsoever without the prior consent in writing of VDL Bus & Coach. This manual shall be governed by and applied in accordance with the laws of the Netherlands. Any dispute here under shall be referred to the decision of the District Court of s-Gravenhage in the Netherlands
0804
Order-No.: 5871 199 002
ZF INDEPENDENT WHEEL SUSPENSION RL-75 EC/EM
ZF Passau GmbH
Donaustr. 25 - 71 D-94 034 Passau
REPAIR MANUAL
for the INDEPENDENT WHEEL SUSPENSION RL-75 EC/EM
IMPORTANT INSTRUCTIONS CONCERNING THE REPAIR MANUAL The great variety of ZF units compels a restriction of the Disassembly and Assembly Manual to a current ZF production unit. Technical development of the ZF units as well as extensions concerning the design possibilities may require differing steps, which can be carried out by qualified Specialists without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare Parts Lists. The described Disassembly and Assembly Manual is based on the design level of a ZF production unit at the time of preparation of the Repair Manual. The ZF Passau GmbH reserve the right to replace the present Disassembly and Assembly Manual by a successional edition without advance notice. Upon request, the ZF Passau GmbH will advise what edition is the latest one. When carrying out maintenance work the specifications of the Lubrication and Maintenance Instructions (ZF order no: 5871 201 932) and ZF List of Lubricants TE-ML 12 must be observed! The List of Lubricants is constantly being updated and can be ordered or looked up as follows: - at all ZF plants - at all ZF Service Stations - Internet site http://www.zf.com/ Service / Technical Information -------------------------------------------------------------------------------------------------------------------------------The Disassembly and Assembly of the brake is in the enclosed Original Manual of the Component Manufacturer (Brake Manufacturer).
See Internet: htpp:\\www.Knorr-bremse.com
ATTENTION:
For the installation as well as for the commissioning of the unit, the Instructions and Specifications of the Vehicle Manufacturer have to be observed!
ZF Passau GmbH
Donaustr. 25 - 71 94034 Passau Abt.: ASD / Section : ASD
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 nderungen vorbehalten! With the reserve of technical modifications! Sous reserve de modification techniques! Design level: 1999/03 1st Edition 2001/07 2nd Edition 2005/02 3rd Edition 2008/04
TABLE OF CONTENTS
Preface General Inscription on Model Identification Plate and Specifications for Spare Parts Conversion Table for Dimensional Units Denomination of Standard Dimensions Torque Limits for Screws
Chapter/Page
0/1 0/2 3 0/4 0/5 0/6 0/7
SPECIAL TOOLS
LIST OF SPECIAL TOOLS ILLUSTRATED TABLES W/1 ... W/6 WB/1 ... WB/3
RL-75 EC/EM
1. 2. 3. 4. 5. 6. 7. Disassembly RL-75 EM Disassembly RL-75 EC Assembly - wheel head RL-75 EC/EM Assembly control arm and tie road RL-75 EM Assembly control arm and tie road RL-75 EC Assembly peripheral components RL-75 EC Attachment wheel head right/left and arious peripheral components am chassis am RL-75 EM 1/1 ... 6 2/1 ... 6 3/1 ... 8 4/1 ... 5 5/1 ... 5 6/1 5 7/1 3
Repair Manual
Off-Road Transmission and Axle System Division
PREFACE
This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair and Maintenance operations on ZF-Units. Treated is a ZF-Serial product according to the design stage of the date of edition. However, due to further technical developments of the product, the repair of the unit at your disposal could require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and theoretical training is constantly completed to the actual situation in our Training School. The Service Stations, established by the ZF Friedrichshafen all over the world, offer you:
1. Constantly trained personnel 2. Prescribed installations, e.g. Special Tools 3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability. Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual contractual conditions, by the ZF-Warranty. Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and afterexpenditures eventually arising from it, are excluded from this contractual responsibility. This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH Service Department
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Repair Manual
GENERAL
The Service Manual covers all work required for dismantling and the pertaining installation. When repairing the unit, ensure utmost cleanliness and that the work is carried out in an expert-like manner. The unit should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices. Dismantling and mounting work must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them:
REFERENCE:
For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used! Parts fitted in heated state have to be installed subsequently after cooling down to ensure a perfect contact.
CAUTION
When assembling the unit, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. By no means, Molykote is permitted to be used. Lined plates with organic friction linings (e.g. paper linings) must not be washed (negative effect on lining adhesion). They are only allowed to be dry-cleaned (leather cloth).
DANGER When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.
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Repair Manual
Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling of the dismantled unit. Special tools required for performing the respective repair work are listed in the text as well as in the Chapters W (List of Special Tools) and WB (Illustrated Tables).
Important information on industrial safety Generally, the persons repairing ZF-units are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair work. Persons performing repair work must familiarize themselves with these regulations. The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training. The following safety references are used in the present Repair Manual:
! CAUTION
DANGER
This symbol is indicated in this repair manual as reference to special working procedures, methods, information, the use of auxiliaries etc.
This symbol refers to situations, if lacking care can lead to personal injury, danger to life and damages on the product.
REFERENCE
Prior to starting the checks and repair work, thoroughly study the present instructions.
REFERENCE
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; conclusions regarding size and weight must not be drawn (not even within a representation). The work must be performed according to the description.
REFERENCE:
After the repair work and the checks, the expert staff must convince itself that the product is properly functioning again.
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Repair Manual
INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE
1 3 5 7
2 4 6 8
1 = Axle Type 2 = Axle Serial No. 3 = ZF - Parts - List No. 4 = Total-Ratio of the Axle / Version with or without ZF-multi-disc self locking differential 5 = Type of lubricant 6 = Lubricant specifications 7 = Oil capacity 8 = Customer no. NOTE FOR 6: ZF - List of lubricants for ZF - Axles TE - ML 12 !
NOTES FOR THE COMPILATION OF SPARE PARTS ORDERS

When ordering genuine ZF - Spare Parts please indicate : 1. Axle type 2. Serial - No. 3. ZF - Parts List No. 4. Trade Mark and Type of vehicle 5. Denomination of the Spare Part 6. Spare Part No. 7. Way of delivery
NOTE : Point 1, 2 and 3 see Model Identification Plate. Please complete the above mentioned details in order to avoid mistakes inthe delivery of ordered spare parts!
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Repair Manual
VERGLEICHSTABELLE FR 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 ) 14,233 psi (pound force per squar inch lbf/in2 ) 1 psi ( lbf/in2 ) 0,264 Gallon ( Imp. ) 1 Gallon ( Imp. ) 0,220 Gallon ( US ) 1 Gallon ( US ) 1 Mile ( Landmeile ) + 32 F ( Fahrenheit ) 273,15 Kelvin
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Repair Manual
BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : Note : Nota : Begriff Unit
lngenbezogene Mae in kg/m; linear density in kg/m; Density lineaire en kg/m; Formelzeichen neu New
flchenbezogene Mae in t/m2 areal density in t/m2 Density superficielle en t/m2 alt old Umrechnung Conversion Conversion Bemerkungen Not e Nota
Uniteo Masse Mass Mass Kraft Force Force Arbeit Work Travail Leistung Power Puissance Drehmoment Torque Couple Kraftmoment Moment (Force) Moment (Force) Druck (ber-) Pressure
(Overpress)
Nouveau Vieu kg (Kilogramm) kg
N (Newton)
kp
1 kp = 9,81 N
J (Joule)
kpm
0,102 kpm = 1J = 1 Nm
KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW 1 KW = 1,36 PS Nm (Newtonmeter) Nm (Newtonmeter) bar kpm 1 kpm = 9,81 Nm T (Nm) = F (N) . r (m) M (Nm) = F (N) . r (m)
kpm
1 kpm = 9,81 Nm
at
Pression (Sur-) Drehzahl Speed Nombre de Tours
1,02 at = 1,02 kp/cm2 = 1 bar = 750 torr
min 1
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Repair Manual
TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARD 148 Friction value: tot.= 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts. Tightening by hand! Torque limits if not especially indicated, can be taken from the following list: Metric ISO-Standard thread DIN 13, Page 13 8.8 10.9 2.8 4.1 5.5 8.1 9.5 14 15 23 23 34 46 68 79 115 125 185 195 280 280 390 390 560 530 750 670 960 1000 1400 1350 1900 1850 2600 2350 3300 3000 4300 Metric ISO-Fine thread DIN 13, Page 13 8.8 10.9 24 36 36 53 52 76 49 72 87 125 83 120 135 200 205 300 310 440 290 420 430 620 580 820 760 1100 730 1050 1100 1600 1050 1500 1550 2200 1500 2100 2050 2900 2000 2800 2700 3800 2500 3500 3450 4900 3200 4600
Dimension M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 Dimension M8x1 M9x1 M 10 x 1 M 10 x 1.25 M 12 x 1.25 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 18 x 2 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 24 x 2 M 27 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M33 x 1.5 M 33 x 2 M 36 x 1.5 M 36 x 3 M 39 x 1.5 M 39 x 3
12.9 4.8 9.5 16.5 28 40 79 135 215 330 460 650 880 1100 1650 2250 3000 3900 5100 12.9 43 62 89 84 150 145 235 360 520 490 720 960 1250 1200 1850 1800 2550 2500 3400 3300 4450 4100 5700 5300
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Manual
Off-Road Driveline Technology and Axle Systems Division
LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF Axle RL 75 EM EC

4474 075 / 064 / 087 Disassembly Chapter/Fig. 1.1 2.1 Reassembly Designation and Application Chapter/Fig Assembly truck assy with tilting device Clamping angle for hub mounting Clamping angle for knuckle mounting Universal use. To fasten and tilt the wheel head assy on the assembly truck. Part number
5870 350 000 5870 350 100 5870 350 101
1.3 2.3
Hot air blower 230 V Hot air blower 115 V Universal use. To warm up components. For easier disassembly and reassembly of parts assembled with LOCTITE.
5870 221 500 5870 221 501
2.4 1.7/2.4 2.7
Two-armed puller # Universal use. In connection with : Pressure piece # To press out bolt 4474 375 012/031 in the upper and 4474 385 030 in the lower control arm.
5870 970 007 5870 100 059
1.5/1.8 2.5/2.8
60 mm Plastic hammer Universal use. For a gentle disassembly and reassembly of components. For removal and reinstallation of the ball sleeve in the control arm.
5870 280 004
1.5/1.8 2.5/2.8
Set of internal pliers # I11 - I21 I31- I41 Universal use. To snap and unsnap internally clamped retaining rings.
5870 900 014
1.5/1.8 2.5/2.8
4.17
Pressing bush # In connection with : Pressure piece # To support control arm when clamping the ball sleeve = repair set 0501 298 336.
5870 506 134 5870 100 056
1.10 2.10
3.27
for SB 7000 Set of tools For repair of disc brake SB 6000 / 7000. Set of tools for SN 7000
5870 080 050 5870 080 056
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4474 075 / 064 / 087 Disassembly Chapter/Fig. 1.12 2.12 Reassembly Designation and Application Chapter/Fig 3.27 Lifting device Universal use. As disassembly and reassembly aid for dismantling and mounting of brake caliper. Part number
5870 281 058
1.14 2.14
Lifting device Universal use. As disassembly and reassembly aid for dismantling and mounting of wheel head assy.
5870 281 043
2.14 3.14
Extractor # For disassembly and reassembly of pre-mounted hub to the knuckle.
5870 000 090
1.16 2.14
Internal extractor Counter support Universal use. To remove both bearing outer rings from the hub.
5870 300 019 5870 300 020
1.17 2.14
I1 I2 I3 I4 Set of internal pliers Universal use. To snap and unsnap internally clamped retaining rings.
5870 900 013
1.18 2.18
Striker Universal use. To remove cover 0501 211 307- 308 from knuckle hole.
5870 650 001
1.19 2.19
Sleeve To press out king pin 0501 317 161 from knuckle. To be used in connection with : Grip
5870 506 130
5870 260 003
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4474 075 / 064 / 087 Disassembly Chapter/Fig. Reassembly Designation and Application Chapter/Fig 4.12 Mounting fixture # To mount control arm bolts through control arm and knuckle carrier. Part number
5870 000 097
3.2
Pressure piece # To insert and to position needle bearing in the lower knuckle carrier. To be used with : grip 5870 260 003
5870 100 044
3.5
Assembly fixture # To mount shaft seal 0501 318 097 into knuckle carrier top.
5870 345 094
3.8
Feeler gauge Universal use . To determine axial play between knuckle and knuckle carrier.
5870 200 112
3.9
Centering mandrel # To align and pre-mount knuckle on knuckle carrier and on axle housing.
5870 912 018
3.9
Hot air blower Hot air blower Universal use. To warm up housing and bearing parts.
230V 115V
5870 221 500 5870 221 501
3.12
Driver # To insert upper needle bearing into knuckle. To be used in connection with: Grip
5870 058 088
5870 260 002
3.13
Set of internal pliers Universal use.
I11 I21 I31 I41
5870 900 014
To snap and unsnap internally clamped retaining rings. 5871 199 002 W/ 3
Repair
Manual

4474 075 / 064 / 087 Disassembly Chapter/Fig. Reassembly Designation and Application Chapter/Fig 3.15 Wheel bolt puller basic device To mount wheel bolts to hub. Repair solution no need to dismantle hub. To be used in connection with: Insert M22x1.5 Part number
5870 610 010
5870 610 002
3.16 3.18 3.19
Driver # To instal the measuring ring = impulse disc and shaft cassette type seal. To be used in connection with: Grip #
5870 053 020
5870 260 011
3.20 3.21 3.22
Extractor # To disassemble and reassemble the pre-mounted hub on knuckle.
5870 000 090
3.23
60 mm Plastic hammer Universal use. To drive ball sleeves into and out of the control arm.
5870 280 004
3.24
Magnetic stand # In connection with: Dial indicator # Universal use. To determine axial play in wheel bearing.
5870 200 055 5870 200 057
3.27
Lifting device Universal use. As disassembly and reassembly aid for dismantling and mounting of brake caliper.
5870 281 058
3.27
for SB 7000 Set of tools To repair disc brake SB 6000 / 7000 . for SN 7000 Set of tools
5870 080 050 5870 080 056
5871 199 002
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Manual

4474 075 / 064 / 087 Disassembly Chapter/Fig. Reassembly Designation and Application Chapter/Fig 4.1 5.2 Pressing bush Pressure piece To support control arm when clamping the ball sleeve = repair set 0501 298 336 . Part number
5870 506 134 5870 100 056
4.3 4.14 5.2 5.17 4.3 5.3
Set of internal pliers I11-I21-I31-I41 Universal use. To snap and unsnap internally clamped retaining rings.
5870 900 014
Driver To drive bearing outer rings 0750 117 224 into knuckle carrier. To be used in connection with: Grip
5870 058 084
5870 260 002
8.4 9.4
Assembly mandrel # To determine bearing preload in knuckle carrier .
5870 345 091
4.8 5.8
3 - 23 Nm Torque wrench # Universal use. To check rolling resistance in der king pin bearing.
5870 203 032
4.12 4.14 5.12 5.14
Mounting fixture # To mount control arm bolts through control arm and knuckle carrier.
5870 000 097
4.15 5.15
Centering mandrel # To align the two control arms before fixing them with the control arm bolt.
5870 912 032
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4474 075 / 064 / 087 Disassembly Chapter/Fig. Reassembly Designation and Application Chapter/Fig 4.17 5.17 Pressing bush # In connection with : Pressure piece # To support control arm when clamping the ball sleeve = repair set 0501 298 336. Part number
5870 506 134 5870 100 056
6.1
230 V Hot air blower Hot air blower 115 V Universal use. To warm up components. For easier disassembly and reassembly of parts assembled with LOCTITE.
5870 221 500 5870 221 501
6.3
Driver To drive bearing outer rings 0750 117 618 into relay lever and intermediate lever. To be used in connection with: Grip
5870 058 084
5870 260 002
6.4
Assembly mandrel # Pressure sleeves # To determine bearing preload in knuckle carrier.
5870 345 091 5870 100 064
6.8
3 - 23 Nm Torque wrench # Universal use. To check rolling resistance in the relay lever and intermediate lever.
5870 203 032
6.12
Mounting fixture # In connection with : Threaded insert # To mount bearing bolts 4474 375 066 through bearing of relay lever and intermediate lever.
5870 000 097 5870 000 104
# Very important special tools for partial repair and for the repair of worn parts.
5871 199 002
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5870 350 101
5870 350 000
5870 350 100
RL-75 EM-EC RADKOPF WHEEL HEAD MOYEU DE PONT 4474 075 064/087
Spezial
e ress 00kN drop press 4 Hy mit aulic ung h hydr nd it w erbi In V e used ob T
5870 650 001
5870 912 018
5870 506 130

SERVICE
5870 221 500
ODER / OR
M22x1,5
230V
5870 610 002
5870 221 501
Repair Manual
115V
5870 610 010
5870 345 094
WB-01
5870 200 055

90 80 70 60 0 10 20 30 40
50
5870 200 057
Off-Road Transmissions and Axle Systems Division
SB-7000 KNORR
SN-7000 KNORR
5870 053 020
5870 000 090
5870 080 050
5870 080 056
5870 281 058
5870 650 001
5870 100 044
5870 200 112
5870 058 088
5870 260 002
ZF Passau GmbH Donaustrae 25-71 94034 Passau
Ausgabe:/Edition: 06/2004
5870 221 500
5870 221 501
5870 912 032
230 V
115 V
RL-75 EM - EC AUFHAENGUNG SUSPENSION 4474 075 064/087
Spezial
57870 000 097 5870 100 059
5870 970 007

SERVICE
Repair Manual
WB-02
3 - 23Nm
5870 058 084
5870 260 002
5870 900 014
5870 280 004
5870 100 056
5870 506 134
5870 203 032
5870 100 060
5870 345 091
5870 221 500
5870 221 501
230 V
115 V
RL-75 EC LENKHEBEL STEERING ARM 4474 075 087
Spezial
57870 000 104 57870 000 097

SERVICE
Repair Manual
WB-03
3 - 23Nm
5870 058 084
5870 260 002
5870 280 004
5870 203 032
5870 100 064
5870 345 091
Repair Manual
Disassembly RL-75 EM
Fasten independent wheel suspension RL-75 EM on the assembly car. (S) Assembly car (S) Clamping bracket (hub fixing) (S) Clamping bracket (fixation of steering knuckle) 5870 350 000 5870 350 100 5870 350 101
Figure 1 Remove cotter pin (Arrow) from the tie rod (1). Loosen castle nut and separate tie rod from tie-rod arm (2). 1 2 Separate tie-rod arm (2) from steering knuckle by loosening the hex. head screws.
Pay attention to the released tie rod and tie-rod arm!
Figure 2 Disassembly upper control arm Figure 3 to 5. Loosen hex. nut.
With hot-air heat hex. nut. (S) Hot-air blower 230 V (S) Hot-air blower 115 V 5870 221 500 5870 221 501
Figure 3 Press pin out, using two-leg puller. Now, remove components of the control arm bearing.
(S) Two-leg puller (S) Pressure piece
5870 970 007 5870 100 059
Pay attention to the released control arm!
Figure 4
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Repair Manual
Preload ball sleeve (1) compl. by means of press and remove cirlip (2). Remove snap ring. Drive ball sleeve out of the control arm bore, using plastic mallet. Disassembly lower ball sleeve accordingly.
(S) Set of pliers (S) Plastic mallet (S) Pressing sleeve (S) Pressure piece
5870 900 014 5870 280 004 5870 506 134 5870 100 056
Figure 5 Disassembly lower control arm Figure 6 to 8. Loosen hex. nut.
With hot-air heat hex. nut.
5870 970 007 5870 100 059
Pay attention to the released control arm!
Figure 7
2 Preload ball sleeve (1) compl. by means of press and remove cirlip (2). Remove snap ring. Drive ball sleeve out of the control arm bore, using plastic mallet. 1 (S) Set of pliers (S) Plastic mallet (S) Pressing sleeve (S) Pressure piece 5870 900 014 5870 280 004 5870 506 134 5870 100 056
Figure 8
5871 199 002
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Repair Manual
Remove revolution counter -ABS- (1) and bush.
Figure 9 At works on the brake system, the Instructions and Specifications of the component Manufacturer are binding. See in this connection the Repair Manual of the Firm of Knorr in Internet. 3 4 2 Figure 10
htpp:\\www.Knorr-bremse.com
Remove cotter pin (1), disk (2) and pin (3), demount lining retaining clip (4). Check lining retaining clip for corrosion. (S) Brake tool set (S) Brake tool set 5870 080 050 SB-7000 5870 080 056 SN-7000
Remove sealing cap and back off hexagon (WAF 8) of the slack adjuster anticlockwise until the brake linings can be removed (see Figure 12).
Due to the breaking moment of the overload clutch in the slack adjuster a Clicking noise will be created! Do not exert an overstress on the hexagon (WAF 8) of the slack adjuster! Do not use an open end wrench! Figure 11 Press inner brake lining in direction of the brake cylinder. Pull brake linings (1) out of the brake lining compartment.
Secure brake calliper by means of lifting device. Loosen fixing screws and separate brake calliper from wheel head. (S) Lifting device 1 Figure 12 5870 281 058
5871 199 002
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Repair Manual
Loosen socket head screws (1) and separate cover (2) along with gasket from the hub.
2 Figure 13 Loosen screw (1) and unscrew clamping nut (2).
Remove pressure plate, separate hub from steering knuckle, using lifting device. 2 Pay attention to the released bearing inner race!
1 Figure 14 2 3 4 1
(S) Lifting device (S) Special device
5870 281 043 5870 000 090
Remove shaft seal (2) out of the bearing inner race (1). Remove bearing inner race (1) and shaft seal (3) out of the hub bore.
Measuring ring pulse disk (4) must not be demounted!
Figure 15 1 Pull both bearing outer races (1) out of the hub bore. (S) Internal puller (S) Counter support 5870 300 019 5870 300 020
5 2
Loosen hex. head screws (4) and separate hub (2) from the brake disk (3).
Wheel studs (5) must not be pressed out.
Figure 16
5871 199 002
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Repair Manual
Squeeze out circlip (1). Remove grease nipple (2). (S) Set of pliers
1 2
5870 900 013
Figure 17
Drive sealing cap by means of striker (1) out of the steering knuckle bore.
(S) Striker
5870 650 001
Remove lower seal retainer accordingly Figure 17 and 18.
Figure 18
There are two versions (see figure 19 and 20)
to
press
the
king
pin
out
Turn steering knuckle 180 and press out under a 40 ton press. The steering knuckle can only be pressed out from this side. At the pressing out of the pin, the needle cages can be taken along. In this case, the released needle cage (see Arrow) must be taken out of the sleeve, before the pin will be pressed completely out of the steering knuckle bore. (S) Sleeve (S) Handle Figure 19
Fix forcing device to the steering knuckle. Press the axle bolt out with the hydraulic cylinder.
5870 506 130 5870 260 003
The steering knuckle can only be pressed out from below. Pay attention that the axle bolts do not drop! (S) Pull rods (S) Pressure plates (S)Hydraulic spindle (S) Hydraulic pump Figure 20 5870 285 028 5870 285 027 5873 003 007 5870 287 010
5871 199 002
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Repair Manual
Fasten steering knuckle in a vise.
Drive needle sleeves, shaft seal out of the steering knuckle bore (1). 2 1 Drive tapered roller bearing (2) out of the lower steering knuckle bore. (1).
Figure 21
5871 199 002
1.6
Repair Manual
Disassembly RL-75 EC
Fasten independent wheel suspension RL-75 EC on the assembly car. (S) Assembly car (S) Clamping bracket (hub fixing) (S) Clamping bracket (fixation of steering knuckle) 5870 350 000 5870 350 100 5870 350 101
Figure 1 Remove cotter pin (Arrow) from the tie rod (1). Loosen castle nut and separate tie rod from tie-rod arm (2). Separate tie-rod arm (2) from steering knuckle by loosening the hex. head screws.
Pay attention to the released tie rod and tie-rod arm !
1 Figure 2 Disassembly upper control arm Figure 3 to 5. Loosen hex. nut.
With hot-air heat hex. nut. (S) Hot-air blower 230 V (S) Hot-air blower 115 V 5870 221 500 5870 221 501
5870 970 007 5870 100 059
Pay attention to the released control arm !
Figure 4
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2.1
Repair Manual
Preload ball sleeve (1) compl. by means of press and remove cirlip (2). Remove snap ring. Drive ball sleeve out of the control arm bore, using plastic mallet. Disassembly lower ball sleeve accordingly.
(S) Set of pliers (S) Plastic mallet (S) Pressing sleeve (S) Pressure piece
5870 900 014 5870 280 004 5870 506 134 5870 100 056
Figure 5 Disassembly lower control arm Figure 6 to 8. Loosen hex. nut.
With hot-air heat hex. nut.
5870 970 007 5870 100 059
Pay attention to the released control arm !
Figure 7
2 Preload ball sleeve (1) compl. by means of press and remove cirlip (2). Remove snap ring. Drive ball sleeve out of the control arm bore, using plastic mallet. 1 (S) Set of pliers (S) Plastic mallet (S) Pressing sleeve (S) Pressure piece 5870 900 014 5870 280 004 5870 506 134 5870 100 056
Figure 8
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2.2
Repair Manual
Remove revolution counter -ABS- (1) and bush.
Figure 9 At works on the brake system, the Instructions and Specifications of the component Manufacturer are binding. See in this connection the Repair Manual of the Firm of Knorr in Internet. 3 4 2 Figure 10
Remove cotter pin (1), disk (2) and pin (3), demount lining retaining clip (4). Check lining retaining clip for corrosion. (S) Brake tool set (S) Brake tool set 5870 080 050 SB-7000 5870 080 056 SN-7000
Remove sealing cap and back off hexagon (WAF 8) of the slack adjuster anticlockwise until the brake linings can be removed (see Figure 12).
Due to the breaking moment of the overload clutch in the slack adjuster a Clicking noise will be created ! Do not exert an overstress on the hexagon (WAF 8) of the slack adjuster ! Do not use an open end wrench ! Figure 11 Press inner brake lining in direction of the brake cylinder. Pull brake linings (1) out of the brake lining compartment.
Secure brake calliper by means of lifting device. Loosen fixing screws and separate brake calliper from wheel head. (S) Lifting device 1 Figure 12 5870 281 058
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2.3
Repair Manual
Loosen socket head screws (1) and separate cover (2) along with gasket from the hub.
2 Figure 13 Loosen screw (1) and unscrew clamping nut (2).
Remove pressure plate, separate hub from steering knuckle, using lifting device. 2 Pay attention to the released bearing inner race !
1 Figure 14 2 3 4 1
(S) Lifting device (S) Special device
5870 281 043 5870 000 090
Remove shaft seal (2) out of the bearing inner race (1). Remove bearing inner race (1) and shaft seal (3) out of the hub bore.
Measuring ring pulse disk (4) must not be demounted !
Figure 15 1 Pull both bearing outer races (1) out of the hub bore. (S) Internal puller (S) Counter support 5870 300 019 5870 300 020
5 2
Loosen hex. head screws (4) and separate hub (2) from the brake disk (3).
Wheel studs (5) must not be pressed out.
Figure 16
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2.4
Repair Manual
Squeeze out circlip (1). Remove grease nipple (2). (S) Set of pliers
1 2
5870 900 013
Figure 17
Drive sealing cap by means of striker (1) out of the steering knuckle bore.
(S) Striker
5870 650 001
Remove lower seal retainer accordingly Figure 17 and 18.
Figure 18
There are two versions (see figure 19 and 20)
to
press
the
king
pin
out
Turn steering knuckle 180 and press out under a 40 ton press. The steering knuckle can only be pressed out from this side. At the pressing out of the pin, the needle cages can be taken along. In this case, the released needle cage (see Arrow) must be taken out of the sleeve, before the pin will be pressed completely out of the steering knuckle bore. (S) Sleeve (S) Handle Figure 19 Fix forcing device to the steering knuckle. Press the axle bolt out with the hydraulic cylinder. The steering knuckle can only be pressed out from below. Pay attention that the axle bolts do not drop! (S) Pull rods (S) Pressure plates (S)Hydraulic spindle (S) Hydraulic pump Figure 20 5870 285 028 5870 285 027 5873 003 007 5870 287 010 5870 506 130 5870 260 003
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2.5
Repair Manual
Fasten steering knuckle in a vise.
Drive needle sleeves, shaft seal out of the steering knuckle bore (1). 2 1 Drive tapered roller bearing (2) out of the lower steering knuckle bore. (1).
Figure 21
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2.6
Repair Manual
Assembly-Wheel head RL-75 EC/EM
! Install the needle bearing on the steering knuckle below (see Figure 2).
At the pressing in of the needle bearing, apply the press-in drift always on the marked (hardened) side (Arrow). steering knuckle, ! Per each must be installed. only needle bearings with the same Part-No. Figure 1 Press both needle bearings (2) into the lower steering knuckle bore (3), using the pressure piece (1). 1 3 2 (S) Pressure piece (S) Handle 5870 100 044 5870 260 003
! Installation dimension see Figure 3.

Figure 2 Only by applying the ZF-Special tool, the installation dimension is ensured. from ! Installation dimensionis Amm. the steering knuckle underside to the needle bearing 18 2 = Needle bearing 3 = Steering knuckle A Figure 3 1
! Lay shaft seal (2) and thrust washer (1) into the pressure piece of 2
Install shaft seal on the steering knuckle above (see Figure 6). the mounting fixture (3). of shaft seal must ! Sealing lipwasher upward. show downward and the grooves of the thrust 3 1 = Thrust washer 2 = Shaft seal 3 = Mounting fixture
Figure 4
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3.1
Repair Manual
The Figure on the left shows the compl. mounting fixture.
!3
3
= Pressure piece
(S) Assembly jig
5870 345 094
Figure 5 Pull shaft seal (2) into the steering knuckle (4), using the mounting fixture. 2 4 3 piece (3), rotate ! Remove pressureagainst shoulder. it 180, apply it again and pull in the shaft seal Remove mounting fixture.
Figure 6 Press tapered roller bearing (2) into the steering knuckle (1) until contact is obtained.
Figure 7 If necessary, adjust the axial play between steering knuckle carrier (1) steering knuckle (2) once more. Use the actual thrust washer (3). play of 0,05 to 0,15 between ! Determine the axialand steering knuckle (2)mm means of steering knuckle carrier (1) by a feeler gauge. (S) Feeler gauge 4 Figure 8 5870 200 112
2 1
if and (3). ! Correctare necessary in theinstall corresponding shim3,0 mm. Shims available thicknesses from 2,2 to Steps 0,05 mm.
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3.2
Repair Manual
To enable the assembly of the steering knuckle pin, the bore of the steering knuckle carrier must be heated to about 100 to 120 C and the steering knuckle pin must be under cooled to approx. 10-20 C 1
! The sequence of the steps (Figure 9 and 10) must be carried out directly in timely order !
Position pre-assembled steering knuckle (2) by means of lifting device, mount shim (4) and center with the center ring pin (3). (S) Center ring pin (S) Hot-air blower 230V (S) Hot-air blower 115V 5870 912 018 5870 221 500 5870 221 501
4 Figure 9 1
Install steering knuckle pin grease free.
It is necessary to heat evenly with the hot air blower. Check with a thermometer. Unqualified heating (e.g. flame) is forbidden. (S) Thermometer 5870 220 011
Figure 10
! Figure 12).
Install the needle bearing on the steering knuckle below (see
At the pressing in of the needle bearing, apply the press-in drift always on the marked (hardened) side (Arrow). steering knuckle, ! Per each must be installed. only needle bearings with the same Part-No.
Figure 11 Drive the needle bearing (4) with the pin (3) into the steering knuckle (2). (S) Driver (S) Handle B 1 5870 058 088 5870 260 002
3 4
! Only at applying the ZF-Special tool, the installation dimension is ensured. from ! Installation dimensionisBmm. the steering knuckle upper side to the needle bearing 15
1 = Steering knuckle carrier
Figure 12
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3.3
Repair Manual
1 2
Insert O-ring (Arrow) into the recess of the sealing cap (1) and grease it. Insert sealing cap (1) into the steering knuckle bore (3) and fix it by means of circlip (2). 3 (S) Set of internal pliers 5870 900 014
!
Figure 13 1
Carry out assembly of the sealing cup (1) and circlip (2) below accordingly.
Grease steering knuckle bearing below and above on grease nipple (1). Lubrication and ! SeeList of LubricantsMaintenance Instructions 5871 201 932 and ZF TE-ML 012.
Figure 14 3 Fasten brake disk (1) with hex. head screws (2) on the hub (3). Torque limit ...................................... 180 Nm
! Renew hex. head screws ! studs in, ! Press the wheelpuller out resp.tool using press.010 (S) Wheel stud - Basic 5870 610
(S) Insert M22x1,5 5870 610 002 Install measuring ring pulse disk (1) flush-mounted to the end face of the hub (2), using a drift (3). (S) Driver (S) Handle 5870 053 020 5870 260 011
Figure 15
3 1
Figure 16
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3.4
Repair Manual
Insert bearing outer races (1 and 2) into the hub (3) until contact is obtained.
2 1 3
1 = Bearing outer race of the inner ball bearing 2 = Bearing outer race of the outer ball bearing
Figure 17 Insert shaft seal (1) with drift (3) into the bearing inner race (2) of the inner tapered roller bearing until contact is obtained. rubber-coated ! Coat shaft seals withoutcircumference. outer surface with sealing compound on the outer ! Mount a new shaft seal. 2 Figure 18 4 1 3 Grease bearing inner race of the inner tapered roller bearing (1) and insert it into the hub (2).
! See Lubrication and Maintenance Instructions 5871 201 932.

Flush mount the cassette type seal (3) into the hub (2) with the drift (4). Grease sealing lips. (S) Driver (S) Handle 5870 053 020 5870 260 011
Figure 19
! Mount a new cassette type seal.

2 1 Mount hub. Screw spindle (1) of the mounting and puller fixture upon the steering knuckle (2). (S) Special device 5870 000 090
Figure 20
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3.5
Repair Manual
Fasten the bracket (1) of the mounting and puller fixture on the hub (2). 2
Figure 21 Pull hub (2) by rotation in arrow direction onto the steering knuckle until contact is obtained.
2 3 1
! Demount mounting and puller fixture (1).

(S) Mounting and puller fixture 5870 000 090
Figure 22 Grease bearing inner race of the outer tapered roller bearing (1) and insert it into the hub (2). 2
! See Lubrication and Maintenance Instructions 5871 201 932.

Mount pressure plate (3), tighten clamping nut (4) until tapered roller bearings have a play free contact. Torque limit ........................................ 240 Nm At the tightening, rotate hub (2) and apply several taps shortly onto the hub, using a plastic mallet. (S) Plastic mallet 5870 280 004
1 3 4
!
Figure 23 1
Check Wheel bearing play 0,02 to 0,04 mm Apply dial indicator arm (3) and dial indicator on the hub. Position the dial indicator tip with preload on the steering knuckle. - Determine wheel play by moving the hub (1) to and fro. If the nominal value is not obtained, adjust wheel bearing play. At new tapered roller bearing, aim at the lower value. Adjust Wheel bearing play. -
2 3
4 Figure 24
- Rotate clamping nut (4) until wheel bearing play is obtained. - Check wheel bearing play once more. (S) Magnetic stand 5870 200 055 (S) Dial indicator 5870 200 057 3.6
5871 199 002
Repair Manual
Fix the clamping nut (1) by tightening the screws (2). Torque limit .................................... 65 Nm
1 2
Figure 25 Fasten cover (1) along with gasket by means of hex. head screws (2) on the hub (3). Torque limit ....................................... 25 Nm 2 1
Figure 26 1 Fasten brake calliper (1) on the steering knuckle carrier (2). 2 Torque limit: Fitting bolt ................................................ 275 Nm Hex. head screw (M16x1.5 10.9) ............. 300 Nm For the mounting of the brake, resp. Maintenance and Repair, the Instructions and Specifications of the component Manufacturer are binding. See in this connection the Repair Manual of the Firm of Knorr in Internet.
Figure 27 (S) Lifting device (S) Brake Tool set (S) Brake Tool set 5870 281 058 5870 080 050 5870 080 056 SB-7000 SN-7000
Adjust steering lock by means of stop screw (1) according to the Specification of the Vehicle Manufacturer. Torque limit .................................. 130 Nm
1 Figure 28
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3.7
Repair Manual
Insert clamping bush (1) and press revolution counter (2) without using striking tools into the bush until contact is obtained. The gap between revolution counter and measuring ring is automatically adjusted by the wheel play. of ! Cover outer diameterface. the sensor with silicone grease (corrosion protection) end (Keyboard area grease free)! 1 2 Figure 29
! Install new bush.
5871 199 002
3.8
Repair Manual
S 6
Assembly Tie road RL-75 EM

2 Insert ball sleeve (1) into the upper control arm (2). Insert snap ring (3) and circlip (4) and press with the pressure piece (S) under axial pressure until the circlip has snapped in.
3 S Figure 1 1 1
! The opening must lay 180 towards the opening of the circlip.
Upper shared control arm (1) (S) Pressure piece (S) Pressing sleeve (S) Set of pliers 5870 100 056 5870 506 134 5870 900 014
Figure 2
1 Press both bearing outer races (1) into the steering knuckle carrier (2) until contact is obtained.
(S) Driver (S) Handle
5870 058 084 5870 260 002
Figure 3
Adjust Rolling moment of the Control arm bearing 8 to 15 Nm (without sealing elements) see Figure 5 to Figure 8. The Figure on the left shows the Special tool required for the rolling moment adjustment. 1 = Assembly drift 2 = Assembly sleeve (2x) (S) = Assembly drift (compl.)
2 1
5870 345 091
Figure 4
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4.1
Repair Manual
Assemble components according to Figure 5 upon the assembly drift. 3 2 4 1 2 3 4 5 6 5 = = = = = = Assembly drift Ring Bearing inner race Shim Bush Assembly sleeve
1 Figure 5 5 6 4 3 2
Insert pre-assembled assembly drift (1) into the steering knuckle carrier and assemble shim (2), bearing inner race (3), ring (4) and Assembly sleeve (5) starting from the other side, and mount hex. nut (6).
! Mount collar of the hex. nut facing the Assembly sleeve (5)
Figure 6 Tighten hex. nut. Torque limit ....................................... 1000 Nm
! Duringinthe tightening, rotate the control arm bearing several times both directions !
Figure 7 Check rolling moment 8 to 15 Nm. In case of deviations from the ! with corresponding shims (Item required rolling moment, correct 4 Figure 5 or Item 2 Figure 6). Loosen hex. nut again and remove components. (S) Torque spanner 5870 203 032
Figure 8
5871 199 002
4.2
Repair Manual
3 1
Install bearing inner race (1), scraper (2) and ring (3) in this order. to ! Pay attentionFigurethe installation location of the scraper (2) (see Arrow A, 10). 2 grease ring the outer ! Insert withbearing inner(3) with the radius onFigure 10).diameter facing the race (see Arrow B,
Figure 9 Legend ref. Figure 10 3 7 B 1 2 3 4 5 6 7 = = = = = = = Roller bearing compl. Scraper Ring Bush Steering knuckle carrier Shim Control arm
1 4
5 Figure 10
2 3 1 4 5
In the opposite side of the steering knuckle carrier install the bush (5) and the determined shim (4).
! Install bearing inner race (1), scraper (2) and ring (3) according to Figure 9.
Figure 11 Install control arm pin (Figure 12 to 15). S 1 Figure 12 shows the required Special tool (S) for the assembly of the control arm pin (1).
(S) Mounting fixture
5870 000 097
Figure 12
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4.3
Repair Manual
Position upper control arm (1) and lower control arm (2) and assembly it by means of .
The installation direction of the control arm pin (3) is only permitted in the driving direction (see Arrow).
3 Figure 13 Press control arm pin by means of a mounting fixture until contact is obtained.
! Now, remove mounting fixture

(S) Mounting fixture 5870 000 097
Figure 14
! of the hex. nut with Loctite Type-No. 262 ! ! Control arm and adjust it by means of centering pin (1).
Tighten hex. nut. Torque limit .................................. 1000 Nm (S) Centering pin 5870 912 032
Install collar of the hex. nut facing the control arm. Wet thread
! Install grease nipple and grease control arm bearing. 283 Use Industrial EPM-Multipurpose grease, Type Glissando
Figure 15 EP 2 LF (Fa. DEA) ! ZF-Order-No. 0671 190 079!
Insert ball piece (2) into the lower control arm (1). Insert snap ring (3) and circlip (4) and press with the pressure piece (S) under axial pressure until the circlip has snapped in.
4 2 3 S Figure 16 1
opening of the must lay the housing ! The shaft (opening iscirclip eyespipe side), towardsthe snap ring, axle facing the and at the opening must lay 180 towards the opening of the circlip.
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4.4
Repair Manual
Bohre Pin
Press both bearing outer races (1) into the steering knuckle carrier (2) until contact is obtained. (S) Pressure piece (S) Pressing sleeve (S) Set of pliers 5870 100 056 5870 506 134 5870 900 014
Control arm
bracket
Figure 17 Assembly of the lower control arm. according to Figure 3 - 14. Mount the collar of the hexagon nut with the disk (see figure 19, pos. 2 and 3) showing to the control arm. Wet thread of the hex. nut with Loctite Type-No. 262 ! Tighten hex. nut. Torque limit .................................. 1000 Nm Install grease nipple and grease control arm bearing. Figure 18 Fasten tie-rod arm (1) by means of hex. head screws on the steering knuckle. Torque limit (M24/10.9)............................... 1 100 Nm 3
2 Figure 19
Fasten tie rod (1) with castle nut (2) on the steering arm. Torque limit (M24x1,5) ......................... MA = 250 - 280 Nm 1 Secure castle nut (2) by means of cotter pin !
2 Figure 20 The tread setting has to be carried out according to the specifications of the Vehicle Manufacturer.
5871 199 002
4.5
Repair Manual
S 6
Assembly Tie road RL-75 EC

2 Insert ball sleeve (1) into the upper control arm (2). Insert snap ring (3) and circlip (4) and press with the pressure piece (S) under axial pressure until the circlip has snapped in.
3 S Figure 1 1 1
! The opening must lay 180 towards the opening of the circlip.
Upper shared control arm (1) (S) Pressure piece (S) Pressing sleeve (S) Set of pliers 5870 100 056 5870 506 134 5870 900 014
Figure 2
1 Press both bearing outer races (1) into the steering knuckle carrier (2) until contact is obtained.
(S) Driver (S) Handle
5870 058 084 5870 260 002
Figure 3
Adjust Rolling moment of the Control arm bearing 8 to 15 Nm (without sealing elements) see Figure 5 to Figure 8. The Figure on the left shows the Special tool required for the rolling moment adjustment. 1 = Assembly drift 2 = Assembly sleeve (2x) (S) = Assembly drift (compl.)
2 1
5870 345 091
Special tool ! Thissleeves (2) arewill be also used at other units. At the RL-75 E the not needed. Figure 4
5871 199 002
5.1
Repair Manual
Assemble components according to Figure 5 upon the assembly drift. 3 2 4 1 2 3 4 5 6 5 = = = = = = Assembly drift Ring Bearing inner race Shim Bush Assembly sleeve
1 Figure 5 5 6 4 3 2
Insert pre-assembled assembly drift (1) into the steering knuckle carrier and assemble shim (2), bearing inner race (3) , ring (4) and Assembly sleeve (5) starting from the other side, and mount hex. nut (6).
Mount collar of the hex. nut facing the Assembly sleeve (5)
! Duringinthe tightening, rotate the control arm bearing several times both directions!
Figure 7 Check rolling moment 8 to 15 Nm. the ! In case of deviations from(Item required rolling moment, correct with corresponding shims 4 Figure 5 or Item 2 Figure 6). Loosen hex. nut again and remove components. (S) Torque spanner 5870 203 032
Figure 8
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5.2
Repair Manual
3 1
Install bearing inner race (1), scraper (2) and ring (3) in this order. to ! Pay attentionFigurethe installation location of the scraper (2) (see Arrow A, 10). 2 grease ring the outer ! Insert withbearing inner(3) with the radius onFigure 10).diameter facing the race (see Arrow B,
Figure 9 Legend ref. Figure 10 3 7 B 1 2 3 4 5 6 7 = = = = = = = Roller bearing compl. Scraper Ring Bush Steering knuckle carrier Shim Control arm
1 4
5 Figure 10
2 3 1 4 5
In the opposite side of the steering knuckle carrier install the bush (5) and the determined shim (4).
Figure 11 Install control arm pin (Figure 12 to 15). S 1 Figure 12 shows the required Special tool (S) for the assembly of the control arm pin (1).
(S) Mounting fixture
5870 000 097
Figure 12
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5.3
Repair Manual
Position upper control arm (1) and lower control arm (2) and assembly it by means of.
The installation direction of the control arm pin (3) is only permitted in the driving direction (see Arrow). 2
3 Figure 13 Press control arm pin by means of a mounting fixture until contact is obtained.

(S) Mounting fixture 5870 000 097
Figure 14
! of the hex. nut with Loctite Type-No. 262 ! ! Control arm and adjust it by means of centering pin (1).
Tighten hex. nut. Torque limit .................................. 1000 Nm (S) Centering pin 5870 912 032
Install collar of the hex. nut facing the control arm. Wet thread
! Install grease nipple and grease control arm bearing. 283 Use Industrial EPM-Multipurpose grease, Type Glissando
Figure 15 EP 2 LF (Fa. DEA) ! ZF-Order-No. 0671 190 079!
Insert ball piece (2) into the lower control arm (1). Insert snap ring (3) and circlip (4) and press with the pressure piece (S) under axial pressure until the circlip has snapped in.
4 2 3 S Figure 16 1
opening of the must lay the housing ! The shaft (opening iscirclip eyespipe side), towardsthe snap ring, axle facing the and at the opening must lay 180 towards the opening of the circlip.
5871 199 002
5.4
Repair Manual
Bohre Pin
Control arm
Press both bearing outer races (1) into the steering knuckle carrier (2) until contact is obtained. (S) Pressure piece (S) Pressing sleeve (S) Set of pliers 5870 100 056 5870 506 134 5870 900 014
bracket
Figure 17 Assembly of the lower control arm. according to Figure 3 - 14. Mount the collar of the hexagon nut with the disk (see figure 19, pos. 2 and 3) showing to the control arm. Wet thread of the hex. nut with Loctite Type-No. 262 ! Tighten hex. nut. Torque limit .................................. 1000 Nm Install grease nipple and grease control arm bearing. Figure 18 Fasten tie-rod arm (1) by means of hex. head screws on the steering knuckle. Torque limit (M24/10.9)............................... 1 100 Nm 3
2 Figure 19
Fasten tie rod (1) with castle nut (2) on the steering arm. Torque limit (M24x1,5) ......................... MA = 250 - 280 Nm Secure castle nut (2) by means of cotter pin !
1 Figure 20
2 The tread setting has to be carried out according to the specifications of the Vehicle Manufacturer.
5871 199 002
5.5
RepairManual
Attachment of various Peripheral components RL-75 EC

Disassembly relay lever:
Disassembly relay lever Figure-1 and Figure-3. Loosen hex. nut (1).
! With hot-air heat hex. nut.

Figure 1 (S) Hot-air blower 230 V (S) Hot-air blower 115 V 5870 221 500 5870 221 501 Press bearing pin (1) out, using two-leg puller.
! Now, remove components of the relay lever bearing.

1
Figure 2
Assembly relay lever:

1 Press both bearing outer races (1) into the relay lever (2) until contact is obtained. (S) Driver (S) Handle 2 5870 058 084 5870 260 002
Figure 3
Adjust Rolling moment of the relay lever bearing 5 to 12 Nm (without sealing elements) see Figure 5 to Figure 8. The Figure on the left shows the Special tool required for the rolling moment adjustment. 1 = 2 = (S) = (S) = Assembly drift Assembly sleeve (2x) Assembly drift (compl.) Pressure sleeve
5870 345 091 5870 100 064
Figure 4
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6/1
RepairManual
3 2
Assemble components according to Figure 5 upon the assembly drift. 1 2 3 4 5 6 = = = = = = Assembly drift Pressure sleeve Ring Bearing inner race Shim Bush
6 1 4
Figure 5 Insert pre-assembled assembly drift (1) into the relay lever and assemble shim (2), bearing inner race (3), ring (4) and Assembly sleeve (5) starting from the other side, and mount hex. nut (6). 6 5 4 3 2 1
! Mount collar of the hex. nut facing the Assembly sleeve (5)
the tightening, ! During directions ! rotate the relay lever bearing several times in both
Figure 7 Check rolling moment 5 to 12 Nm. the ! In case of deviations from(Item required rolling moment, correct with corresponding shims 5 Figure 5 or Item 2 Figure 6). Loosen hex. nut again and remove components. (S) Torque spanner 5870 203 032
Figure 8
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6/2
RepairManual
Install bearing inner race (1), scraper (2) and ring (3) in this order. 2 to the installation location of the scraper (2) (see ! Pay attentionFigure 10). Arrow A, grease ring the outer ! Insert withbearing inner(3) with the radius onFigure 10).diameter facing the race (see Arrow B,
Figure 9 Legend ref. Figure 10 7 B 1 2 3 4 5 6 7 = = = = = = = Roller bearing compl. Scraper Ring Bush relay lever Shim Hex. nut
1 4
5 Figure 10
In the opposite side of the relay lever install the bush (5) and the determined shim (4). 2 3 1 4 5
Figure 11 Install relay lever bearing (Figure 12 to 14). 1 S Figure 12 shows the required Special tool (S) for the assembly of the bearing pin (1).
(S) Mounting fixture (S) Thread insert
5870 000 097 5870 000 104
Figure 12
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6/3
RepairManual
Press bearing pin by means of a mounting fixture until contact is obtained. 1

(S) Mounting fixture (S) Thread Insert 5870 000 097 5870 000 104 pin ! Bearing bore(1) must become of the flat side of the relay lever (2) into the pressed.
Figure 13
! hex. nut with Loctite Type-No. 262!

Tighten hex. nut.
Install collar of the hex. nut facing the ring. Wet thread of the
Torque limit .................................. 1000 Nm Install grease nipple and grease control arm bearing. EPM-Multipurpose grease, Type Glissando 283 ! Use2 IndustrialDEA)! EP LF (Fa. ZF-Order-No. 0671 190 079! Figure 14
! Figure 1 - 14.
1
Disassembly and assembly of the intermediate lever according to
Figure 15 Fasten tie rod (1) with castle nut (2) on the steering arm. Torque limit (M24x1,5) ......................... MA = 250 - 280 Nm
! Secure castle nut (2) by means of cotter pin!
1 Figure 16
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6/4
RepairManual
5 5
Fasten tie rods (1) with castle nuts (4) on the relay lever (2) and intermediate lever (3).
Torque limit (M24x1,5): MA = 250 - 280 Nm 5 castle ! Securepin! nut (4) by means of cotter installation ! Pay attention to thelever (2) and location of the relay intermediate lever (3). 3
1 4 5 1 2
! Torque limit clip (5): 70 - 80 Nm M12x1,5......... M =

A
Figure 17
Fasten tie rod (1) with castle nut (4) between relay lever (2) and intermediate lever (3). Torque limit (M24x1,5): MA = 250 - 280 Nm castle ! Securepin! nut (4) by means of cotter
4 1 4 2 3
the ! Pay attention to rodsinstallation location of the tie (1)
! Torque limit clip (5): 70 - 80 Nm M12x1,5......... M =

A
Figure 18
! !
The tread setting has to be carried out according to the specifications of the Vehicle Manufacturer!
Prior to commissioning the vehicle, pay attention to the ZF-Lubrication and Maintenance Instructions, (5871 201 932). For the installation of the unit into vehicle, the Specifications of the Vehicle Manufacturer are binding!
5871 199 002
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Repair Manual
Attachment wheel head right/left and various Peripheral components am chassis RL-75 EM
Direction of travel
Wheel head RE
Fasten wheel head am chassis by means of hex. head screws and hex. nuts (1, 2, 3).
Wheel head LE
4 5
1 = M22x1,5 2 = M18x1,5 3 = M18x1,5
!
2
See too Figure 2
!
1 3 Figure 1
Air suspension (4) and shock absorber (5) not scope of supply ZF.
!
2
Torque limit: M18x1,5 .....MA 440 40 Nm M22x1,5 .....MA 820 80 Nm
3 3
Figure 2
5871 199 002
7/1
Repair Manual
!
4 3
Fasten steering gear am chassis by means of hex. head screws (2). Disk (3) and hex. nuts (4). Torque limit: M22/10.9 .....MA 670 60 Nm Fasten steering drop arm (5) am steering gear (1) by means of safety nuts (6).
!
5
Marking (7) must agree with steering drop arm and steering sector shaft Torque limit: M42x1,5 .......MA 520 50 Nm
2 Figure 3
7 1
To be staked the safety nuts after assembly of steering drop arm (see arrow).
Figure 4 4 1 2 4 Fasten tie rod (1) with castle nut (4) on the steering drop arm (2) and steering lever (3).
!
3
Torque limit M24x1,5....MA = 250 - 280 Nm Secure castle nut (4) by means of cotter pin !
Torque limit clip (5) M16x1,5.............MA = 40 Nm
3 4 Figure 5 5
5871 199 002
7/2
Repair Manual
! !
The tread setting has to be carried out according to the specifications of the Vehicle Manufacturer.
Prior to commissioning the vehicle, pay attention to the ZF-Lubrication and Maintenance Instructions, (5871 201 932).
For the installation of the unit into vehicle, the Specifications of the Vehicle Manufacturer are binding!
5871 199 002
7/3

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WORKSHOP MANUAL

Order-No.: 5871 199 002

ZF INDEPENDENT WHEEL SUSPENSION RL-75 EC/EM

See Internet: htpp:\\www.Knorr-bremse.com

0/1 0/2 3 0/4 0/5 0/6 0/7

Off-Road Transmission and Axle System Division

ZF Passau GmbH Service Department

Off-Road Transmission and Axle System Division

Off-Road Transmission and Axle System Division

Off-Road Transmission and Axle System Division

INSCRIPTIONS ON THE MODEL IDENTIFICATION PLATE

NOTES FOR THE COMPILATION OF SPARE PARTS ORDERS

Off-Road Transmission and Axle System Division

VERGLEICHSTABELLE FR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION

Off-Road Transmission and Axle System Division

Hinweis : Note : Nota : Begriff Unit

Nouveau Vieu kg (Kilogramm) kg

Pression (Sur-) Drehzahl Speed Nombre de Tours

1,02 at = 1,02 kp/cm2 = 1 bar = 750 torr

Off-Road Transmission and Axle System Division

Off-Road Driveline Technology and Axle Systems Division

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF Axle RL 75 EM EC

5870 350 000 5870 350 100 5870 350 101

5870 221 500 5870 221 501

2.4 1.7/2.4 2.7

5870 970 007 5870 100 059

5870 280 004

5870 900 014

5870 506 134 5870 100 056

5870 080 050 5870 080 056

5871 199 002

Off-Road Driveline Technology and Axle Systems Division

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF Axle RL 75 EM EC

5870 281 058

5870 281 043

Extractor # For disassembly and reassembly of pre-mounted hub to the knuckle.

5870 000 090

5870 300 019 5870 300 020

5870 900 013

5870 650 001

5870 506 130

5870 260 003

5871 199 002

Off-Road Driveline Technology and Axle Systems Division

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF Axle RL 75 EM EC

5870 000 097

5870 100 044

5870 345 094

5870 200 112

5870 912 018

5870 221 500 5870 221 501

5870 058 088

5870 260 002

Set of internal pliers Universal use.

I11 I21 I31 I41

5870 900 014

Off-Road Driveline Technology and Axle Systems Division

LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF Axle RL 75 EM EC

5870 610 010

5870 610 002

3.16 3.18 3.19

5870 053 020