Repair Manual F 4-B

Rear Axles for Buses

AP Axles for Buses

H07, H09, HONL, HONM

HOM7, HOM9, HONG
 General information
-
This survey presents a summary of the important regulations listed according to major topics. The intention
is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. Additional information is given in the operator's manual for driven axles.

Important:
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident
involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze
spraying into eyes, etc.

1. Regulations for preventing accidents leading to injury to personnel.

Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.

Secure the vehicle to prevent it from rolling away.

Support the frame when working on the pneumatic or spring suspension system.
Secure units during their removal.

Collect any brake fluid that leaks out. Treat brake fluid as hazardous waste.
Comply with the safety regulations for preventing environmental pollution, see
page 4.
Brake fluid is poisonous! Do not allow brake fluid to come into contact with food
or open wounds.

Only authorised personnel are permitted to start and operate an engine.

Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.

Do not touch an axle with your bare hands when it is at operating temperature.
Danger of burns1

Keep the area around the axle as well as any ladders and stairways free of oil
and grease. Accidents caused by slipping can have very serious consequences.
Do not use any tools that are not in perfect condition. Worn-out spanners can
slip: Danger of injury!
No-one is allowed to stand under a unit susoended from a crane hook. Keeo all
lifting tackle in good condition.

Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit). Fluid
spraying out represents an injury hazard!
.--
 WHEEL BRAKE (CAM BRAKE)

Dismantling and assembling wheel brake

Work involved

Jacking up and lowering the vehicle, securing the vehicle to prevent it rolling away (Operator's Manual)
Removing and fitting wheels (Operator's Manual)
Removing and installing brake drum (cam brake) (3.21)

Protective plate
Brake shoe
Brake lining
Brake lining (brake lining wear indicator)
Bearing block
Slack adjuster
Brake camshaft
Backing plate
Brake springs
Brake drum
WHEEL BRAKE (CAM BRAKE)

Special tools

Forcing bolts ...............................................................................06.01734.4320

For forcing off brake drum

Assembly lever ............................................................................ 80.99606.6003

For brake shoe return springs

I41
J-#@

Removing device ........................................................................ 80.99604.0013

For removing bearing bush from brake camshaft

af l
For removing and fitting seal holder on brake camshaft
n201 For seal holder in the brake camshaft bearing block

Pressing pin ................................................................................

80.99617.0010
For removing and fitting brake shoe pin and bush

[I211

Pressing pin ................................................................................80.9961 7.001 1

For removing and fitting bush in brake shoe roller

f9d Q
Clamping device .........................................................................80.99606.001 4
For machining brake lining
Q4li&7
[I231 %$3%k
\&

11251
a Clamping device ........................................................................
For turning brake drum
80.99614.0008

Thrust ring ....................................................................................

For removing brake camshaft bearing bush, included with
80.99604.0127

fitting device 80.99604.6008 [ I 191

I WHEEL HUB HOMG I HOM7 I HOM9 I
Dismantling and assembling wheel hub

Work involved

Jacking up and lowering the vehicle, securing the vehicle to prevent it rolling away (Operator's Manual)
Removing and fitting wheels (Operator's Manual)
Removing and installing brake drum (3.21)
Removing and installing axle shafts (4.30)

a Race
@ Oil baffle
@ Shaft seal (if ABS fitted: Pulse transmitter gear with integral shaft seal)
@ Shaft seal
@ Cover plate
@ Tapered roller bearing
@ Wheel hub
@ Spacer ring
@ Slotted nut
@ Tab washer
0 Wheel hub cover

Technical data

0.01 - 0.03 mm
Wheel hub end play ..............................................................................................................
Heat race to 150 "C when installing.
 WHEEL HUB HOMG / HOM7 / HOM9

Special tools

Removing device for tapered roller bearing outer races ............. 80.99604.601 0
For pressing out tapered roller bearing outer races

1121

4 3-armed puller .............................................................................

80.99601.0099
0

Front axle output flange

I
For removing wheel hub shaft seals (in conjunction with
[391 I

support 80.99606.01 99 [55])

For removing power divider ball bearings

Support .......................................................................................
80.99606.01 99

PSI
8 For removing wheel hub shaft seals (in conjunction with 3-
armed puller 80.99601.0099 [39])

Sliding pin handle ........................................................................80.99606.0241

/
For fitting and removing wheel hub, included with fitting
device 80.99606.6001 [72]
[GO1

Fitting device ...............................................................................

80.99606.6001
Front axle output flange
Rear axle wheel hub
1721 Device consists of
Spindle 1831............................................................................80.99606.0240
Sliding pin handle [60] ........................................................... 80.99606.0241
Fitting cover [l29] ..................................................................80.99606.0239
Bush [369]..............................................................................80.99606.0243
Adapter [370] .........................................................................80.99606.0242
Spindle ........................................................................................80.99606.0240
Included with fitting device 80.99606.6001 [72]
Output shaft, pulling off tapered roller bearing
1831 L/
For fitting and removing wheel hub

Plug-on handle .......................................................................... 80.99617.0129

Pressing tool

[1101
 REMOVING AND INSTALLING WHEEL HUB

H07 1 H09 / HONM 1 HONL axles: Push ring gear

and carrier onto the axle stub.

HOMG / HOM7 1 HOM9 axles: Fit spacer ring on the

axle stub.

Adjust the wheel bearings (5.20)

Check the wheel brake (3.1 1)
Install the planetary final drive (4.10)
Install the axle shafts (4.30)
Install the brake drum (3.21)
Fit the wheels (Operator's Manual)
ADJUSTING WHEEL BEARINGS

Mount the magnetic stand and dial gauge on the

outer edge and measure the end play by moving the
part vigorously back and forth. -

End play on wheel hub: 0.01 - 0.03 mm

Note
Adjust the end play by undoing or tightening the
inner slotted nut.

Secure both the slotted nuts once the correct end

play has been obtained.
 DISMANTLING AND ASSEMBLING BEVEL GEAR HOUSING

Dismantling bevel gear housing

Drain the oil (Maintenance Manual)

Remove the axle shafts (4.30)
Remove the axle drive (7.2017.21)
Remove the bevel gear housing (7.3017.31)
Additional work in the case of HONL axles:
Remove the Ihs brake drum (3.21 )
Remove the Ihs brake shoes (3.31)

Note
Bolting the bevel gear housing to clamping plate
[373] makes it easier to undo the mounting nut.

Undo mounting nut a on the input flange.

Attach socket a [374] and adapter flange @

[375,408] to the input flange.

Attach torque multiplier a [353] and unscrew the

mounting nut.

Take off the input flange.

Note
Use a 2-armed puller if necessary.

Unscrew the bevel gear housing from clamping plate

[373].

a
Press drive pinion out of bevel gear housing @.
Remove the bush and the shim ring.

Note
The bush is only fitted in axle drives with crown
wheel 0 300.
 DISMANTLING AND ASSEMBLING BEVEL GEAR HOUSING

Input flange @ Shim ring

@ Mounting nut @ Oil baffle
@ Shaft seals @ Bush
@ Sealing ring holder @ Tapered roller bearing
@ Bevel gear housing (bevel gear end)
@ Taper. roller bearing 0 Drive pinion
(flange end)

Note
The sealing ring holder and the bush are only fitted
in axle drives with crown wheel 0 300.

Assembling bevel gear housing

Press the oil baffle into the bevel gear housing using
the insert plate (outer 0 115 mrn).

Press the outer race of the tapered roller bearing into

the bevel gear housing using insert plate @ [377,379]
a
and plug-on handle [I 101.

Turn over the bevel gear housing and press the

outer race of the tapered roller bearing on the flange
end into the bevel gear housing using insert plate @
a
[378,379]and plug-on handle [I 101.

Heat up inner tapered roller bearing @ t o approx.

100 "C- 120 "Cand slide it onto the drive pinion until
it reaches the stop.

RA - F 4-B 7.35 - 3
 DISMANTLING AND ASSEMBLING BEVEL GEAR HOUSING

Flatten over collar to secure the mounting nut.

- Unscrew the bevel gear housing from clamping plate
[373].

lnstall the bevel gear housing (7.3017.31).

lnstall the axle drive (7.2017.21)
lnstall the axle shafts (4.30)
Fill with oil (Maintenance Manual)
Additional work in the case of HONL axles:
Install the Ihs brake drum (3.21)
lnstall the Ihs brake shoes (3.31)
 -
CHARACTERISTIC DATA HOM7 1100
 -
CHARACTERISTIC DATA H07 1012011 1120113120

CHARACTERISTIC DATA H07 11120 04 - -

-
Design .....................................................................
Driven, non-steering rear axle with planetary final drive
and axle drive.
Permitted axle load .................................................. 11,500 kg
at road speed ...........................................................100 kmlh
Permitted axle load with vehicle stationary ..............23,000 kg
Permitted wheel load per side (stationary vehicle) .. 11,500 kg
Service weight incl. oil, not incl. wheels ...................770 kg
Service brake .....................................................Compressed air, cam brake
Actuation type ..........................................................Double Tristop brake cylinder
Handbrakelparking brake ........................................ Spring-loaded accumulators
Brake and drum 0 ...................................................41 0 mm
Brake width ..............................................................220 mm
Wheel fastenings ...................... ....10 wheel studs, hole circle 0 335 mm
Disc wheels .............................. .... Stud or hub centring
Aluminium disc wheels ............. ....Hub centring and spec. wheel nuts
Tublex and Trilex wheels .........................................Trilex wheel rim with wheel spider
Authorised rim manufacturers .................................KP = Kronprinz
LE = Lemmerz
SD = Siidrad -
GR = Gianette Ruote
GF = Georg Fischer
GL = Grasdorf
Aluminium wheels .................................................BO = BORBET
AL = ALCOA
SL = Speedline
AT = ATS

CHARACTERISTIC DATA H07 11120 - 07,16 -

Design .....................................................................Driven, non-steering rear axle with planetary final drive
and axle drive.
Permitted axle load .................................................. 11,500 kg
at road speed ......................................................... 130 kmlh
Permitted axle load with vehicle stationary ..............23,000 kg
Permitted wheel load per side (stationary vehicle) .. 11,500 kg
Service weight incl. oil, not incl. wheels ...................790 kg
Service brake ...........................................................Compressed air, cam brake
Actuation type ..........................................................Combination brake cylinder
4

Handbrakelparking brake ........................................ Spring-loaded accumulators

Brake and drum 0 ...................................................41 0 rnm
Brake width .............................................................. 220 rnm
Wheel fastenings ..................................................... 10 wheel studs, hole circle 0 335 mm
Disc wheels .............................................................Stud or hub centring
Aluminium disc wheels ............................................Hub centring and spec. wheel nuts
Tublex and Trilex wheels ....................... .....Trilex wheel rim with wheel spider
Authorised rim manufacturers ............... ..... KP = Kronprinz
LE = Lemmerz
SD = Sudrad
GR = Gianette Ruote
GF = Georg Fischer
GL = Grasdorf
Aluminium wheels .................................. ..... BO = BORBET
AL = ALCOA
SL = Speedline
AT = ATS
 I -
CHARACTERISTIC DATA H 0 7 10120111120113120 1
Ratios and torque capacity
_- H 0 7 - 11120-00
Planetary final Drive pinion ratio Total ratio Max. input torque on Gross vehicle weight
drive ratio id itot clutch flange
iP
3.480 29:15 = 1.933 6.727 11,770 Nm 18t128t
3.480 29:17 = 1.706 5.937 14,710 Nrn 18t128t
3.480 27:18 = 1.500 5.220 16,680 Nm 18tl28t
3.4t 28:21 = 1.333 4.t 17,660 Nrn 18tl28t

H07 11'-
Planeta'ry final Drive pinion ratio TotaI ratio Max. input torque on Gross vehicle weight
drive v all"
qi;n
id itm4
VL C:lutch flange
iP

planetary tlnal Drive pinion ratio Total ratio Max. input torque on Gross vehicle weight
drive ratio id itot clutch flange
ip

3.480 29:17 = 1.706 5.937 14,710 Nrn 28 t

3.480 27118 = 1.500 5.220 16,680 Nm
3.480 28:21 = 1.333 4.639 17,660 Nrn

-
H07 11120 13,14 -
Planetary final Drive pinion ratio Total ratio Max. input torque on Gross vehicle weight
drive ratio id itot clutch flange
ip
3.480 27:12 = 2.250 7.830 9810 Nrn 23.6 t

3.480 29:17 = 1.706 5.937 14,710 Nrn 23.6 t

-
H07 11120 16 -
Planetary final Drive pinion ratio Total ratio Max. input torque on Gross vehicle weight
drive ratio id itot clutch flange
iP
3.947 29:17 = 1.706 6.734 14,710 Nrn 28 t
 -
CHARACTERISTIC DATA H07 10120111120113120

Trilex with wheel -:-

/

Rim Rstat E H S BA QB BI

Rim size and permitted t)

Disc wht,.
snl
 -
CHARACTERISTIC DATA H 0 7 1012011 1120113120
SPECIAL TOOLS

Clamping plate............................................................................ 80.9961 3.0009

for crown wheel 0300 mm
For dismantling and assembling bevel gear housing
,3631
@ For dismantling and assembling power divider cover

Pressing pin .......................................................................... 80.99617.0029

For removinglfitting planet carrier pins

P641
,.=3
Support handle ......................................................................... 80.9961 7.0005
For removing and installing axle shafts

[3651
@
Universal hand pump .................................................................. 80.99629.6005

13661

d Slotted nut spanner socket ......................................................... 80.99603.6001

[3671 0
69
with centring sleeve [368] ........................................................... 80.99603.0155
Removing and installing wheel hub

Centring sleeve 047.5 mm ........................................................ 80.99603.0156

For removing and installing wheel hub (in conjunction with

[3681
0 slotted nut spanner socket 80.99603.6001 [367])

Centring sleeve 051 .8 mm ...................................................... 80.99603.01 55

For removing and installing wheel hub, included with

13681
0 slotted nut spanner socket 80.99603.6001 [367]

Centring sleeve 056.5 mm ...................................................... 80.99603.0154

For removing and installing wheel hub (in conjunction with
slotted nut spanner socket 80.99603.6001 [367])
[3681
MAN Nutzfahrzeuge Aktiengesellschaft
Dachauer Str. 667 or Postfach 50 06 20
80995 MUNCHEN 80976 MUNCHEN

Repair Manual - F 4-8 -

(AP Rear Axles for Buses)

- English -

Publication No. 81.99198.4322

Printed in Germany