Replace kingpin

AR33.25-G-0410B

Replace kingpin

23.06.2017

Front axle

737.220/221/222/223/224/570/571/572/580/581/583/590/592

Front axle

737.365/366/367/368 in model 437.4

Front axle

737.910 in model 000.001

1

Kingpin

3

Kingpin eye

2

Kingpin

4

Kingpin eye

1

Kingpin

2

Kingpin

A

Installed dimension

B

Installed dimension



Remove

1

Remove steering knuckle

Front axle 737.570/571/572/580/581/583/590/592

AR33.25-G-0400B

Front axle 737.365/366/367/368 in model 437.4
Front axle 737.910 in model 000.001

AR33.25-G-0400C

Front axle 737.220/221/222/223/224

AR33.25-G-0400CC

2

Remove sealing rings and needle bearing from axle tube

Front axle 737.570/571/572/580/581/583/590/592

AR33.25-G-0460B

Front axle 737.365/366/367/368 in model 437.4
Front axle 737.910 in model 000.001

AR33.25-G-0460C

Front axle 737.220/221/222/223/224

AR33.25-G-0460CC

3

Close opening in axle tube with rags

4

Support axle tube as far as possible to the outside with jack stand

 To avoid any deformation to axle tube.

5

Grind off weld seams (arrows) inside on the kingpins (1, 2)

6

Drill a balance hole of Ø 8 mm in each kingpin (1, 2)

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

7

Heat up each kingpin eye (3, 4) to approx. 180 °C

 The kingpin eyes (3, 4) must be heated up in stages. It is essential to use a temperature measuring instrument.

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

8

Use suitable tool to knock out kingpin (1, 2) from outside inwards



Check

9

Check mounting holes of kingpins (1, 2)

If there is wear, scuff marks or if the bores are worn out



Replace axle tube.

Front axle 737.570/571/572/580/581/583/590/592
Front axle 737.910 in model 000.001

AR33.10-G-0060B

Front axle 737.365/366/367/368 in model 437.4

AR33.10-G-0060C

Front axle 737.220/221/222/223/224

AR33.10-G-0060CC



Clean

10

Clean and deburr bores



Install

 Warning

Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.

Wear heat protective gloves, protective clothing and full eye protection. Ensure that the work area is adequately ventilated.

AS00.00-Z-0003-01A

11

Place new kingpins (1, 2) in the cool box and fill with liquid nitrogen

 Cool new kingpin (1, 2) for approx. 30 minutes.

 Supercooler box

*346589006300

 Warning

Risk of injury when handling liquid nitrogen or from touching extremely cool objects. Risk of asphyxiation from inhaling nitrogen gas.

Wear heat protective gloves, protective clothing and full eye protection. Ensure that the work area is adequately ventilated.

AS00.00-Z-0003-01A

12

Remove kingpins (1, 2) from cool box using pliers and pound into the bores using the press-in tool



Press-in too for kingpins

Front axle 737.2/3/5/9

WF58.50-G-3325-04B

 The chamfers of the kingpin (1, 2) must face inwards.
Pound in kingpins (1, 2) from the outside inwards.
Observe installed dimensions (A, B) of kingpins (1, 2).

Front axle 737.221/222/223/224/366/367/368/571/572/581/583/592Installed dimension of kingpin

*BE33.25-N-1001-01I

Front axle 737.220/365/570/580/590/910Installed dimension of kingpin

*BE33.25-N-1003-01D

 Danger

The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases

Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly inflammable materials from the hazard area. Use air extraction system.

AS00.00-Z-0007-01A

13

Weld on kingpins (1, 2) using electric welder

General notes on welding

AH60.00-N-0005-01A

 Use special rod electrode 3.2x350 mm. Welding may only take place on the chamfer of the kingpins (1, 2), not on the carburized layer.



Check

14

Check weld seams (arrows) for cracks using crack detector fluid

Crack detector

*BR00.45-Z-1001-03A

If there are problems



Re-weld weld seams (arrows).

15

Install sealing rings and needle roller bearings in axle tube

Front axle 737.570/571/572/580/581/583/590/592

AR33.25-G-0460B

Front axle 737.365/366/367/368/910

AR33.25-G-0460C

Front axle 737.220/221/222/223/224

AR33.25-G-0460CC

16

Install steering knuckle

Front axle 737.570/571/572/580/581/583/590/592

AR33.25-G-0400B

Front axle 737.365/366/367/368/910

AR33.25-G-0400C

Front axle 737.220/221/222/223/224

AR33.25-G-0400CC

Check values of kingpin

Number

Designation

Front axle 737.366/367/368/571/572/581

Front axle 737.221/222/223/224/583/592

BE33.25-N-1001-01I

Installed dimension of kingpin

Top

Dimension A

mm

19,5...20,0

21,3...21,7

Bottom

Dimension B

mm

20,5...21,0

22,3...22,7

Check values for steering knuckle

Number

Designation

Front axle 737.220

Front axle 737.365

BE33.25-N-1003-01D

Installed dimension of kingpin

Top

Dimension A

mm

21,3...21,7

19,0

Bottom

Dimension B

mm

22,5...22,7

20,5...21,0

Check values for steering knuckle

Number

Designation

Front axle 737.570

Front axle 737.580

BE33.25-N-1003-01D

Installed dimension of kingpin

Top

Dimension A

mm

19,0

19,0

Bottom

Dimension B

mm

20,5...21,0

20,5...21,0

Check values for steering knuckle

Number

Designation

Front axle 737.590

Front axle 737.910

BE33.25-N-1003-01D

Installed dimension of kingpin

Top

Dimension A

mm

21,3...21,7

19,0

Bottom

Dimension B

mm

22,5...22,7

20,5...21,0

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-03A

Crack detector

A 000 989 03 59