ZF AV 110 Repair Instructions Download Page 3

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1.1

Document overview

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Safety Instructions

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2.1

General safety instructions

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2.2

Signal words and symbols

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Notes on Repairs and Assembly

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3.1

General notes

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3.2

Cleaning the ZF product

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3.3

Dismantling the ZF product

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3.4

Assembling the ZF product

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3.5

Cleaning parts

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3.6

Reusing parts

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3.7

Replacing parts

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3.8

Reworking parts

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Technical Data

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4.1

Oil grade

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4.2

Type plate

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Setting Data

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Tightening Torques

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Workshop Equipment

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7.1

Special tools

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7.2

Standard tools and fixtures

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7.3

Operating supplies and auxiliary materials

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Dismantling

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8.1

Clamp the axle

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8.2

Drain oil

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8.3

Remove mounting parts

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8.4

Removal of brake

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8.5

Remove and dismantle hub.

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8.5.1

Remove hub

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8.5.2

Dismantling hub

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8.6

Remove tachometer

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8.7

Remove and dismantle left portal drive

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8.7.1

Remove left portal drive

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8.7.2

Dismantling left portal drive

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8.8

Remove breather

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8.9

Remove and dismantle right portal drive.

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8.9.1

Remove right portal drive

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8.9.2

Dismantle right portal drive

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Table of Contents

EN 4472.751.001 - 2015-11

Summary of Contents for AV 110

Page 1: ...REPAIR INSTRUCTIONS AV 133 Bus axle with compact bearing BUSES ...

Page 2: ...ected by copyright Complete or partial reproduction or distribution of this document is not permitted without the approval of ZF Friedrichshafen AG Infringements lead to civil and criminal prosecution This document is a translation of the German original ...

Page 3: ...orques 15 7 Workshop Equipment 17 7 1 Special tools 17 7 2 Standard tools and fixtures 30 7 3 Operating supplies and auxiliary materials 35 8 Dismantling 36 8 1 Clamp the axle 36 8 2 Drain oil 36 8 3 Remove mounting parts 38 8 4 Removal of brake 39 8 5 Remove and dismantle hub 42 8 5 1 Remove hub 42 8 5 2 Dismantling hub 44 8 6 Remove tachometer 47 8 7 Remove and dismantle left portal drive 48 8 7...

Page 4: ...rtal drive 103 9 6 1 Assemble right portal drive 103 9 6 2 Install right portal drive 116 9 7 Install breather neck 117 9 8 Install breather 118 9 9 Install tachometer 118 9 10 Assemble and install hub 120 9 10 1 Assembling hub 120 9 10 2 Install hub 124 9 11 Install brake 127 9 12 Install mounting parts 129 9 13 Filling oil 131 10 Testing Measuring Adjusting 133 10 1 Check contact pattern 133 10 ...

Page 5: ...d by authorized trained and instructed specialized staff only It is the responsibility of the company that performs repair assembly or maintenance tasks to ensure that their specialized staff is properly trained and that current documents are made available ZF Friedrichshafen AG 1 1 Document overview The specifications listed in these documents must be observed because they are a prerequisite for ...

Page 6: ...l provisions Work must only be performed by trained instructed and authorized specialized staff Only original ZF spare parts may be used Only original ZF accessories may be used Only original ZF special tools may be used Changes and modifications of the ZF product may lead to the expiry of the operator s license warranty or guarantee In case of damage immediate action is mandatory in order to rest...

Page 7: ...suspended loads Keep distance Lifting and moving heavy parts without tools may lead to health damage or serious injury Only use permitted means of transport lifting tools with a sufficient load capacity and suitable lifting technology Observe safety regulations Increased risk of injury in the event of contact with cooled down or heated parts Only touch parts when wearing suitable protective gloves...

Page 8: ...ting supplies and auxiliary materials in a sufficiently large container Dispose of operating supplies and auxiliary materials waste containers soaked cleaning cloths contaminated filters etc in accordance with the regulations of the environmental protection laws Pay attention to the manufacturer s regulations and accident prevention regulations When selecting operating supplies and auxiliary mater...

Page 9: ...to a severe injury or death ð Information as to how the danger can be prevented CAUTION The signal word CAUTION indicates a dangerous situation that if not prevented can lead to a slight or moderate injury ð Information as to how the danger can be prevented The signal word NOTICE indicates a situation that if not prevented can lead to property damage ð Information as to how the property damage can...

Page 10: ...ust ensure that the ZF product is again functioning perfectly and is safe to operate 3 2 Cleaning the ZF product Clean the ZF product with an appropriate cleaning agent prior to repair or assembly works Possible damage to ZF product due to water infiltration ð Be careful when using a pressure washer on the ZF product 3 3 Dismantling the ZF product To avoid mixing up parts the parts must be clearly...

Page 11: ...usable parts Remove sealing compound residue on sealing faces or retaining agent residue e g in tapped holes or on splines Clean joining surfaces Clean blind holes and blind hole threads Lubricating bores oil bores oil ducts bores for oil press fits and lubricating grooves must be free from dirt preservative and foreign matter Check for free passage Hose assemblies tubes and joining elements must ...

Page 12: ... impaired Minor damage includes Indentation marks on sealing faces Score marks or burs caused by the disassembly of the ZF product Frictional corrosion Damage caused by paint or corrosion If rework is needed on spacer washers or shims because of clearance settings ensure that the reworked surface is level with the starting face and has the same surface quality Debur all edges that can cause chip f...

Page 13: ...type plate contains the most important data TE ML TE ML TE ML ltr List of lubricants Customer s Code No Oil Parts List No Total Ratio Version Made in Germany Serial No ZF Friedrichshafen AG Type 3 1 2 4 5 6 7 8 40_020020_01 Fig 1 Type plate 1 Product designation 2 Serial number 3 Parts list number 4 Transmission ratio 5 Oil specification 6 Approximate oil quantity for initial filling 7 No of List ...

Page 14: ...t axle ratio i 7 38 Total rolling torque Pinion bearing rollin g torque 2 Nm 1 Nm Torque wrench with dial gauge Setting backlash and differential bearing rolling torque and checking axial run out and contact pattern page 81 Total rolling torque at axle ratio i 7 38 Total rolling torque Pinion bearing rollin g torque 1 5 Nm 0 5 Nm Torque wrench with dial gauge Setting backlash and differential bear...

Page 15: ...ther page 118 Stud bolt 33 Nm Torque wrench Assemble left portal drive page 88 Cylindrical screw 185 Nm Torque wrench Assemble left portal drive page 88 Assemble right portal drive page 103 Hexagon nut 200 Nm Torque wrench Install left portal drive page 102 Torx screw M16 x 1 5 10 9 270 Nm Torque wrench Assembling hub page 120 Slotted nut M105 x 1 5 100 Nm Torque wrench Install hub page 124 Torx s...

Page 16: ...asuring instrument Comment Chapter section Screw plug oil filling M24 x 1 5 70 Nm Torque wrench Filling oil page 131 Screw plug oil level M24 x 1 5 70 Nm Torque wrench Filling oil page 131 Tightening Torques 16 EN 4472 751 001 2015 11 ...

Page 17: ...xle page 36 1 5870 350 000 Assembly truck Clamp the axle page 36 Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88 Assemble right portal drive page 103 1 5870 281 046 Load carrying fixture Removal of brake page 39 Install brake page 127 1 5870 204 084 Eyebolt Removal of brake page 39 Install brake page 127 1 M16 Workshop Equipment EN 4472...

Page 18: ...ge 42 Dismantling hub page 44 1 1 set 2 units 5870 401 146 Slotted nut wrench Remove hub page 42 Install hub page 124 1 AA01 395 095 Load carrying fixture Remove hub page 42 Install hub page 124 1 5870 100 069 Assembly fixture Dismantling hub page 44 1 Workshop Equipment 18 EN 4472 751 001 2015 11 ...

Page 19: ...rive page 102 Install right portal drive page 116 2 M20 x 1 5 5870 350 110 Connection plate Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88 Assemble right portal drive page 103 1 AA02 041 051 Driver tool Dismantling left portal drive page 48 Assemble left portal drive page 88 Assemble right portal drive page 103 1 AA01 311 408 Rapid gri...

Page 20: ...x 2 length of sleeve 125 mm AA02 049 488 Disassembly device Dismantling left portal drive page 48 1 5870 281 054 Eye nut Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88 Assemble right portal drive page 103 1 M105 x 1 5 5870 300 009 Extracting device Dismantling left portal drive page 48 Dismantle right portal drive page 58 Dismantle dif...

Page 21: ...pid grip Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 5870 300 035 Extracting device Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 5870 204 022 Locating pin Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88 Assemble right portal drive page 103 1 1 set 2 units M14 x 100 Worksho...

Page 22: ...m 58 mm 5870 300 003 Extracting device Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 AA01 305 639 removing tool Dismantling left portal drive page 48 1 Ø14 mm AA02 038 564 Disassembly device Dismantle right portal drive page 58 1 5873 002 025 Gripping device Dismantle differential page 68 1 M95 x 2 Workshop Equipment 22 EN 4472 751 001 2015 11 ...

Page 23: ...he drive page 86 1 AA00 640 418 Support fixture Remove input page 70 Install input page 74 Install shaft seal onto the drive page 86 1 5870 203 002 Power screwdriver Remove input page 70 Install input page 74 Install shaft seal onto the drive page 86 1 Torque multiplier Maximum output torque 3600 Nm 5870 240 002 Locking mechanism Remove input page 70 Install shaft seal onto the drive page 86 1 Wor...

Page 24: ...er Remove input page 70 2 5870 080 044 Press out device Remove input page 70 1 5873 002 051 Gripping device Remove input page 70 1 M95 x 2 5870 300 020 Extracting device Remove input page 70 1 5870 345 080 Assembly fixture Install input page 74 1 Workshop Equipment 24 EN 4472 751 001 2015 11 ...

Page 25: ...e page 88 Assemble right portal drive page 103 1 Length 160 mm 5870 056 008 Driver tool Install input page 74 1 5870 204 025 Locating pin Assemble differential page 79 1 1 set 2 units M14 x 1 5 x 85 AA02 015 690 Driver tool Assemble differential page 79 1 AA02 056 505 Pressure piece Assemble differential page 79 1 Workshop Equipment EN 4472 751 001 2015 11 25 ...

Page 26: ...checking axial run out and contact pattern page 81 1 Length 390 mm AA01 266 870 Load lifting equipment Setting backlash and differential bearing rolling torque and checking axial run out and contact pattern page 81 1 Ø 35 mm 46 mm AA02 060 628 Test device Setting backlash and differential bearing rolling torque and checking axial run out and contact pattern page 81 1 5870 048 216 Driver tool Insta...

Page 27: ...ble right portal drive page 103 1 5870 058 061 Driver tool Assemble left portal drive page 88 Assemble right portal drive page 103 1 5870 200 094 Measuring arbor Assemble left portal drive page 88 Assemble right portal drive page 103 1 5870 700 004 Load cell Assemble left portal drive page 88 Assemble right portal drive page 103 1 Measuring range 1 to 60 kN Workshop Equipment EN 4472 751 001 2015 ...

Page 28: ...no Assemble left portal drive page 88 Assemble right portal drive page 103 Install tachometer page 118 1 5870 610 010 Assembly fixture Assembling hub page 120 1 Use only in connection with insert 5870 610 002 Insert Assembling hub page 120 1 Use only in connection with assembly device M22 x 1 5 5870 050 007 Driver tool Assembling hub page 120 1 Workshop Equipment 28 EN 4472 751 001 2015 11 ...

Page 29: ...ge 120 1 Length 230 mm 5870 345 121 Support arbor Assembling hub page 120 1 AA00 607 922 Driver tool Assembling hub page 120 1 5870 651 085 Assembly aid Install hub page 124 1 5870 204 029 Locating pin Install hub page 124 1 1 set 2 units M18 x 1 5 x 105 Workshop Equipment EN 4472 751 001 2015 11 29 ...

Page 30: ...5870 203 030 Torque wrench 0 6 Nm to 6 0 Nm 5870 203 031 Torque wrench 1 0 Nm to 12 Nm 5870 203 032 Torque wrench 3 0 Nm to 23 Nm 5870 203 033 Torque wrench 5 0 Nm to 45 Nm 5870 203 034 Torque wrench 10 Nm to 90 Nm 5870 203 039 Torque wrench 80 Nm to 400 Nm 5870 203 016 Torque wrench 140 Nm to 750 Nm 5870 203 011 Torque wrench 750 Nm to 2 000 Nm 5870 203 048 Torque wrench 1 500 Nm to 3 000 Nm Fig ...

Page 31: ...100 mm 5870 970 002 Two armed extractor Jaw width 120 mm Throat depth 125 mm 5870 970 003 Two armed extractor Jaw width 170 mm Throat depth 125 mm 5870 970 004 Two armed extractor Jaw width 200 mm Throat depth 175 mm 5870 970 006 Two armed extractor Jaw width 350 mm Throat depth 250 mm 5870 970 007 Two armed extractor Jaw width 520 mm Throat depth 300 mm to 500 mm 5870 970 026 Two armed extractor ...

Page 32: ...width 295 mm Throat depth 235 mm 5870 971 005 Three armed extractor Jaw width 390 mm Throat depth 270 mm 5870 971 006 Three armed extractor Jaw width 640 mm Throat depth 300 mm Fig 9 5870 281 026 Lifting strap Load bearing capacity 500 kg Effective length 4 m Fig 10 AA02 000 695 Round sling Load bearing capacity 2 000 kg Effective length 2 m Fig 11 5870 281 047 Lifting chain Fig 12 5870 221 500 Ho...

Page 33: ...ig 13 5870 345 071 Pry bar Fig 14 5870 280 004 Plastic hammer 5870 280 006 Nylon insert Spare part Fig 15 5870 650 004 Striker Fig 16 5870 200 055 Magnetic holder Fig 17 5870 200 057 Dial gauge Workshop Equipment EN 4472 751 001 2015 11 33 ...

Page 34: ... Load bearing capacity min 1 500 kg Arbor press Manual operation Press force max 30 kN Hydraulic press Hydraulic actuation Tab 3 Other Equipment Comment Requirement Socket wrenches open end wrenches box wrenches hammers screw drivers pliers front cutting pliers Various sizes respectively in a set Commercial Sand paper In different grit sizes to clean surfaces Flat scraper For removal of sealing co...

Page 35: ...ll shaft seal onto the drive page 86 0666 690 078 Sealing compound Loctite 243 Threadlockers Assemble left portal drive page 88 Install mounting parts page 129 0666 790 037 Sealing compound Drei Bond Silikon Typ 1207 Install left portal drive page 102 0671 190 065 Silicone grease UNIREX N3 Install tachometer page 118 0671 190 180 Grease Renolit LX NHU 2 400 g package Install hub page 124 Workshop ...

Page 36: ...xture 5870 350 000 Assembly truck 1 Fix axle 1 with 5870 350 093 Fixture 2 to 5870 350 000 Assembly truck 3 Support axle from below 4 Fig 21 8 2 Drain oil Observe the environmental regulations see General safety instructions Dismantling 36 EN 4472 751 001 2015 11 ...

Page 37: ...il drain screw plugs 2 2 Remove screw plug oil filling 3 In case of the version with mounted breather slight overpressure can build up in the axle 3 Remove screw plug oil level 1 and O ring 4 Remove screw plugs oil drain 2 and O ring 5 Completely drain oil into the containers Dismantling EN 4472 751 001 2015 11 37 ...

Page 38: ...e the upper longitudinal control arm 2 Fig 23 2 Loosen hexagon screws 1 and remove the lower longitudinal control arm 2 Fig 24 3 Loosen hexagon nut 4 and remove disk 3 joint ring 2 and disk 1 4 Remove shock absorber 5 Fig 25 Dismantling 38 EN 4472 751 001 2015 11 ...

Page 39: ...ier 1 by means of lifting device 8 Loosen hexagon screws and remove spring carrier Fig 27 8 4 Removal of brake Special tools 5870 281 046 Load carrying fixture 5870 204 084 Eyebolt Observe the specifications of the brake manufacturer Dismantling EN 4472 751 001 2015 11 39 ...

Page 40: ... Tightening torque 20 Nm 5 Nm maximum loosening torque Fig 28 2 Loosen locknuts 3 Remove brake cylinder Fig 29 4 Remove rubber cap 5 Turn adjuster in counterclockwise direction manually until contact is obtained Fig 30 Dismantling 40 EN 4472 751 001 2015 11 ...

Page 41: ...acket 3 Fig 31 9 Remove brake lining set Fig 32 10 Fix brake caliper with 5870 281 046 Load carrying fixture 1 5870 204 084 Eyebolt 2 and crane 11 Loosen hexagon screws and fit bolt on the brake caliper 12 Remove brake caliper Fig 33 Dismantling EN 4472 751 001 2015 11 41 ...

Page 42: ...ls 5870 345 036 Pry bar 5870 401 146 Slotted nut wrench AA01 395 095 Load carrying fixture 1 Fix hub Loosen bolted connection of the flange shaft Fig 34 2 Pull out flange shaft with 5870 345 036 Pry bar and remove Fig 35 Dismantling 42 EN 4472 751 001 2015 11 ...

Page 43: ...ed nut with 5870 401 146 Slotted nut wrench 6 Remove retaining plate Fig 37 7 Use AA01 395 095 Load carrying fixture to fix the hub to the crane 8 Loosen slotted nut with 5870 401 146 Slotted nut wrench 9 Pull hub from the hub carrier Fig 38 Dismantling EN 4472 751 001 2015 11 43 ...

Page 44: ...8 5 2 Dismantling hub Special tools 5870 345 036 Pry bar 5870 100 069 Assembly fixture 1 Risk of crushing due to hydraulic tool Slight to moderate injury possible ð Do not reach into danger area Use press to fix hub 2 Loosen Torx screws 3 Remove hub Fig 40 Dismantling 44 EN 4472 751 001 2015 11 ...

Page 45: ...41 5 Use 5870 345 036 Pry bar to pull ABS ring out of the hub and remove it Fig 42 6 Remove retaining ring 1 7 Remove tapered roller bearing at the brake disk side from the hub Fig 43 Dismantling EN 4472 751 001 2015 11 45 ...

Page 46: ...g Fig 44 9 Press tapered roller bearing and shaft seal from the hub Fig 45 10 Risk of injury due to parts flying away Slight or moderate injury possible ð Wear protective goggles Force out bearing outer rings 11 Press wheel studs from the hub Fig 46 Dismantling 46 EN 4472 751 001 2015 11 ...

Page 47: ...6 Remove tachometer 1 Pull cable 1 out of the clamp 2 2 Remove clamp Fig 47 3 Push tachometer out of the hub carrier Fig 48 4 Push bush out of the hub carrier Fig 49 Dismantling EN 4472 751 001 2015 11 47 ...

Page 48: ...erate injury possible ð Secure parts against falling down Remove portal with differential and stub shaft Stub shaft can also be removed from the right side 3 Pull stub shaft out of the differential 4 Pull differential from portal 5 Remove two pieces AA00 844 345 Load ring 1 Fig 51 8 7 2 Dismantling left portal drive Special tools 5870 350 110 Connection plate 5870 350 000 Assembly truck AA02 041 0...

Page 49: ...vice 5873 012 013 Rapid grip 5870 300 035 Extracting device 5870 204 022 Locating pin 5870 300 007 Extracting device 5870 300 003 Extracting device AA01 305 639 removing tool 1 Fix portal drive with 5870 350 110 Connection plate to 5870 350 000 Assembly truck Fig 52 2 Remove retaining ring Fig 53 Dismantling EN 4472 751 001 2015 11 49 ...

Page 50: ...ip and 5873 002 001 Basic tool 6 Remove shim Fig 55 7 Slide AA02 049 488 Disassembly device onto the drive gear stub shaft 8 Tighten cylindrical screws of AA02 049 488 Disassembly device evenly Tightening torque 68 Nm 9 Use AA02 049 488 Disassembly device and a two armed puller to pull the drive gear out of the portal housing Fig 56 Dismantling 50 EN 4472 751 001 2015 11 ...

Page 51: ...10 Remove parts from the drive gear Fig 57 11 Loosen Torx screws and remove hub carrier with 5870 281 054 Eye nut Fig 58 12 Remove O ring 1 Fig 59 Dismantling EN 4472 751 001 2015 11 51 ...

Page 52: ... Extracting device to pull the bearing inner ring out of the hub carrier Fig 60 14 Use a three armed puller to pull the screen sheet from the hub carrier Fig 61 15 Remove the output gear from the portal housing Fig 62 Dismantling 52 EN 4472 751 001 2015 11 ...

Page 53: ...grip to pull both tapered roller bearings from the output gear Fig 63 17 Pull bearing outer ring 1 with 5870 300 035 Extracting device out of the portal housing 18 Remove shim Fig 64 19 Loosen cylindrical screw Fig 65 Dismantling EN 4472 751 001 2015 11 53 ...

Page 54: ... Force out and remove bearing bolt Fig 66 22 Remove O rings 1 Fig 67 23 Hold shaft washer axial roller cage and disk 1 24 Push tapered roller bearing 2 and intermediate gear outwards and remove the releasing parts 1 Fig 68 Dismantling 54 EN 4472 751 001 2015 11 ...

Page 55: ...ight or moderate injury possible ð Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 70 27 Loosen cylindrical screw on the bearing bolt 28 Bolt in 5870 204 022 Locating pin at the bearing bolt 29 Force out and remove bearing bolt Fig 71 Dismantling EN 4472 751 001 2015 11 55 ...

Page 56: ...oller bearing and intermediate gear Fig 73 32 Risk of injury due to parts flying away Slight or moderate injury possible ð Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 74 Dismantling 56 EN 4472 751 001 2015 11 ...

Page 57: ...ust washers out of the portal housing Fig 75 34 Use AA01 305 639 removing tool to loosen the stud bolts Fig 76 8 8 Remove breather 1 Open hose clamp 1 2 Pull corrugated hose and hose 2 from the breather neck 3 Loosen Torx screws 3 and remove breather Fig 77 Dismantling EN 4472 751 001 2015 11 57 ...

Page 58: ...e injury possible ð Secure parts against falling down Remove portal and stub shaft Stub shaft can also be removed from the left side 3 Pull stub shaft from the portal 4 Remove two pieces AA00 844 345 Load ring 1 5 Remove O ring 2 Fig 79 8 9 2 Dismantle right portal drive Special tools 5870 350 110 Connection plate 5870 350 000 Assembly truck AA02 038 564 Disassembly device 5870 281 054 Eye nut 587...

Page 59: ...rip 5870 300 035 Extracting device 5870 204 022 Locating pin 5870 300 007 Extracting device 5870 300 003 Extracting device 1 Fix portal drive with 5870 350 110 Connection plate to 5870 350 000 Assembly truck Fig 80 2 Remove O ring 1 Fig 81 Dismantling EN 4472 751 001 2015 11 59 ...

Page 60: ...ing ring Fig 82 4 Insert three piece tool of AA02 038 564 Disassembly device into the bush Fig 83 5 Push bush of AA02 038 564 Disassembly device onto the three piece tool Fig 84 Dismantling 60 EN 4472 751 001 2015 11 ...

Page 61: ...y into the three piece tool 7 Hold spindle of AA02 038 564 Disassembly device Turn hexagon nut and pull bush out of the portal housing Fig 85 8 Remove drive gear and individual parts Fig 86 9 Remove retaining ring Fig 87 Dismantling EN 4472 751 001 2015 11 61 ...

Page 62: ...with 5870 281 054 Eye nut Fig 88 11 Remove O ring 1 Fig 89 12 Use 5870 300 009 Extracting device and 5870 300 019 Extracting device to pull the bearing inner ring out of the hub carrier 13 Remove shim Fig 90 Dismantling 62 EN 4472 751 001 2015 11 ...

Page 63: ...eet from the hub carrier Fig 91 15 Remove the output gear from the portal housing Fig 92 16 Use 5873 002 001 Basic tool and 5873 012 013 Rapid grip to pull both tapered roller bearings from the output gear Fig 93 Dismantling EN 4472 751 001 2015 11 63 ...

Page 64: ...870 300 035 Extracting device out of the portal housing Fig 94 18 Loosen cylindrical screw Fig 95 19 Bolt in 5870 204 022 Locating pin at the bearing bolt 20 Force out and remove bearing bolt Fig 96 Dismantling 64 EN 4472 751 001 2015 11 ...

Page 65: ... washer axial roller cage and disk 2 23 Push tapered roller bearing 1 and intermediate gear outwards and remove the releasing parts 2 Fig 98 24 Remove tapered roller bearing and intermediate gear Fig 99 Dismantling EN 4472 751 001 2015 11 65 ...

Page 66: ...ssible ð Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 100 26 Loosen cylindrical screw Fig 101 27 Bolt in 5870 204 022 Locating pin at the bearing bolt 28 Force out and remove bearing bolt Fig 102 Dismantling 66 EN 4472 751 001 2015 11 ...

Page 67: ...oller bearing and intermediate gear Fig 104 31 Risk of injury due to parts flying away Slight or moderate injury possible ð Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 105 Dismantling EN 4472 751 001 2015 11 67 ...

Page 68: ... 106 8 10 Dismantle differential Special tools 5873 002 025 Gripping device 5873 002 001 Basic tool 5870 300 009 Extracting device 5870 300 019 Extracting device AA02 015 365 Fixing spider 1 Use 5873 002 025 Gripping device and 5873 002 001 Basic tool to pull off the tapered roller bearing Fig 107 Dismantling 68 EN 4472 751 001 2015 11 ...

Page 69: ...Extracting device and AA02 015 365 Fixing spider to pull the bearing outer ring out of the differential Fig 108 3 Fix differential Loosen locking screws Fig 109 4 Press differential out of the crown wheel Fig 110 Dismantling EN 4472 751 001 2015 11 69 ...

Page 70: ...ver 5870 240 002 Locking mechanism 5870 400 001 Offset screwdriver 5870 080 044 Press out device 5873 002 051 Gripping device 5873 002 001 Basic tool 5870 300 019 Extracting device 5870 300 020 Extracting device 1 Use AA02 016 086 Plug insert AA00 640 418 Support fixture and 5870 203 002 Power screwdriver to loosen the double hexagon nut Fig 112 Dismantling 70 EN 4472 751 001 2015 11 ...

Page 71: ...he input flange with a three armed puller from the pinion Fig 113 3 Press screen sheet from the input flange Fig 114 4 Use 5870 400 001 Offset screwdriver to remove the shaft seal from the axle housing Fig 115 Dismantling EN 4472 751 001 2015 11 71 ...

Page 72: ...ress the pinion out of the tapered roller bearing and remove it Fig 116 6 Remove ring Fig 117 7 Use 5873 002 051 Gripping device and 5873 002 001 Basic tool to pull off the tapered roller bearing Fig 118 Dismantling 72 EN 4472 751 001 2015 11 ...

Page 73: ...g 119 9 Use a suitable plate and 5870 080 044 Press out device to press the bearing outer ring out of the housing 10 Remove shim Fig 120 11 Risk of injury due to parts flying away Slight or moderate injury possible ð Wear protective goggles Force breather neck out of the axle housing Fig 121 Dismantling EN 4472 751 001 2015 11 73 ...

Page 74: ...8 Support fixture 5870 203 002 Power screwdriver 1 Read dimension U 1 from the axle housing Dimension U e g 201 20 mm Fig 122 2 Compare mating number 1 e g 17 with mating number on the crown wheel Both mating numbers must be identical 3 Read pinion distance deviation 2 Pinion distance deviation A e g 5 0 05 mm Fig 123 Assembly 74 EN 4472 751 001 2015 11 ...

Page 75: ... Calculation example s U A B C s 201 20 mm 0 05 mm 150 mm 50 05 mm s 1 1 mm Fig 125 8 Carry out the following two work steps immediately one after the other Risk of burn injuries due to contact with cold surface Slight to moderate injury possible ð Wear protective gloves Undercool the bearing outer ring 9 Insert the bearing outer ring into the axle housing until contact is obtained Fig 126 Assembl...

Page 76: ...derate injury possible ð Wear protective gloves Undercool the bearing outer ring 1 12 Insert bearing outer ring 1 into axle housing until contact is obtained Fig 127 13 Use 5870 345 080 Assembly fixture to bring both bearing outer rings into contact position Fig 128 14 Press on the bearing inner ring until contact with the pinion is obtained Fig 129 Assembly 76 EN 4472 751 001 2015 11 ...

Page 77: ...at tapered roller bearing 17 Insert pinion into the axle housing from inside Slide the heated tapered roller bearing onto the pinion until contact is obtained Fig 131 18 If available insert the hexagon screws into the input flange 19 Use 5870 260 002 Handle and 5870 056 008 Driver tool to press the screen sheet onto the input flange Fig 132 Assembly EN 4472 751 001 2015 11 77 ...

Page 78: ...disassembly Tightening torque 1 000 Nm Fig 134 23 Rotate pinion several times in both directions 24 Check the necessary pinion bearing rolling torque 4 Nm 10 Nm 25 If the rolling torque is too small retighten the double hexagon nut until the necessary rolling torque is reached Tightening torque 1 000 Nm 1 700 Nm In case of an insufficient rolling torque install a thinner ring In case of an excessi...

Page 79: ...n wheel Both mating numbers must be identical 2 Note ideal backlash 1 e g 0 22 mm Fig 136 3 Bolt in two pieces 5870 204 025 Locating pin into the crown wheel 4 Risk of burn injuries due to contact with hot surfaces Slight or moderate injury possible ð Wear protective gloves Heat crown wheel 5 Slide crown wheel onto the differential until contact is obtained Fig 137 Assembly EN 4472 751 001 2015 11...

Page 80: ...hten crosswise Tightening torque 250 Nm Fig 138 7 Insert bearing outer ring with AA02 015 690 Driver tool and 5870 260 002 Handle until contact is obtained Fig 139 8 Press in bearing inner ring with AA02 056 505 Pressure piece until contact is obtained Fig 140 Assembly 80 EN 4472 751 001 2015 11 ...

Page 81: ...m with s e g 1 mm into the axle housing 2 Use 5870 058 070 Driver tool and 5870 260 003 Handle to insert the bearing outer ring Fig 141 3 Cover several drive and coast flanks on the crown wheel with marking ink 4 Risk of crushing due to moving load Slight or moderate injury possible ð Move load slowly and carefully ð Do not reach into danger area Use AA01 266 870 Load lifting equipment to insert t...

Page 82: ...Nm 9 Turn pinion Speed 50 1 min Duration always left and right 15 s Fig 144 10 Place dial gauge at right angled surface of a hexagon screw at the differential 11 Backlash bevel gear set e g 0 22 mm 0 04 mm Check see Reassemble differential If the required backlash is not reached replace the disk as specified below In case of an insufficient backlash install a thicker shim In case of an excessive b...

Page 83: ...the front face of the AA02 060 628 Test device to the front face of the bearing inner ring Measure distance of each hole and calculate average Distance A e g 59 44 mm Fig 147 15 Remove AA02 060 628 Test device 16 Use AA01 266 870 Load lifting equipment to remove the differential from the axle housing 17 Check contact pattern See Check contact pattern Correct deviations from the contact pattern If ...

Page 84: ...nting face of the portal housing to the contact face of the bearing inner ring Distance C e g 26 26 mm 21 Calculate shim thickness for Differential bearing rolling torque 4 Nm 7 Nm Calculation example s Distance C Distance X s 26 26 mm 25 26 mm s 1 00 mm Fig 149 22 Slide the calculated shim 2 onto the bearing seat 23 Risk of burn injuries due to contact with hot surfaces Slight or moderate injury ...

Page 85: ...everal times into both directions 31 Check total rolling torque Total rolling torque at axle ratio i 7 38 Total rolling torque Pinion bearing rolling torque 2 Nm 1 Nm Total rolling torque at axle ratio i 7 38 Total rolling torque Pinion bearing rolling torque 1 5 Nm 0 5 Nm If the required rolling torque is not achieved replace the disk as specified below In case of an insufficient rolling torque i...

Page 86: ...ver tool Operating supplies and auxiliary materials 0666 690 191 Spirit 0666 690 313 Sealing compound 1 Use AA02 016 086 Plug insert AA00 640 418 Support fixture and 5870 203 002 Power screwdriver to loosen the double hexagon nut Fig 152 2 Use 5870 240 002 Locking mechanism to pull the input flange with a three armed puller from the pinion Fig 153 Assembly 86 EN 4472 751 001 2015 11 ...

Page 87: ...0 313 Sealing compound onto the thread Use AA02 016 086 Plug insert AA00 640 418 Support fixture and 5870 203 002 Power screwdriver to tighten the double hexagon nut Tightening torque 1 000 Nm Fig 155 6 Rotate pinion several times in both directions 7 Check the necessary Pinion bearing rolling torque 4 5 Nm 10 5 Nm 8 If the rolling torque is too small retighten the double hexagon nut until the nec...

Page 88: ...dle 5870 058 061 Driver tool 5870 200 094 Measuring arbor 5870 204 022 Locating pin AA02 041 051 Driver tool 5870 700 004 Load cell AA00 372 127 Driver tool 5870 281 054 Eye nut AA00 387 830 Pressing fixture no Operating supplies and auxiliary materials 0666 690 078 Sealing compound 1 Use 5870 350 110 Connection plate to fix the portal housing to 5870 350 000 Assembly truck Fig 157 Assembly 88 EN ...

Page 89: ...l housing Tightening torque 33 Nm Fig 158 4 Use AA02 041 179 Driver tool and 5870 260 002 Handle to insert the bushes thrust washers into the portal housing Fig 159 5 In case of used bearings always allocate the bearing inner rings to the respective bearing outer rings Slide the tapered roller bearing onto the bearing bolt Fig 160 Assembly EN 4472 751 001 2015 11 89 ...

Page 90: ...02 Handle to insert the bearing inner rings into the intermediate gear Fig 161 7 Put the intermediate gear onto the tapered roller bearing Fig 162 8 Slide the tapered roller bearing onto the bearing bolt Fig 163 Assembly 90 EN 4472 751 001 2015 11 ...

Page 91: ...ar with a pry bar and check the necessary setting of the intermediate gear bearing 0 01 mm preload 0 05 mm clearance If the required axial play is not reached replace the shim as specified below In case of an insufficient axial play install a thicker shim In case of an excessive axial play install a thinner shim 13 Mark the installation position of the individual parts 14 Dismantle the individual ...

Page 92: ...into the intermediate gear 18 Place intermediate gear and tapered roller bearing onto a bush thrust washer in the portal housing Fig 167 19 Grease O rings 1 and insert them into the annular grooves 20 Glue the determined shim 2 with grease onto the bearing bolt 21 Bolt 5870 204 022 Locating pin 3 into the bearing bolt Fig 168 Assembly 92 EN 4472 751 001 2015 11 ...

Page 93: ... Locating pin Fig 169 24 Fix bearing bolt with a cylindrical screw Tightening torque 185 Nm Fig 170 25 Set the bearing of the second intermediate gear as illustrated 26 Insert the tapered roller bearing into the portal housing 27 Insert the intermediate gear into the portal housing Fig 171 Assembly EN 4472 751 001 2015 11 93 ...

Page 94: ... to wrong arrangement of the parts possible ð Observe installation position of the individual parts Put the roller cage onto the shaft washer Radius or chamfer on the internal diameter of the shaft washer must be opposite of the roller cage Fig 173 31 Place disk with radius or chamfer on the outer diameter showing upwards onto the roller cage Fig 174 Assembly 94 EN 4472 751 001 2015 11 ...

Page 95: ...housing 1 and hold them 34 Place tapered roller bearing and intermediate gear 2 in such a way that the stacked parts are fixed in the hole 1 Fig 176 35 Grease O rings 1 and insert them into the annular grooves 36 Glue the determined shim 2 with grease onto the bearing bolt 37 Bolt 5870 204 022 Locating pin 3 into the bearing bolt Fig 177 Assembly EN 4472 751 001 2015 11 95 ...

Page 96: ...g 178 40 Fix bearing bolt with a cylindrical screw Tightening torque 185 Nm Fig 179 41 Place shaft washer 4 onto the drive gear 42 Place the axial roller cage 3 onto the drive gear 43 Place disk 2 onto the drive gear 44 Place cup spring 1 with the concave side showing downwards onto the drive gear Fig 180 Assembly 96 EN 4472 751 001 2015 11 ...

Page 97: ... at the edges 1 47 Place the bush 2 with the groove showing downwards onto the portal housing 48 Risk of crushing due to hydraulic tool Slight to moderate injury possible ð Do not reach into danger area Press the bush 2 with max 60 kN by using AA02 041 051 Driver tool 3 and 5870 700 004 Load cell 4 into the housing Fig 182 49 Insert retaining ring Fig 183 Assembly EN 4472 751 001 2015 11 97 ...

Page 98: ...the lower bearing outer ring and onto the upper bearing outer ring 53 Measure total height of output gear tapered roller bearing and rings Total height A e g 165 05 mm Fig 185 54 Measure height of the rings Total height of the rings B e g 30 00 mm 55 Calculate total height of output gear and tapered roller bearing Calculation example C A B C 165 05 mm 30 00 mm C 135 05 mm Fig 186 Assembly 98 EN 44...

Page 99: ...g 44 68 mm 58 Calculate thickness s of the shim Calculation example s Housing depth D Dimension F Total height output gear and tapered roller bearing C s 180 83 mm 44 68 mm 135 05 mm s 1 1 mm Fig 188 59 Insert the determined shim 60 Use AA00 372 127 Driver tool and 5870 260 002 Handle to insert the bearing outer ring Fig 189 Assembly EN 4472 751 001 2015 11 99 ...

Page 100: ...70 260 002 Handle to insert the bearing outer ring Fig 190 62 Place the output gear into the portal housing Fig 191 63 Grease the O ring and insert it into the annular groove on the hub carrier 1 Fig 192 Assembly 100 EN 4472 751 001 2015 11 ...

Page 101: ...Nm Fig 194 66 Put the screen sheet onto the hub carrier 67 Align the recess of the screen sheet on the boss of the hub carrier 68 Align the recess of the AA00 387 830 Pressing fixture no on the boss of the hub carrier 69 Use AA00 387 830 Pressing fixture no to force the screen sheet onto the hub carrier Fig 195 Assembly EN 4472 751 001 2015 11 101 ...

Page 102: ...oderate injury possible ð Move load slowly and carefully ð Do not reach into danger area Slide differential onto the drive gear 2 Apply 0666 790 037 Sealing compound 1 onto the portal housing 3 Grease O ring 2 and insert it into the annular groove on the portal housing Fig 196 4 Bolt in two pieces AA00 844 345 Load ring 1 onto the portal housing Fig 197 Assembly 102 EN 4472 751 001 2015 11 ...

Page 103: ...l drive 9 6 1 Assemble right portal drive Special tools 5870 350 110 Connection plate 5870 350 000 Assembly truck AA02 041 179 Driver tool 5870 260 002 Handle 5870 058 061 Driver tool 5870 700 004 Load cell 5870 200 094 Measuring arbor 5870 204 022 Locating pin AA02 041 051 Driver tool AA00 372 127 Driver tool 5870 281 054 Eye nut AA00 387 830 Pressing fixture no 1 Use 5870 350 110 Connection plat...

Page 104: ...es thrust washers into the portal housing Fig 200 3 Slide the tapered roller bearing onto the bearing bolt Fig 201 4 Use 5870 058 061 Driver tool and 5870 260 002 Handle to insert the bearing inner rings into the intermediate gear Fig 202 Assembly 104 EN 4472 751 001 2015 11 ...

Page 105: ...rmediate gear onto the tapered roller bearing Fig 203 6 Slide the tapered roller bearing onto the bearing bolt Fig 204 7 Put shim with e g s 2 80 mm onto the bearing bolt Fig 205 Assembly EN 4472 751 001 2015 11 105 ...

Page 106: ... bearing 0 01 mm preload 0 05 mm clearance If the required axial play is not reached replace the shim as specified below In case of an insufficient axial play install a thicker shim In case of an excessive axial play install a thinner shim 11 Mark the installation position of the individual parts 12 Dismantle the individual parts Fig 206 13 Insert the tapered roller bearing into the portal housing...

Page 107: ... 17 Grease O rings 1 and insert them into the annular grooves 18 Glue the determined shim 2 with grease onto the bearing bolt 19 Bolt 5870 204 022 Locating pin 3 into the bearing bolt Fig 209 20 Slide the bearing bolt into the portal housing and fix intermediate gear and tapered roller bearing 21 Remove 5870 204 022 Locating pin Fig 210 Assembly EN 4472 751 001 2015 11 107 ...

Page 108: ...ated 24 Insert the tapered roller bearing into the portal housing 25 Insert the intermediate gear into the portal housing Fig 212 26 Insert the tapered roller bearing into the intermediate gear 27 Place intermediate gear and tapered roller bearing onto a bush thrust washer in the portal housing Fig 213 Assembly 108 EN 4472 751 001 2015 11 ...

Page 109: ... shaft washer Radius or chamfer on the internal diameter of the shaft washer must be opposite of the roller cage Fig 214 29 Place disk with radius or chamfer on the outer diameter showing upwards onto the roller cage Fig 215 30 Place cup spring with the concave side showing downwards onto the disk Fig 216 Assembly EN 4472 751 001 2015 11 109 ...

Page 110: ...in the 2 hole are fixed Fig 217 33 Grease O rings 1 and insert them into the annular grooves 34 Glue the determined shim 2 with grease onto the bearing bolt 35 Bolt 5870 204 022 Locating pin 3 into the bearing bolt Fig 218 36 Slide the bearing bolt into the portal housing and fix intermediate gear and tapered roller bearing 37 Remove 5870 204 022 Locating pin Fig 219 Assembly 110 EN 4472 751 001 2...

Page 111: ... gear Thereby the retaining ring in the drive gear must show downwards 41 Place the axial roller cage 3 onto the drive gear 42 Place disk 2 onto the drive gear 43 Place cup spring 1 with the concave side showing downwards onto the drive gear 44 Push drive gear and individual parts into the portal housing Fig 222 Assembly EN 4472 751 001 2015 11 111 ...

Page 112: ...ing 47 Risk of crushing due to hydraulic tool Slight to moderate injury possible ð Do not reach into danger area Press the bush 2 with max 60 kN by using AA02 041 051 Driver tool 3 and 5870 700 004 Load cell 4 into the housing Fig 223 48 Insert retaining ring Fig 224 49 Press bearing outer rings onto the output gear Fig 225 Assembly 112 EN 4472 751 001 2015 11 ...

Page 113: ...re total height of output gear tapered roller bearing and rings Total height A e g 165 05 mm Fig 226 53 Measure height of the rings Total height of the rings B e g 30 00 mm 54 Calculate total height of output gear and tapered roller bearing Calculation example C A B C 165 05 mm 30 00 mm C 135 05 mm Fig 227 55 Measure dimension from mounting face to hole bottom Housing depth e g 180 83 mm Fig 228 A...

Page 114: ... F Total height output gear and tapered roller bearing C s 180 83 mm 44 68 mm 135 05 mm s 1 1 mm Fig 229 58 Insert the determined shim 59 Use AA00 372 127 Driver tool and 5870 260 002 Handle to insert the bearing outer ring Fig 230 60 Use AA00 372 127 Driver tool and 5870 260 002 Handle to insert the bearing outer ring Fig 231 Assembly 114 EN 4472 751 001 2015 11 ...

Page 115: ...portal housing Fig 232 62 Grease the O ring and insert it into the annular groove on the hub carrier 1 Fig 233 63 Place hub carrier with 5870 281 054 Eye nut and crane onto the portal housing Fig 234 Assembly EN 4472 751 001 2015 11 115 ...

Page 116: ...he screen sheet on the boss of the hub carrier 67 Align the recess of the AA00 387 830 Pressing fixture no on the boss of the hub carrier 68 Use AA00 387 830 Pressing fixture no to force the screen sheet onto the hub carrier Fig 236 9 6 2 Install right portal drive Special tools AA00 844 345 Load ring Assembly 116 EN 4472 751 001 2015 11 ...

Page 117: ...ing and bring the portal housing into contact position with the axle housing Fig 237 5 Support axle from below 1 6 Fix portal drive with Torx screws Tightening torque 185 Nm Fig 238 9 7 Install breather neck 1 Push the breather neck into the hole on the axle housing so that an edge of the hexagon is parallel to the portal housing 2 Risk of injury due to parts flying away Slight or moderate injury ...

Page 118: ...amp 1 onto the hose 3 Push the hose 2 onto the breather neck 4 Secure hose 2 with hose clamp 1 Fig 240 9 9 Install tachometer Special tools AA00 387 830 Pressing fixture no Operating supplies and auxiliary materials 0671 190 065 Silicone grease 1 Push bush 1 into the hub carrier Fig 241 Assembly 118 EN 4472 751 001 2015 11 ...

Page 119: ...tact face of the compact bearing Fig 242 4 Align the recess of the AA00 387 830 Pressing fixture no on the boss of the hub carrier Push AA00 387 830 Pressing fixture no slowly until contact position with the hub carrier and position the tachometer Fig 243 5 Push the clamp 2 into the hole on the screen sheet until engagement of the securing clips 6 Push the cable 1 into the clamp 2 Fig 244 Assembly...

Page 120: ...port arbor AA00 607 922 Driver tool 1 Use the tools only with hubs where wheel studs have already been installed Use 5870 610 010 Assembly fixture and 5870 610 002 Insert to install the wheel studs Fig 245 2 Use 5870 050 007 Driver tool and 5870 260 004 Handle to press both bearing outer rings into the hub until contact is obtained Fig 246 Assembly 120 EN 4472 751 001 2015 11 ...

Page 121: ...inner ring and bearing cage 40_020226_01 1 2 3 4 Fig 247 1 Grease 2 O ring 3 Retaining ring 4 Compact bearing consisting of two individual tapered roller bearings 4 Place bearing inner ring at the brake disk side onto 5870 345 121 Support arbor 5 Insert the retaining ring into the bearing inner ring at the brake disk side Fig 248 Assembly EN 4472 751 001 2015 11 121 ...

Page 122: ...inner ring into the hub Fig 249 8 Press the outer bearing inner ring slowly downwards until engagement of the retaining ring is audible 9 Rotate hub several times in both directions Fig 250 10 Check whether the retaining ring 1 is completely engaged Fig 251 Assembly 122 EN 4472 751 001 2015 11 ...

Page 123: ... the shaft seal at the brake disk side Fig 253 13 Put hub onto the brake disk 14 Risk of crushing due to hydraulic tool Slight to moderate injury possible ð Do not reach into danger area Use press to fix hub 15 Screw in Torx screws and tighten Tightening torque 270 Nm Fig 254 Assembly EN 4472 751 001 2015 11 123 ...

Page 124: ...85 Assembly aid AA01 395 095 Load carrying fixture 5870 401 146 Slotted nut wrench 5870 204 029 Locating pin Operating supplies and auxiliary materials 0671 190 180 Grease 1 Push 5870 651 085 Assembly aid 1 into the hub carrier 2 Apply 0671 190 180 Grease evenly onto both bearing seats 2 Fig 256 Assembly 124 EN 4472 751 001 2015 11 ...

Page 125: ...ch Tightening torque 100 Nm 7 Rotate hub several times in both directions 8 Tighten slotted nut with 5870 401 146 Slotted nut wrench Tightening torque 850 Nm 9 Mount locking plate with the tab showing inwards onto the hub carrier Fig 257 10 Bolt on slotted nut with the chamfer showing inwards 11 Tighten slotted nut with 5870 401 146 Slotted nut wrench Tightening torque 1 200 Nm Fig 258 Assembly EN...

Page 126: ...e 1 Fig 259 13 Grease O ring 1 and insert it into the annular groove on the flange shaft Fig 260 14 Bolt two pieces 5870 204 029 Locating pin into the hub 15 Push flange shaft into the hub carrier Fig 261 Assembly 126 EN 4472 751 001 2015 11 ...

Page 127: ...yebolt Observe the specifications of the brake manufacturer 1 Use 5870 281 046 Load carrying fixture 1 5870 204 084 Eyebolt 2 and crane to place the brake caliper onto the hub carrier brake carrier 2 Screw in fit bolt at the front in driving direction and tighten Tightening torque 270 Nm 3 Turn in hexagon screws and tighten Tightening torque 270 Nm Fig 263 Assembly EN 4472 751 001 2015 11 127 ...

Page 128: ... pin 2 into the opposite driving direction into the hole on the brake caliper 7 Push disk 1 onto pin 2 8 Fix pin 2 with spring split pin Fig 265 9 Mount brake cylinder with the connections showing backwards to the brake caliper 10 Fix brake cylinder with new locknuts Tightening torque 195 Nm 15 Nm Fig 266 Assembly 128 EN 4472 751 001 2015 11 ...

Page 129: ...ealing compound 1 Screw in two units 5870 204 044 Locating pin 2 Fix spring carrier 1 by means of lifting device 3 Push on spring carrier 1 and align in horizontal position 4 Manually bolt in two screws with disks into the axle 5 Remove two pieces 5870 204 044 Locating pin 6 Manually bolt in two screws with disks into the axle 7 Tighten hexagon screws Tightening torque 620 Nm Fig 268 Assembly EN 4...

Page 130: ...shock absorber 5 to the spring carrier 12 Push disk 1 joint ring 2 and disk 3 at the thread of the shock absorber 13 Fix shock absorber with hexagon nut 4 Tightening torque 70 Nm Fig 270 14 Horizontally suspend the lower longitudinal control arm 2 with the lifting device 15 Fix the lower longitudinal control arm 2 with hexagon screws 1 Tightening torque 390 Nm Fig 271 Assembly 130 EN 4472 751 001 ...

Page 131: ... the upper longitudinal control arm 2 with hexagon screws 1 Tightening torque 390 Nm Fig 272 9 13 Filling oil Observe the environmental regulations see General safety instructions Fig 273 1 Screw plug oil level 3 Screw plug oil fill 2 Screw plug oil drain Assembly EN 4472 751 001 2015 11 131 ...

Page 132: ...cant from the currently valid ZF List of Lubricants Slowly fill in oil at the oil filling hole until the bottom edge of the oil level hole 1 is reached 4 Check oil level after some minutes and correct if necessary 5 Screw in screw plug oil filling 3 and tighten Tightening torque 70 Nm 6 Turn in screw plug oil level 1 and tighten Tightening torque 70 Nm Assembly 132 EN 4472 751 001 2015 11 ...

Page 133: ...heel Fig 274 Ideal contact pattern Left Crown wheel convex drive side 1 Ideal contact pattern 3 Heel Right Crown wheel concave coast side 2 Toe The possible deviations and required correction measures are described in the following sections Testing Measuring Adjusting EN 4472 751 001 2015 11 133 ...

Page 134: ...the root Fig 275 Tooth root contact Left Crown wheel convex drive side 1 Contact pattern too close to the root 3 Heel Right Crown wheel concave coast side 2 Toe 1 Insert a thinner pinion distance disk on the drive 2 Setting backlash 3 Check contact pattern Testing Measuring Adjusting 134 EN 4472 751 001 2015 11 ...

Page 135: ...ds the tip Fig 276 Tooth tip contact Left Crown wheel convex drive side 1 Contact pattern too close at the tip 3 Heel Right Crown wheel concave coast side 2 Toe 1 Insert a thicker pinion distance disk on the drive 2 Setting backlash 3 Check contact pattern Testing Measuring Adjusting EN 4472 751 001 2015 11 135 ...

Page 136: ...11 Annex 11 1 Overview of revisions Index Date of issue Initiator Chapter Section Comment 11 2015 First edition Tab 5 Annex 136 EN 4472 751 001 2015 11 ...

Page 137: ......

Page 138: ...EN 4472 751 001 2015 11 ZF Friedrichshafen AG ZF Services Donaustraße 71 94034 Passau Deutschland Germany Telefon Phone 49 851 494 0 Telefax Fax 49 851 494 905 000 www zf com ...

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ZF AV 110, Repair Instructions

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Summary of Contents for AV 110

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