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1. A W ZR IS T SDLG ZF AP 410 DK Axle Service Manual Fig 3 107 1 Dial indicator Fig 3 108 1 Dial indicator Fig 3 109 1 Tension pin piece 2 Adjusting nut 1 piece ys 9 The dial indicator shall be so mounted that its contact is vertical to the tooth face of driven spiral bevel gear and is pressed at the outer edge The magnetic base of dial indicator shall be fixed on driving axle box body and keep relative rest with the box body to eliminate the error 10 Slightly shake left and right the driven spiral bevel gear and then use the dial indicator to measure the backlash of driving and driven spiral bevel gears Generally three points shall be measured and the measured value shall be 0 20 0 35 mm K CAUTION When shaking the driven spiral bevel gear it is necessary to maintain the driving spiral bevel gear immobile to avoid the occurrence of error 11 If the measured value is less than the specified value rotate the adjusting nuts at two sides to make the driven spiral bevel gear leave from the driving spiral bevel gear Contrarily make the former approach to the latter amp CAUTION In order to maintain the adjusted pretension of bearing the screwing in turns of adjusting nut at one end shall be equal to the screwing out turns at the other side A W ZR IS T SDLG ZF AP 410 DK Axle Service Manual Fig 3 110 1 Red lead powder Fig 3 111 54 12 Apply the
2. different speed Tere converter Front axle Rear axle a3 Fl As fs r gt Ange E3 3 i h AA 2 gt Limited slip Parking Limited slip l differential brake differential Wet brake EP C D C D Fig 2 1 Position drawing of driving axle 2 2 Structure and performance parameter of ZF axle ZF ZF Friedrichshafen AP 400 series driving axles have many advantages Firstly it benefits from limited slip differential to play an outstanding role in helping vehicle out of difficulty reducing tire abrasion and improving working efficiency Additionally it is not larger than the conventional differential It can be installed as required and needs no special maintenance Secondly with wet brake it is characterized by easy maintenance long service life and high ground clearance Because of such advantages ZF axle has been widely applied to non road machinery A WRIS I ZF AP 410 DK Axle Service Manual 2 2 1 Structure and performance parameter of assembly Each assembly of ZF axle is as shown in Fig 2 2 and its performance is as shown in Table 2 1 1 2 3 4 9 Fig 2 2 ZF driving axle assembly 1 Wheel reducer 2 Wet brake 3 Axle shaft 4 Axle housing 5 Main actuator Table 2 1 Performance parameter of ZF axle Load Maximum static load t 21 8 25 0 Maximum dynamic load t 13 3 15 3 Output torque Normal Nem 81030 101140 Pe
3. Axle shaft gear 3 Di ifferential housing 4 Planet gear 5 Cross axle 6 Driven spiral bevel gear 2 3 2 Torque distribution The torque distribution of ordinary symmetrical bevel gear differential has following relation When the torque from final drive is taken as Mo the torque Mo is always evenly distributed onto left and right axle shaft gears if the planet gear doesn t revolve on its own axis namely Mi M2 M 2 When the two axle shaft gears rotate at different speed along same direction namely at differential speed the planet gear will revolve on the cross axle along the arrow n4 direction in Fig 2 4 if the left axle shaft rotating speed n is larger than the right axle shaft rotating speed nz On this account there is friction between planet gear hole and cross axle journal and between gear back and differential housing The direction of friction torque M on planet gear is reverse to that of its rotating speed n4 This friction torque respectively generates two peripheral forces F and Fp which are same quantitatively but reverse directionally on left and right axle shaft gears F reduces the torque M transferred on the left axle shaft rotating at a higher speed while Fz increases the torque M transferred on the right axle shaft rotating at a lower speed Therefore when the left and right driving wheels have speed difference M Mo M 2 M2 Mo M 2 The torque difference of left and right wheels is equal to the interna
4. 928 1237 550 700 680 850 825 1100 1120 1400 1160 1546 es ao 7142952 969 1293 1319 1759 1698 2259 1559 2079 952 1269 1293 1723 1759 2345 2259 3012 2923 3898 5 N mm A WRIST ZF AP 410 DK Axle Service Manual 0 1400 1650 1700 2000 2473 3298 2800 3350 4111 5481 1080 1606 2142 2181 2908 2968 3958 3812 5082 4933 6577 1 4 Table for bolt tightening torque and adjusting clearance of ZF driving axle Table 1 3 Table for bolt tightening torque and adjusting clearance of ZF driving axle Mounting position Part specification Bracket locking nut M14x1 5x40 Bracket connecting bolt 12 9 Wheel locking nut Wheel supporting axle bolt M18x60 10 9 Planet wheel carrier M14x40 10 9 connecting bolt Adjusting clearance of wheel Adjusting clearance of sun gear shaft A WRIST ZF AP 410 DK Axle Service Manual 2 Structure and principle of ZF driving axle 2 1 General description on driving axle The driving axle is located at the end of loader power train as shown in Fig 2 1 It is mainly composed of final drive differential axle shaft wheel reducer and axle housing Its function is to 1 transmit the torque from drive shaft to driving wheel to reduce the speed and increase the torque 2 change the transfer direction of torque via bevel gear pair of final drive 3 realize the differential function of wheels at two sides to ensure the inner and outer wheels can rotate at
5. 1 Disassembling of axle accessories 1 Remove the hollow bolt and seal gasket from grease pipe on front swinging bracket l 2 Fig 3 001 Tool Wrench 17 1 Hollow bolt 1 piece 2 Copper gasket 2 pieces 2 Remove the hollow bolt and seal gasket from grease pipe on rear swinging bracket 1 2 Fig 3 002 Tool Wrench 17 1 Hollow bolt 1 piece 2 Copper gasket 2 pieces ZF AP 410 DK Axle Service Manual 3 Use a screwdriver to remove screw washer and pipe clip from grease pipe and take off the grease pipe Fig 3 003 Tool Screwdriver 1 Pipe clip 2 pieces 2 Washer 4 pieces 3 Screw 4 pieces 4 Take apart the brake oil pipe joint and place an oil container under it Drain the brake fluid amp CAUTION It is necessary to use the iron made oil container other than plastic container to Fig 3 004 Tool Wrench 22 prevent polluting the oil The disassembled 1 Brake oil pipe joint shall be protected appropriately 5 Remove the pipe clip and other oil pipe fasteners amp Fig 3 005 Tool Wrench 10 1 Pipe clip 1 piece 2 Bolt 1 piece A WRIS I ZF AP 410 DK Axle Service Manual le Fig 3 006 Tool Wrench 22 1 Brake oil pipe 1 2 3 Fig 3 007 Tool Wrench 10 1 T joint 1 piece 2 Bolt 1 piece 3 Cushion block 1 piece le Fig 3 008 Tool Wrench 1 Bolt 4 pieces 6 Place an oil container under the oil pipe joint and remove the brake oil pipe Be sure to pr
6. during reassembling to prevent any sundries entering the reassembled body 2 Mount the gasket The raised part of gasket shall match with the oil groove to prevent the gasket rotating 3 Mount the cooper gasket with oil groove A LU Zax Hes E ZF AP 410 DK Axle Service Manual Fig 3 083 1 Force transfer pin 6 pieces Ji ie Fig 3 084 1 Driving friction plate 2 pieces Fig 3 085 1 Driven friction plate 2 pieces 4 Insert the force transfer pin into the groove of differential housing 5 Place a driving friction plate to ensure its key groove at outer edge can match with the force transfer pin 6 Place a driven friction plate Alternatively place the driving friction plate and driven friction plate till there are two driving friction plates and two driven friction plates 45 A LU Ze Hes E ZF AP 410 DK Axle Service Manual 7 Mount the thrust pressure plate to ensure its key groove can match with the force transfer pin 1 Fig 3 086 1 Thrust pressure plate 1 piece do 8 Mount the axle shaft gear to ensure its outer spline can match with the inner spline of driven friction plate Fig 3 087 1 Axle shaft gear 1 piece 9 Assemble two slotted shafts together with their grooves opposite Mount the planet gear on Slotted shaft with the small end of former inward l Fig 3 088 1 Slotted shaft 2 pieces 2 Planet gear 4 pieces bo 46 J W ZR IS I SDLG ZF
7. on planet carrier 3 Use the snap ring pliers to mount the snap ring 4 Mount the lock washer A LU SR tes E ZF AP 410 DK Axle Service Manual 5 Mount the planet carrier Be careful not to damage the O ring at planet carrier edge Planet carrier Fig 3 143 1 Planet carrier 1 piece 2 O ring piece 6 Tighten bolt diagonally and gradually 7 Screw thread sealant 1262 gt kom Tightening torque 193 257 Nem Fig 3 144 Tool Wrench 24 1 Bolt 18 pieces 3 2 6 Reassembling of front and rear swinging brackets 1 Mount the gasket in rear swinging bracket Fig 3 145 1 Gasket 1 piece 2 Rear swinging bracket 1 piece 66 A WRIST ZF AP 410 DK Axle Service Manual 2 Mount the rear swinging bracket on axle housing s Rear swinging bracket 1 Fig 3 146 1 Rear swinging bracket piece oa 3 Mount the gasket cushion block washer and bolt and tighten the bolt Ly kom Tightening torque 376 502 Nem 1 2 3 4 Fig 3 147 Tool Wrench 30 1 Bolt 4 pieces 2 Washer 4 pieces 3 Cushion block 1 piece 4 Gasket 1 piece 4 Clean the end cover apply little grease on paper gasket and align it with bolt hole and stick it on end cover Fig 3 148 1 End cap 1 piece 2 Gasket 1 piece 67 A WRIST ZF AP 410 DK Axle Service Manual Fig 3 149 Tool Wrench 18 1 Bolt 6 pieces 1 Fig 3 150 1 Front swinging bracket 1 piece Fig 3 151 Tool A
8. or lubrication Such abnormality shall be eliminated immediately to avoid the damage of relevant components 2 Reason and troubleshooting of heating of driving axle The reason why the driving axle heats can be considered from two aspects firstly the excessive heat is generated secondly the heat generated cannot give out immediately The main heat source of driving axle is the friction heat generated due to too small fit clearance between relative motion parts The fitting piece of driving axle includes bearing and gear so the basic heating reason of driving axle is too small bearing fit clearance or small gear backlash The main reason why the heat of driving axle and wheel reducer cannot give out is short of oil or bad oil quality On this account not only will the friction heat generated from driving axle not give out but also the friction heat of relative motion parts will largely increase due to dry friction We can determine the heating reason based on heating position For instance if the bearing heats we can determine that it may be caused by too small fit clearance if the whole driving axle housing heats this may be caused by abnormal gear engagement or shortage of oil At this time the gear oil as required shall be refilled 4 1 3 Oil leakage of driving axle 1 Symptom and danger The oil leakage of driving axle occurs at axle housing and wheel reducer and the oil mainly leaks from sealing junction plane The oil leakage
9. 051 Tool Screwdriver 1 Screw 4 pieces 23 Remove the exhaust valve and O ring l 2 Fig 3 052 Tool Wrench 1 Exhaust valve 1 piece 2 O ring piece 3 1 6 Disassembling of main actuator 1 Remove the fixing bolts from main actuator i Fig 3 053 Tool Wrench 21 1 Bolt 18 pieces 34 A USR ISE ZF AP 410 DK Axle Service Manual 2 Screw two M14 bolts in top thread hole and then use the wrench to tighten it downwards to push out the main actuator Fig 3 054 1 Bolt 2 pieces 3 Loosen the main actuator with crow bar to raise 1t out m s Main actuator Fig 3 055 1 Main actuator 1 piece 4 Place the main actuator at clean cushion protected properly Fig 3 056 35 A WRIST ZF AP 410 DK Axle Service Manual 5 Use a wrench to remove fixing bolt and gasket 1 2 Fig 3 057 Tool Wrench 24 1 Bolt 4 pieces 2 Gasket 4 pieces a 6 Remove the upper bearing seat K CAUTION Mark shall be made during disassembling to prevent mixing the bearing seats at two sides 1 Fig 3 058 1 Upper bearing seat 2 pieces E TP 1 7 Remove the adjusting nut l Fig 3 059 1 Adjusting nut 2 pieces 36 A WRIS I ZF AP 410 DK Axle Service Manual 8 Remove the bearing outer ring Fig 3 060 1 Bearing outer ring 2 pieces 9 Take off the differential 10 Remove the nut and take off the washer and input flange Fig 3 062 1 Nut 1 piece 2 Was
10. AP 410 DK Axle Service Manual 10 Mount the shaft journal of slotted shaft on V groove of thrust pressure plate to ensure the planet gear can engage with axle shaft gear Fig 3 089 11 Mount the planet gear at other side to ensure it can engage with planet gear 1 Fig 3 090 1 Axle shaft gear 1 piece 12 Mount the thrust pressure plate at other side to ensure the V groove can match with the shaft journal of slotted shaft and the key groove can be opposite to that on differential housing Fig 3 091 1 Thrust pressure plate 1 piece 47 ZF AP 410 DK Axle Service Manual 13 Insert the force transfer pin to the hole between differential housing and thrust pressure plate Fig 3 092 1 Force transfer pin 6 pieces 14 Mount a driven friction plate Fig 3 093 1 Driven friction plate 2 pieces 15 Mount a driving friction plate to ensure its key groove at outer edge can match with force transfer pin Alternatively place the driving friction plate and driven friction plate till there are two driving friction plates and two driven friction plates Fig 3 094 1 Driving friction plate 2 pieces 48 pu W RIS L ZF AP 410 DK Axle Service Manual 16 Mount the gasket on differential cover The raised part of gasket shall match with the groove on differential cover to prevent the gasket rotating 1 Fig 3 095 1 Gasket 1 piece 17 Mount the copper gasket with oil gro
11. ZFAP 410 DK Jka EAF ZFAP 410 DK Axle Service Manual UW 2 liS L SDLG AX wir ws SDLG ZF AP 410 DK Axle Service Manual Contents FOREWORD reagan scan E sees 1 TINTRODUC TION esevessccececcccssestesscccsconcecsvecsscesssenceceseuaaseescanceessussscasscencesesesaascescasceuss 2 WO OEM Y PRECAUTIONS crerrier irnia e e E NEE E EE 2 1 2 DESCRIPTION ON MARK AND SYMBOL o oo eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeens 4 1 3 TABLE FOR TIGHTENING TORQUE OF ORDINARY BOLT THREAD cccceeeeeeeeees 5 1 4 TABLE FOR BOLT TIGHTENING TORQUE AND ADJUSTING CLEARANCE OF ZF DRING AKEE aa A A tees 6 2 STRUCTURE AND PRINCIPLE OF ZF DRIVING AXLE oooossssssssssssscceeee 7 2 1 GENERAL DESCRIPTION ON DRIVING AXLE ssssssssseeeesesssssseseerrrressssseseerrrrresssse 7 2 2 STRUCTURE AND PERFORMANCE PARAMETER OF ZF AXLE cceseeeccceeeeeeccceees 7 2 2 1 Structure and performance parameter of assembly ccccccceeseeeeeeees 8 2S OPERATING PRINCIPER OP AF AXT E eeren ea EE EEEE EEEN 8 Zsolt IDI Pea INCI E AE A E E E EE 8 Zi Pe NOT OUC CIS COU OM A E E A oieceacannsers 10 2 3 3 Operating principle of limited slip differential cc eeeeeeeeeees 11 2 34 Pinciple of wet DEAK C asscensacesedaacssassesacsoodeestasicnssssondiwsese EN a Ei 15 3 DISASSEMBLING AND REASSEMBLING OF ZF DRIVING AXLE 17 3 1 DISASSEMBLING OF ZF DRIVING AXLE cccsscccccccceesseessnneceeeeeeeeeeseesesnaaeee
12. ak Nem 145850 182050 Brake torque Nem 39548 3 discs 52732 4 discs Wheel speed reduction ratio 6 353 6 353 2 3 Operating principle of ZF axle Firstly the following is the differential principle and torque distribution of ordinary driving axle 2 3 1 Differential principle The kinematic relation differential speed principle of each component in ordinary symmetrical bevel gear differential can be shown by Fig 2 3 The symmetrical bevel gear differential is a planet A WRIST ZF AP 410 DK Axle Service Manual gear mechanism The differential housing 3 is connected with the cross axle 5 to form planet carrier Because it is fixed together with the driven spiral bevel gear 6 the differential housing cross axle and driven spiral bevel gear enjoy a same rotary speed The differential is driving part and its angular speed is assumed as Wo while the axle shaft gears 1 and 2 are driven parts with their angular speed as and z respectively A and B are the engagement points of the planet gear 4 and the axle shaft gears 1 and 2 The planet gear center is C and the distance from the points A B and C to the differential rotating axis is r When the planet gear only revolves with planet carrier around differential rotating axis obviously those points A B and C at same radius r enjoy a same peripheral speed which is equal to or Then 0050 02 This shows the differential doesn t play any differential role and the axle shaft angular
13. ally Fz generates a reacting force F3 namely the reacting force of cross axle on thrust pressure plate to drive the thrust pressure plate to move outwards so as to press against the driving and driven friction plates After they are pressed the driving friction plate can drive the driven friction plate to realize the power output Fig 2 7 Stress analysis chart 1 When driving in a straight line the two axle shafts have no differential rotating speed and the torque is evenly distributed to two axle shafts There is no relative slippage between friction plates 13 A WRIST ZF AP 410 DK Axle Service Manual if no differential speed Due to the pressing force F3 the two thrust pressure plates press against their respective driving and driven friction plates at outer end At this time the torque is transited to axle shaft via two routes one is to transmit the most torque to axle shaft via cross axle planet gear and axle shaft gear and the other one is to transmit to axle shaft via differential housing force transfer pin and driving and driven friction plates The torque flow is as shown in Fig 2 8 a 2 When the wheel at one side slips on road surface take the rotating speed of differential housing as Wo the rotating speed of left side axle shaft gear as and the rotating speed of right side axle shaft gear as 2 Because the driving friction plate and differential housing are wedged together by force transfer pin the rotating spe
14. can not only cause the heating of driving axle and affect the performance but also result in the pollution on environment 2 Reason and troubleshooting of oil leakage of driving axle The oil leakage of driving axle is mainly caused by damaged sealing element or seal gasket 19 A WRIST ZF AP 410 DK Axle Service Manual In any oil leakage it is necessary to check the oil seal for aging crack or damage Do not extend the oil seal forcibly to avoid the occurrence of plastic deformation The oil seal is advisable to be dipped in the liquid with temperature equal to operating temperature before installed When installation the special tool and process shall be used 4 2 Maintenance of ZF driving axle 4 2 1 Inspection on oil level Park the vehicle horizontally and clean all the oil filler holes before inspection Drain oil after the vehicle runs for a period of time When opening the screw plug to drain oil much attentional shall be paid to the splashing hot oil Wheel oil level to check the oil level in wheel reducer rotate the hub till the words of OIL LEVEL are at horizontal position The oil level shall reach the position where the oil overflows from screw plug Axle body oil level the oil level shall reach the position where the oil overflows from the middle oil filler hole or screw plug hole Inspection after refilling it is necessary to refill oil till the specified oil level is maintained if the oil level lowers after s
15. d driving axle 4 2 6 Lubricating grease It is necessary to select the multipurpose lubricating grease such as lithium grease characterized by dropping point of 170 C class NLGI2 and good corrosion and water resistance and extrusion stability Apply the grease on grease nozzle once a week 4 2 7 Inspection on tightening torque It is necessary to check the tightening torque of connecting bolts between the driving axle and the frame drive shaft and wheel rim regularly The first inspection shall be done after 50 h of operation 78
16. d the inner side and outer side of axle shaft spline to avoid l Fig 3 028 incorrect installation during reassembling 1 Axle shaft 1 piece 4 Use a snap ring pliers to remove the snap ring l Fig 3 029 Tool Snap ring pliers 1 Snap ring piece 26 A LU 2a les I ZF AP 410 DK Axle Service Manual 5 Take off the end gasket l Fig 3 030 1 End gasket 1 piece 6 Take off the driving and driven friction plates Fig 3 031 1 Driven friction plate 3 pieces 2 Driving friction plate 3 pieces 7 Use a special tool to remove the slotted nut Fig 3 032 1 Slotted nut 1 piece 27 A WRIS I ZF AP 410 DK Axle Service Manual 1 Fig 3 033 1 Special tool 8 Use an inner gear ring puller to pull out the gear ring assembly Fig 3 034 1 Gear ring assembly 1 piece Fig 3 035 1 Inner gear ring puller 6399006949 2 Iron gasket 28 A LU SR les E ZF AP 410 DK Axle Service Manual 9 Remove the tension spring with iron hook and take off the slotted ring Fig 3 036 1 Slotted ring 1 piece 2 Iron hook piece 10 Take off the tension spring and the slotted ring at other side Fig 3 037 1 Tension ring 8 pieces 2 Ring groove piece 11 Knock at the special tool to pack out the bearing Fig 3 038 1 Special tool 2 Bearing piece 29 A UWUR lls ZF AP 410 DK Axle Service Manual 12 Take off the piston rear mounted seal ring and piston guid
17. e ring Fig 3 039 1 Piston 1 piece 2 Rear mounted seal ring 2 pieces 3 Piston guide ring 2 pieces 13 Pry out the elastic retainer ring l Fig 3 040 Tool Screwdriver 1 Elastic retainer ring piece 14 Knock at the tooling to pack out the spline hub Fig 3 041 1 Tooling 2 Spline hub 1 piece 30 ZF AP 410 DK Axle Service Manual 15 Knock at the hub to remove the hub Fig 3 042 1 Hub 1 piece 16 Take off the bearing outer ring Fig 3 044 1 Bearing outer ring piece 2 Bearing outer ring piece 1 Fig 3 043 1 Bearing outer ring puller 6399006951 l A WRIST ZF AP 410 DK Axle Service Manual 17 Take off the O ring and adjusting gasket ELUL Fig 3 045 1 O ring 1 piece 2 O ring 1 piece 3 Adjusting gasket 1 piece 18 Use the bearing inner ring puller to remove the bearing inner ring D T _ Fig 3 046 1 Bearing inner ring 1 piece 1 Fig 3 047 1 Bearing inner ring puller 6399006950 2 Iron gasket 32 A WRIS I ZF AP 410 DK Axle Service Manual 19 Remove the seal ring Fig 3 048 1 Seal ring 1 piece 20 Remove the dust cover Fig 3 049 1 Dust cover piece 21 Remove the bolt and wheel supporting axle 1 2 Fig 3 050 Tool Wrench 27 1 Wheel supporting axle piece 2 Bolt 14 pieces 33 A LU 2k les I ZF AP 410 DK Axle Service Manual 22 Remove the screw 1 Fig 3
18. e shaft gear 3 Thrust pressure plate 4 Driven friction plate 5 Driving friction plate 6 Force transfer pin 7 Differential housing 1 3 2 6 Limited slip differential 12 A WRIST ZF AP 410 DK Axle Service Manual 1 Driving spiral bevel gear 2 Driven spiral bevel gear 3 Driving and driven friction plates 4 Slotted shaft 5 Axle shaft gear 6 Thrust pressure plate 7 Differential housing 8 Planet gear 9 Force transfer pin When the differential operates its power transmission route is as follows the driving spiral bevel gear drives the driven spiral bevel gear to rotate Because the latter is fixed with the differential housing the differential housing is also driven to rotate The differential housing drives the thrust pressure plate and driving friction plate via force transfer pin while the thrust pressure plate V groove drives the cross axle to rotate When the planet gear on cross axle drives the axle shaft gear to rotate the power output occurs When the thrust pressure plate drives the cross axle to rotate as per the direction shown in the drawing the stress analysis is as shown in Fig 2 7 V groove applies a force F that is vertical to the inclined plane to cross axle This force can be divided into forces F and Fz of which F1 drives the cross axle assembly to rotate to transfer power outwards while F2 combines the thrust pressure plate at other side to balance the force on the other slotted shaft Addition
19. e technology in relation to how to disassemble and reassemble the driving axle assembly correctly In order to avoid the occurrence of personal injury A is used as safety mark in this manual The precautions with such mark shall be done carefully without any neglect If the danger occurs it is necessary to firstly consider the personal safety and then take necessary measure During disassembling and reassembling the wrong operating method will cause damage shortened service life and weakened performance of part and component as well as result in occurrence of unsafe factor Therefore please read this manual carefully before disassembling and reassembling 1 The parameter graph and content included in this manual are applicable to standard product For the product with variation please contact SDLG or refer to relevant data 2 In repair shop it is necessary to arrange for a separate or special area for disassembling and reassembling purpose and storage of disassembled parts and place the relevant tool and part in appropriate area Additionally the operating area shall be clean without any oil stain and pollutant Smoking is allowed only at specified area During operation no smoking will be allowed and relevant fire extinguisher shall be provided 3 The welding operation if any shall be undertaken by such person that has been trained and has some welding experiences During welding it is necessary to wear welding gloves baffle safet
20. e this situation 2 3 3 Operating principle of limited slip differential The limited slip differential develops from the symmetrical bevel gear differential and its structure is as shown in Fig 2 5 The cross axle assembly consists of two slotted shafts 1 and the four planet gears are applied onto the slotted shaft to engage with the axle shaft gear 2 At two sides of axle shaft gear there is one thrust pressure plate 3 respectively In the thrust pressure plate there are four V grooves mounted on the shaft journal of slotted shaft At each side of thrust pressure plate there 11 A UR ISE ZF AP 410 DK Axle Service Manual are driving and driven friction plates 5 and 4 respectively The six semicircular key grooves at edge of driving friction plate can wedge the driving friction plate 5 thrust pressure plate 3 and differential housing 7 together via cylindrical force transfer pin 6 This structure enables these parts revolve around axle shaft as a whole and the thrust pressure plate and friction plate slightly move along axle shaft The driven friction plate has many grooves on its surface to increase friction and the spline on its inner edge to match with the outer spline of axle shaft gear The axle shaft gear is mounted on the outer spline of axle shaft via the inner spline The differential assembly is as shown in Fig 2 6 1 2 3 4 A 6 7 mi Jig CAR a 7 Fig 2 5 Structure of limited slip differential 1 Slotted shaft 2 Axl
21. ed of driving friction plates at two sides are the same namely Wo However the driven friction plate is assembled together with axle shaft gear so the rotating speed of driven friction plate on the left is and that on the right is 2 It is assumed that the wheel on the right slips and the differential plays a differential role Though the thrust pressure plate generates a pressing force on friction plate the external resistance is so small that the driving torque transmitted by thrust pressure plate is relatively small As a result the pressing force on friction plate is also small F is positively correlated with F Additionally the torque torque on driving friction plate transmitted from drive shaft is largely different from the torque torque on driven friction plate of axle shaft from outside so the driving and driven friction plates conquer the friction force between them to slip oppositely The relationship among them can be shown as lt o lt 2 It can be concluded that the rotating speed of driven friction plate on the right is higher than that of driving friction plate When the driving friction plate applies a resistance torque to the driven friction plate therefore it is equivalent to an additional reacting torque from the ground to the axle shaft at slippage side This can help wheels at two sides to obtain driving torque so as to get out of trouble However the left side is just the opposite The rotating speed of driving fric
22. eees 17 3 1 1 Disassembling of axle accessories cccccccccccccceeeeeeseeececeeeeeaaaeeeeeees 17 AF GEA OG sspears sane E antes EE E deus sestanasnnseconsceteeacpecess eb 20 3 1 3 Disassembling of driving axle aSSeMDLy cc eeeeeeseeeeeeeeeeeeeeeeeeeees 21 3 1 4 Disassembling of wheel reducer cc ceeccccccccceeceeeeeesseeeeeeeeeeeaaeeeeeeees 23 3 3 Disassembling of wet Drake wsscisisascecienseaedsa dere savenyiddnedesaeitendudeiaadesonieieny 25 3 1 6 Disassembling of main actuator seesssseoeeeesssssssseseeerrsssssssssceeeressssssss 34 3 1 7 Disassembling of differential cunsevsscnsvnsscsncussasawesaatnennusreorseesaseusuarnoawesonse 40 REAS OE INGO ZTA NE E oiea EN E E E A E E E EEEE 43 E O E T e E E A T A onsen 43 3 2 2 REASSEMDHNS OF CITELONUIA scssessesnasesasswsnnnquavssessabunsesioretasaaaivetoriusuoanaes 44 3 2 3 Reassembling Of main actuator ou cceecccccccccesssesecceecsaeeseeeceeeseaeenees 50 3 2 4 ReEassembline OF Wet Drake disccercosssesasswsnnnasavssesiabunsesieroiadaaasvietorieseswantes 56 3 2 5 Reassembling of wheel reducer cc ceecccceccccccecceeeeesseeeeeeeeeeeaaaeeeeeeees 64 3 2 6 Reassembling of front and rear swinging brackets cccccceeeseeeeeeeees 66 Sed RET Ol ear Ol r E E 68 3 2 8 Reassembling of axle assembly and other components 0088 70 4 FREQUENT FAULT DIAGNOSIS AND MAINTENANCE OF DRIVING aE cocsveusinesssoesesevevecescssssensevesse
23. esesssucceussvusesssseeeedesseedessssseeeaesss40asaes4seeasasssesaeseceseaiasses 73 4 1 FAULT DIAGNOSIS AND TROUBLESHOOTING OF DRIVING AXLE 73 A WRIST ZF AP 410 DK Axle Service Manual 4 1 1 Abnormal sound of driving axle eeseesssseseeennsssssssseeeerrsssssssssseereeses 73 4 1 2 Heating of driving axle nn00seneennnnsseeeensssssseerssssseeeeesssssserrsssssseeresssse 74 4 1 3 Oil leakage of driving axle ou cece ccccccceessseecceeeeaeeeeeeceeeeaaeeseeeeeeeeaas 75 4 2 MAINTENANCE OF ZF DRIVING AXLE ccccsssessseessssscaaaaaeeeceeeeeeeeeseeeeeeeseens 76 4 2 1 Inspection on Oil level ce ccccccsssssecceccceeesseecceeesaeeeeeceeesaeaeeeeeeeeeeaas 76 Aired INC LACS INC C OR Olli sercnsnsnsiemaasadasyinenecamseesnuciuvnctannedactanasenciaadeuacsaneruoetdaony 76 4 2 3 Measurement of wear extent of friction plate 0 ce eececcccceesseeeeeeeeeees 76 4 2 4 Inspection on sealing performance of brake hydraulic system 78 Ay CPC Tat COMIC HANGS eee E E 78 aA DE a AU SCAG Cos A O A 78 4 2 7 Inspection on tightening torque essssssssseeeeessssssssseeeerrsssssssssseeereses 78 II A WRIST ZF AP 410 DK Axle Service Manual Foreword Taking ZF AP 410 DK rear axle now LZZF replaces AP411 with AP412 front axle and AP409 with AP410 rear axle as an example this manual specifies the assembling and disassembling process of ZF driving axle and its operating principle and includes the mai
24. everal minutes Check the oil level once a month 4 2 2 Replacement of oil For a new vehicle the driving axle oil shall be replaced firstly after running for 500 h The subsequent oil replacement cycle shall follow Table 4 2 The oil shall be replaced at least once a year Table 4 2 Oil replacement cycle Load grade Interval of oil replacement General load Wheel loader land leveler 1000 h or one year at least Heavy load Loader in bad operation or brake condition 500 h or half a year at least Heavy load Ambient temperature of vehicle gt 40 C 500 h or half a year at least 4 2 3 Measurement of wear extent of friction plate We can determine whether the wear extent of friction plate is as required requiring no removal of 76 A UR ISE ZF AP 410 DK Axle Service Manual hub The measuring tool adopted is only a bolt The specification of bolt selected for each model is as shown in the table below Table 4 3 Selection of measuring tooling Bolt specification Applicable model M16x1 5x170 AP 411 420 M16x1 5x120 AP 407 409 The detailed measuring method is as follows rotate the plug A on hub to its highest position as shown in Fig 4 1 a use Allen wrench to remove the plug step down the brake oil pressure of 80 120 bar screw on the measuring tooling with tightening torque of 25 Nem and then measure the distance X from hexagon head to planet carrier surface as shown in Fig 4 1 b Release the brake retighten
25. friction plate bracket while the driven friction plate 4 outer spline is fixed on inner gear ring 6 The sun gear shaft 7 has outer spline at one end to match with the inner spline of friction plate bracket so the axle shaft friction plate bracket and sun gear shaft are connected together via inner spline to realize synchronous rotation The sun gear shaft is engaged with four planet gears 8 and the four planet gear shafts integrate into the hub During operation the planet gear revolves around its own axis 15 A U SR les E ZF AP 410 DK Axle Service Manual and the sun gear shaft When revolving around sun gear shaft the planet gear will drive the hub to transfer power to tires When the brake pedal is stepped the high pressure brake oil will enter the internal oil duct 10 through brake oil pipe to drive the piston 2 to firmly press the driving and driven friction plates together Because the driven friction plate is immobile a resistance torque is generated on the driving friction plate to arrest the rotation of friction plate bracket and sun gear shaft so as to realize the wet brake Fig 2 9 Wet brake and wheel reducer 1 Axle shaft 2 Piston 3 Driving friction plate 4 Driven friction plate 5 Friction plate bracket 6 Inner gear ring 7 Sun gear 8 Planet gear 9 Hub 10 Oil pipe 16 A LU 2 les I ZF AP 410 DK Axle Service Manual 3 Disassembling and reassembling of ZF driving axle 3 1 Disassembling of ZF driving axle 3 1
26. g 3 074 1 Thrust pressure plate 1 piece 41 oy W RIST ZF AP 410 DK Axle Service Manual 7 Take off the axle shaft gear Fig 3 075 1 Axle shaft gear 1 piece 8 Take off the planet gear and two slotted shafts Fig 3 076 1 Slotted shaft 2 pieces 2 Planet gear 4 pieces 9 Take off the axle shaft gear and thrust pressure plate at the other side Fig 3 077 1 Axle shaft gear 1 piece 2 Thrust pressure plate 1 piece 42 A WRIS I ZF AP 410 DK Axle Service Manual 10 Take off the driving and driven friction plate lubricating gasket and friction gasket at the other side Q a 1 2 3 4 5 Fig 3 078 1 Driven friction plate 2 pieces 2 Driving friction plate 2 pieces 3 Gasket 1 piece 4 Gasket 1 piece 5 Force transfer pin 6 pieces x 3 2 Reassembling of ZF axle 3 2 1 Cleaning 1 Clean the disassembled parts and components with brush and wipe them with lint free paper Fig 3 079 X CAUTION It is allowed to use the ordinary gasoline for cleaning It is allowed to use the diesel oil drained from oil tank for cleaning if repair in field 43 AA WRIS I ZF AP 410 DK Axle Service Manual l Fig 3 080 1 Differential housing 1 piece 1 Fig 3 081 1 Gasket 1 piece Fig 3 082 1 Gasket 1 piece 44 3 2 2 Reassembling of differential 1 Take the differential housing in a clean environment amp CAUTION Do not wear gloves
27. her 1 piece 3 Input flange 1 piece 37 A WR les ZF AP 410 DK Axle Service Manual 11 Knock at and remove the driving spiral bevel gear shaft 1 Fig 3 063 1 Driving spiral bevel gear shaft 1 piece 12 Take off the framework oil seal Fig 3 064 1 Framework oil seal 1 piece 13 Take off the bearing inner ring Fig 3 065 1 Bearing inner ring 1 piece 38 A W SR les E ZF AP 410 DK Axle Service Manual 14 Use the puller to remove the bearing outer ring Fig 3 066 1 Bearing outer ring 2 pieces 15 Take off the adjusting gasket Fig 3 067 1 Adjusting gasket 1 piece o 16 Use the bearing inner ring puller to remove the bearing inner ring Fig 3 068 1 Bearing inner ring 1 piece 39 AX URISI ZF AP 410 DK Axle Service Manual 1 Fig 3 069 Tool Wrench 21 1 Bolt 12 pieces Fig 3 070 1 Differential cover 1 piece Fig 3 071 1 Gasket 1 piece 40 3 1 7 Disassembling of differential 1 Remove the fixing bolt 2 Use a screwdriver to pry up the differential COVCET 3 Take off the gasket oy W RISI ZF AP 410 DK Axle Service Manual 4 Take off the gasket Fig 3 072 Gasket 1 piece e 09 5 Take off the driving and driven friction plates oe and force transfer pin NR A a Fig 3 073 1 Driving friction plate 2 pieces 2 Driven friction plate 2 pieces 6 Take out the thrust pressure plate l Fi
28. ine in differential and the spline of driven friction plate amp CAUTION The left and right axle shafts are of different length and cannot be mounted incorrectly Fig 3 136 The splines at two ends of each axle shaft are 1 Axle shaft 1 piece of different length and cannot be mounted inversely 63 A URIS E ZF AP 410 DK Axle Service Manual 23 Mount the lock washer on the slotted nut The raised part of lock washer shall be clamped in the groove of slotted nut Fig 3 137 1 Lock washer 1 piece a 24 Firstly align the inner splines of driving friction plate and then mount the friction plate bracket and sun gear shaft amp CAUTION Because the friction plate bracket must match with both the driving friction plate and the axle shaft spline the small assembling space Fig 3 138 increases the assembling difficulty To mount 1 Sun gear shaft 1 piece 2 Friction plate bracket 1 piece the sun gear shaft in friction shake the sun gear shaft 3 2 5 Reassembling of wheel reducer 1 Take the planet gear and bearing assembly Fig 3 139 1 Planet gear 4 pieces 2 Bearing 4 pieces 64 WR IS I SDL Fig 3 140 Planet carrier 1 piece 2 Planet gear 4 pieces 3 Bearing 4 pieces Fig 3 141 Tool Snap ring pliers 1 Snap ring 4 pieces Fig 3 142 1 Lock washer 1 piece 65 ZF AP 410 DK Axle Service Manual 2 Mount the planet gear and bearing assembly
29. ket 3 1 3 Disassembling of driving axle assembly 1 Uphold two ends of the driving axle and place a cart under it use a pneumatic wrench to remove the fixing bolts from front and rear swinging brackets and place the driving axle on the cart Rear axle assembly 2 Push out the cart and place the driving axle on appropriate bracket AA CAUTION The front swinging bracket has no axial positioning and shall be protected from hurting the operator 3 The front swinging bracket has no axial positioning and can be removed directly Front swinging bracket Al oy W RIST ZF AP 410 DK Axle Service Manual 4 Remove the rear end cover fixing bolt Fig 3 005 Tool Wrench 18 1 Bolt 6 pieces 5 Remove the end cover and gasket Fig 3 016 1 End cap 1 piece 2 Shim 1 piece 6 Clean up the grease and remove the bolt and gasket with wrench k wa Fig 3 007 Tool Wrench 30 1 Bolt 4 pieces 2 Gasket 4 pieces 22 ZF AP 410 DK Axle Service Manual 7 Remove the cushion block and gasket AA CAUTION After the cushion block and gasket are removed the rear swinging bracket has no axial positioning and shall be protected from hurting the operator Fig 3 018 1 Cushion block 1 piece 2 Gasket 1 piece 8 Remove the rear swinging bracket and gasket from its inner hole o Rear swinging bracket Fig 3 019 1 Rear swinging bracket 1 piece 2 Gasket 1 piece 3 1 4 Disasse
30. l friction torque M of differential 10 A WRIS I ZF AP 410 DK Axle Service Manual Fig 2 4 Torque distribution of differential The popular symmetrical bevel gear differential has relatively small internal friction torque so it can be said to some extent that the torque is evenly distributed whether the rotating speed of left and right driving wheels is the same This is known as the force transfer characteristics of differential speed with same force of ordinary differential Such distribution proportion is reasonable for straight driving on good road However the trafficability will be severely affected if the vehicle runs on bad road For instance when the driving wheel at one side touches the muddy or snowy road the wheel at muddy road will slip on the spot while the wheel at good road will maintain immobile This is because the adhesion between the wheel at muddy road and the road surface is so small that the road surface applies only very small reactive torque on axle shaft Though the adhesion between the wheel at other side and the good road surface is relatively large the evenly distributed torque of symmetrical bevel gear differential makes the torque distributed onto this wheel is equal to the small torque transferred on the driving wheel in slippage On this account the total driving force is not enough to conquer the running resistance so the wheel cannot run forward However the limited slip differential on ZF axle can improv
31. l supporting axle 1 piece 3 Apply appropriate amount of sealant on wheel supporting axle and then mount dust cover 7 Sealant 1680 Fig 3 117 1 Dust cover 1 piece 4 Mount the seal ring l Fig 3 118 1 Seal ring 1 piece 57 ZF AP 410 DK Axle Service Manual Fig 3 119 1 Bearing inner ring piece Fig 3 120 1 Seal ring 1 piece 2 O ring 2 piece Fig 3 121 1 Bearing outer ring piece 2 Bearing outer ring piece 08 5 Knock at the tooling and mount the bearing inner ring 6 Mount the seal ring and O ring 7 Mount the outer ring of wheel bearing and spline hub bearing on hub A WRIS I ZF AP 410 DK Axle Service Manual 8 Mount the hub Fig 3 122 1 Hub 1 piece 9 Mount the screw 1 Fig 3 123 Tool Screwdriver 1 Screw 2 pieces 10 Mount the spline hub 1 Fig 3 124 1 Spline hub 1 piece 59 A WRIS I ZF AP 410 DK Axle Service Manual 11 Mount the retainer ring l Fig 3 125 Tool Screwdriver 1 Retainer ring piece 12 Mount the piston guide ring rear mounted seal ring and piston E 23 Fig 3 126 1 Piston guide rod 2 pieces 2 Rear mounted seal ring 2 pieces 3 Piston 1 piece 13 Mount the bearing inner ring 1 Fig 3 127 1 Bearing inner ring 1 piece 60 A LL 2 les I ZF AP 410 DK Axle Service Manual 14 Mount the tension spring and slotted ring Fig 3 128 1 Tension ring 8 pieces 2 Slotted
32. llen wrench 1 Screw plug 1 piece 5 Mount the end cover on rear swinging bracket and tighten the bolt A kom Tightening torque 78 104 Nem 6 Mount the front swinging bracket Front swinging bracket amp CAUTION The front swinging bracket has no axial positioning and shall be protected from hurting the operator 3 2 7 Refilling of gear oil 1 Tighten the oil drain plug under axle Be careful not to damage O ring 68 A WRIS I ZF AP 410 DK Axle Service Manual Fig 3 152 1 Fig 3 153 Tool Allen wrench 1 Screw plug 1 piece 69 2 Horizontally place the axle rotate the hub or main actuator till the line of OIL LEVEL on hub is at horizontal position and refill the gear oil till it overflows from screw plug hole Lal Refill the special lubricating oil for ZF axle This oil contains LS limited slip additive known as API GL 5 SAE90 LS amp CAUTION After refilling it is necessary to refill oil till the specified oil level is maintained if the oil level lowers after several minutes Add about 7 L to left and right hubs respectively 3 Tighten the screw plug Be careful not to damage O ring at edge A kam Tightening torque 50 Nem 4 Horizontally place the axle screw off the oil filler plug in the middle of axle refill the gear oil till the oil overflows from the screw plug hole After refilling tighten the screw plug im Refill the special lubricating oil for ZF axle This oil co
33. mbling of wheel reducer 1 Remove the fixing bolt from planet carrier 1 Fig 3 020 Tool Wrench 24 1 Bolt 24 pieces 2 A LU SR les E ZF AP 410 DK Axle Service Manual 44 CAUTION plate bruising operator Fig 3 021 Planet carrier 1 piece O ring Fig 3 022 Planet carrier 1 piece 4 Remove the snap ring l Fig 3 023 Tool Snap ring pliers 1 Snap ring 4 pieces 24 2 Insert the crow bar into the groove at hub edge to slowly pry out the planet carrier Appropriate protection shall be done to prevent the internal sun gear and friction 3 Remove the planet carrier and planet gear from axle remove the lock washer and then protect the A LU 2 les I ZF AP 410 DK Axle Service Manual 5 Remove the planet gear and bearing with puller i Fig 3 024 1 Puller 2 Bearing 4 pieces 3 Planet gear 4 pieces bo a 3 1 5 Disassembling of wet brake Fig 3 025 1 Remove the friction plate bracket and sun gear shaft i i i iy iy j n i i l Fig 3 026 1 Friction plate bracket 1 piece 2 Sun gear shaft 1 piece 29 A LU 28x Hes I ZF AP 410 DK Axle Service Manual 2 Take off the lock washer Fig 3 027 1 Lock washer 1 piece 3 Take out the axle shaft K CAUTION Because the spline end matchable with axle shaft and friction plate bracket has different length from that matchable with axle shaft gear it is necessary to keep in min
34. nents in axle including wheel reducer due to collision or interference The sound caused by different components is of different strength and nature under different conditions so the sound source and reason can be determined upon the condition and position of abnormal sound Based on the reason of abnormal sound the abnormal sound can be classified into as follows one is the abnormal sound generated between components due to loose connection or component damage This abnormal sound is often due to the abnormal friction and collision between components so the sound is relatively clear The other is the sound due to abnormal fit of bearing or abnormal engagement of gear The abnormal engagement of gear includes too small or large backlash incorrect engagement position and insufficient engagement area This will often cause continuous and clear sound and the sound volume will become large when the rotating speed rises The abnormal fit of bearing covers two small or large bearing clearance When the bearing clearance is too large the continuous sound will be caused and the sound volume will increase when the vehicle speed rises 73 A WRIST ZF AP 410 DK Axle Service Manual If there is abnormal sound at axle housing it is necessary to check whether any component is loose and whether the engagement area and backlash of bevel gear pair of main actuator are reasonable If the engagement area and backlash are not as required the following adj
35. ntains LS limited slip additive known as API GL 5 SAE90 LS A WRIST ZF AP 410 DK Axle Service Manual Fig 3 154 Tool Allen wrench 1 Screw plug 1 piece CAUTION After refilling it is necessary to refill oil till the specified oil level is maintained if the oil level lowers after several minutes Add about 20 L to axle housing 3 2 8 Reassembling of axle assembly and other components 1 Clean the joint with cleanser and then tighten the brake oil pipe A kom Tightening torque 30 40 Nem 1 Fig 3 155 Tool Wrench 22 1 Brake oil pipe piece 2 Tighten the fixing bolt and other fasteners of T joint A kom Tightening torque 22 30 Nem 1 2 Fig 3 156 Tool Wrench 10 1 Bolt 1 piece 2 Cushion block 1 piece TO A WRIS I ZF AP 410 DK Axle Service Manual 3 Hoist and place the axle on cart push the cart to the position below frame hoist the axle and align the bolt hole on swinging bracket with that on frame w Rear axle assembly Fig 3 157 4 Mount and tighten the bolt nut and gasket A kom Tightening torque 540 650 Nem 1 2 3 Fig 3 158 1 Bolt 12 pieces 2 Gasket 12 pieces 3 Nut 12 pieces 5 Fix the grease pipe on front and rear swinging brackets A m Tightening torque 25 35 Nem l 2 3 Fig 3 159 Tool Wrench 17x19 1 Hollow bolt 1 piece 2 Copper gasket 2 pieces 3 Grease pipe 1 piece 71 A LU 28 les I ZF AP 410 DK Axle Service Manual 6 Tigh
36. ntenance technology and relevant standard requirements of driving axle in order to help service technician to further understand the assembling and disassembling method of driving axle and provide them with a basis for correct fault judgment and elimination The front axle ZFAP 411 HK is structurally same with rear axle so it can be subject to repair according to this service manual This manual mainly includes Chapter 1 Introduction This chapter mainly specifies the repair precautions of driving axle meanings of each symbol in this manual and tightening torque of ordinary thread Chapter 2 Structure and principle of ZF driving axle system This chapter mainly specifies the structure and operating principle of ZF axle Chapter 3 Disassembling and assembling of driving axle This chapter specifies how to correctly disassemble and reassemble each part and component and the precautions during disassembling and reassembling Chapter 4 Fault diagnosis and maintenance This chapter specifies the fault diagnosis and maintenance of ZF driving axle CAUTION The specification of part and component in this manual may vary with product improvement without prior notice Please contact or ask SDLG for latest data A WRIST ZF AP 410 DK Axle Service Manual 1 Introduction 1 1 Safety precautions Ad Important safety precautions It is very important for safe operation of vehicle to conduct maintenance and repair This manual describes th
37. otect the oil pipe Drain the brake fluid 7 Remove the bolt and cushion block and take down the tee union and brake oil pipe 8 Remove the bolt on the transmission shaft flange plate and disconnect its connection with the gearbox A WRIS I ZF AP 410 DK Axle Service Manual Fig 3 009 Tool Wrench 1 Bolt 4 pieces Fig 3 010 Tool Allen wrench 1 Screw plug 1 piece 2 O ring piece Fig 3 011 1 Screw plug 1 piece Tool Allen wrench 2 O ring piece 9 Remove the bolt disconnect the connection between the transmission shaft and rear axle and remove the transmission shaft 3 1 2 Oil drainage 1 Rotate the left and right hubs till the screw plug is at the lowest point place a iron made oil container under it and then use a Allen wrench to remove the screw plug to drain oil from hub Drain gear oil from hub amp CAUTION The screw plug has O ring and shall be protected A CAUTION The oil shall be drained after vehicle runs for a period of time It is necessary to slowly screw off screw plug to prevent the hot oil splashing 2 Place an oil container under screw plug and then use an Allen wrench to remove the screw plug to drain oil The O ring on screw plug shall be protected t Drain the gear oil from axle housing 20 A WRIS 0 ZF AP 410 DK Axle Service Manual Fig 3 012 1 Bolt 12 pieces 2 Washer 12 pieces 3 Nut 12 pieces 1 Fig 3 014 1 Front swinging brac
38. ove on differential cover 1 Fig 3 096 1 Gasket 1 piece 18 Mount the differential cover on differential housing 1 Differential cover 1 piece 49 A WRIS I ZF AP 410 DK Axle Service Manual 1 Fig 3 098 Tool Wrench 21 1 Bolt 12 pieces Fig 3 099 1 Special tool 2 Bearing inner ring piece 3 Driving spiral bevel gear shaft 1 piece Fig 3 100 1 Driving spiral bevel gear shaft 1 piece 2 Bearing outer ring piece 3 Adjusting gasket piece 19 Mount and tighten the bolt so Screw thread sealant 1262 _ km Tightening torque 209 278 Nem 3 2 3 Reassembling of main actuator 1 Knock at the special tool to mount the bearing inner ring into gear shaft K CAUTION Do not inversely mount the bearing inner ring The force shall be even during knocking It is not allowed knock at one position of bearing inner ring only 2 Place the appropriate adjusting gasket on bearing seat and use a copper bar to knock at and mount the gear shaft and bearing outer ring K CAUTION The force shall be even during knocking It is not allowed knock at one position of gear shaft only A WRIST ZF AP 410 DK Axle Service Manual 3 Knock at the special tool to mount the bearing at the other side 1 Fig 3 101 1 Bearing 1 piece 4 Mount the framework oil seal K CAUTION Because the sealing performance of original framework oil seal is damaged during disassembling a ne
39. red lead powder onto the driven spiral bevel gear generally three teeth and rotate the gear to make it engage with the driving spiral bevel gear repeatedly and then check the engagement mark Ensure the contact area is not less than 60 along tooth length and tooth height and the center along tooth height is slightly nearer to the small end while that along tooth length is also slightly nearer to the small end If the above requirements cannot be met the following adjustment must be done a when the engagement mark is nearer to the large end of driven spiral bevel gear rotate the adjusting nut to make the driven spiral bevel gear approach to the driving spiral bevel gear After such adjustment measure the backlash If the backlash is too small less than 0 20 mm it is allowed to reduce the adjusting gasket of driving spiral bevel gear to make the driving spiral bevel gear away from the driven spiral bevel gear so as to obtain a reasonable backlash when the engagement mark is nearer to the small end of driven spiral bevel gear the opposite adjustment shall be done b When the engagement mark is nearer to the tooth top increase the adjusting gasket of driving spiral bevel gear to make it approach to the driven spiral bevel gear Then measure the A W ZR lls T SDLG ZF AP 410 DK Axle Service Manual Fig 3 112 1 Main actuator 1 piece DD backlash If the backlash is too small rotate the adjusting nut to make
40. ring piece 15 Mount the slotted ring and use the hook to mount the tension spring 1 Fig 3 129 1 Slotted ring 1 piece 16 Knock at the special tool to mount the gear ring assembly on wheel supporting axle 1 Fig 3 130 1 Gear ring assembly piece 61 A USR les E ZF AP 410 DK Axle Service Manual Fig 3 131 1 Slotted nut 1 piece 1 Fig 3 132 1 Tension meter Fig 3 133 1 Driven friction plate 3 pieces 2 Driving friction plate 3 pieces 17 Tighten the slotted nut when rotating the hub kom Tightening torque 800 1000 Nem for AP 407 409 410 1300 1500 Nem for AP 411 412 415 2000 2200 Nem for AP 417 420 18 Measure the rolling resistance torque at wheel side XK CAUTION 11 18 Nem for AP 407 409 410 411 412 415 14 20 Nem for AP 417 420 If the resistance torque is inappropriate it is necessary to select the thickness of adjusting gasket again 19 Alternatively mount the driving and driven friction plates amp CAUTION It is necessary to align inner splines of driving friction plate for mounting the friction plate bracket A WRIS I ZF AP 410 DK Axle Service Manual 20 Mount the end gasket Fig 3 134 1 End gasket piece 21 Mount the snap ring at groove of inner gear ring with snap ring pliers Fig 3 135 Tool Snap ring pliers 1 Snap ring piece 22 Insert the axle shaft The spline at axle shaft head shall match with the axle shaft spl
41. rt and component to be directly assembled by hand a special attention shall be paid to the hand gripping position to avoid the occurrence of injury 11 The disassembled part must be subject to detection The part and component with performance affected shall be replaced with a new one 12 Any interference is not allowed after each part and component is reassembled 13 When the oil seal and seal ring are assembled they shall be protected with relevant measures to avoid the damage of oil seal and seal ring if they pass through key groove screw hole and step 14 When the part and component are assembled the tool adopted shall be matchable with screw thread fastener to avoid the damage of screw thread fastener 15 Do not use the pneumatic wrench or other tightening tools to tighten the joint and screw plug It is necessary to tighten them to an extent by hand and then tighten them to the specified torque with a torque wrench 16 To drain oil from driving axle be sure to slowly screw off oil drain plug to avoid ejection of oil The drained oil shall be contained in special vessel to avoid polluting environment A WRIST ZF AP 410 DK Axle Service Manual 1 2 Description on mark and symbol In order to give a full play of this manual the following marks shall be used in respect of important safety and quality requirements Table 1 1 Description on mark and symbol The operation is in process and a special attention shall be paid to
42. safety Safety f A special attention shall be paid to internal pressure during operation Much attention shall be paid to technical requirement during Caution operation to ensure the operating quality is up to standard Weight of part or device and disassembling and reassembling method Much attention shall be paid to sling selection and posture during operation Tightening Much attention shall be paid to tightening torque of torque subassembly during assembling The position where the adhesive and grease shall be applied gp Oiland water Add a certain amount of engine oil water or fuel oil The position where the oil or water shall be drained and Drainage drainage capacity A WRIST ZF AP 410 DK Axle Service Manual 1 3 Table for tightening torque of ordinary bolt thread Table 1 2 Table for tightening torque Strength grade of bolt 2 Tightening torque Nem 109 fo 0 13 16 30 36 65 78 110 130 180 210 1080 16 21 38 51 75 100 131 175 209 278 Yield Nominal diameter of bolt Strength grade of bolt N mm Tightening torque Nem 110 140 130 190 210 270 290 350 370 450 oe 480 148 193 oa 282376 384 512 88 650 193 257 264 354 376 502 521 683 651 868 109 900 280 330 380 450 540 650 740 880 940 1120 1080 326 434 448 597 635 847 864 1152 1098 1464 Yield Nominal diameter of bolt Strength grade of bolt N mm Tightening torque Nem 450 530 540 680 670 880 900 1100
43. speed is equal to the angular speed of differential housing 3 When the planet gear 4 revolves on its own axis 5 at the angular speed in addition to revolution the peripheral speed of engagement point A will be o r or y4r4 assume the radius of planet gear as r4 and that of engagement point B will be w2r or wa4ry Then 1 1 or Wort alr4 Wopr WMal4 namely 1 02 200 The above equation shows the motion characteristic equation of symmetrical bevel gear differential This shows the sum of rotating speed of left and right axle shaft gears is twice than the rotating speed of differential housing at all times irrespective of the rotating speed of planet gear Therefore when the loader turns or operates in other modes the planet gear can revolve on its axis at the same rotating speed to make the driving wheels at two sides roll on ground at different speed without slip Additionally the above equation also shows 1 When the rotating speed of axle shaft gear at any side is equal to zero the rotating speed of axle shaft gear at the other side will be twice than that of differential housing 2 When the rotating speed of differential housing is equal to zero the axle shaft gear at one side will reversely rotate at the same rotating speed if the axle shaft gear at the other side is driven to rotate by other external torque A UR ISE ZF AP 410 DK Axle Service Manual a b c Fig 2 3 Differential speed principle of differential 1 2
44. ten the screw and fix the grease pipe on frame Fig 3 160 Tool Screwdriver 1 Screw 4 pieces 2 Gasket 4 pieces 3 Pipe clip 2 pieces 7 Clean the brake pipe joint with cleanser and mount it on T joint A kam Tightening torque 30 40 Nem Fig 3 161 Tool Wrench 22 1 Oil pipe 1 piece 8 Mount the drive shaft on the flange of main actuator and transmission kom Tightening torque 75 105 Nem amp CAUTION Be sure to align the balance positioning arrows of two drive shafts Fig 3 162 1 Bolt 8 pieces l2 A WRIST ZF AP 410 DK Axle Service Manual 4 Frequent fault diagnosis and maintenance of driving axle 4 1 Fault diagnosis and troubleshooting of driving axle 4 1 1 Abnormal sound of driving axle 1 Symptom and danger The abnormal sound of driving axle includes continuous sound or intermittent or occurs when vehicle speed changes during normal running or when going uphill or downhill Some sounds are toneless and some are ringing The sound of driving axle is mainly from main actuator and differential Some occurs at wheel reducer The abnormal sound of driving axle reflects the abnormal technical condition among parts and components of driving axle It is necessary to find out and eliminate the reason immediately Otherwise the severe fault or accident may be caused 2 Reason and troubleshooting of abnormal sound of driving axle The abnormal sound of driving axle is often caused by some compo
45. the driven spiral bevel gear away from the driving gear when the engagement mark is nearer to the tooth root the opposite adjustment shall be done After above adjustment is completed smash tension pin to make it insert the groove of adjusting nut and tighten the bolt Pa Screw thread sealant 1262 kam Tightening torque of bolt 280 330 Nem k CAUTION The adjustment of backlash and engagement area is very important for operating performance and service life so it shall be completed carefully Remove the red lead powder after adjustment 13 Apply a coat of sealant to junction plane mount main actuator in axle housing and align bolt hole with pin hole s Main actuator 7 __ Plane sealant 1596 A WRIS I ZF AP 410 DK Axle Service Manual 14 Apply a turn of screw thread sealant at thread head Screw thread sealant 1262 Fig 3 113 1 Bolt 18 pieces 2 Screw thread sealant 15 Tighten bolt diagonally and gradually A kam Torque requirement 180 210 Nem l Fig 3 114 Tool Wrench 21 1 Bolt 18 pieces 3 2 4 Reassembling of wet brake 1 Mount exhaust valve and screw Fig 3 115 Tool Screwdriver 1 Exhaust valve 1 piece 2 O ring piece 3 Screw 4 pieces 56 A WRIS I ZF AP 410 DK Axle Service Manual 2 Tighten bolt and mount supporting axle 7 Screw thread sealant 1277 kam Tightening torque 380 450 Nem 1 2 Fig 3 116 Tool Wrench 27 1 Bolt 14 pieces 2 Whee
46. the measuring tooling with same torque 25 Nem and then measure the distance Y from hexagon head to planet carrier surface as shown in Fig 4 1 c Obviously the piston stroke is equal to X Y WY fps li en Wf i Yi T agne S X WAI ae a J l v 77 BKRAY Hi BAS KY X H ft _ tE ff VSS me Hy a b c Fig 4 1 Measurement of wear extent of friction plate The maximum piston stroke is as shown in Table 4 4 If this range is exceeded this shows the friction plate has been worn out and shall be replaced Table 4 4 Maximum piston stroke X Y Piston stroke mm 0 A WRIST ZF AP 410 DK Axle Service Manual 4 2 4 Inspection on sealing performance of brake hydraulic system It should be noted that the brake shall exhaust before the sealing performance of brake hydraulic system is inspected Apply the brake for 10 times conduct exhaust operation and then do the following pressure tests 1 Use a hydraulic pump to produce the pressure of 120 bar tighten the switch After the pressure is maintained for 5 min the pressure cannot be lower than 117 bar 2 When producing the pressure of 5 bar and maintaining the pressure for 5 min any pressure drop cannot be allowed 4 2 5 Operating temperature The operating temperature of axle shall not exceed 90 C after continuous operation If its operating temperature exceeds 130 C it is necessary to stop machine to check the brake system an
47. tion plate is greater than that of driven friction plate so a driving torque will be generated on driven friction plate to drive the driven friction plate to rotate On this account the wheel that runs at a low speed can obtain additional power to get out of trouble If the adhesion condition at two ends is different the torque flow is as shown in Fig 2 8 b The turning mode is similar to the mode of slippage at one side When turning the outer wheels are 14 A UR ISE ZF AP 410 DK Axle Service Manual of high rotating speed and small resistance torque while the inner wheels are of low rotating speed and large resistance torque However the limited slip differential can increase the driving torque of inner wheels but reduce that of outer wheels Moreover the driving and driven friction plates slip each other producing no influence on differential function When turning the torque flow is as shown in Fig 2 8 b Torque flow under the same adhesion Torque flow when turning left or under condition when driving in a straight line different adhesion conditions at two ends a b Fig 2 8 Torque flow under different modes 2 3 4 Principle of wet brake The structure of wheel reducer and wet brake is as shown in Fig 2 9 The friction plate bracket 5 has the inner spline applied on the spline of axle shaft 1 The driving friction plate 3 is applied onto the outer side of friction plate bracket via the inner spline and rotates with the
48. ustment must be done Table 4 1 Adjustment of engagement area and backlash Tooth face contact area of driven Adjusting method Travel direction of gear bevel gear Move the driven gear toward the AN i driving gear If the backlash is too i large move the driving gear A outwards Move the driven gear away from YV the driving gear If the backlash is K too large move the driving gear inwards Move the driving gear toward the N LL driven gear If the backlash is too large move the driven gear outwards Move the driving gear away from Q GCG the driven gear If the backlash is too large move the driving gear l4 inwards The engagement area can often be adjusted by increasing or reducing adjusting gasket and rotating adjusting nut The adjustment of contact area is very important for operating performance and service life so it shall be completed carefully 4 1 2 Heating of driving axle 1 Symptom and danger 74 A WRIST ZF AP 410 DK Axle Service Manual The heating of driving axle means that the temperature of driving axle exceeds the allowable range after it operates for a period of time that is to say you will burn your hand if touching it by hand The heating of driving axle often occurs at axle housing of driving axle beyond main actuator and differential and wheel reducer The heating of driving axle also shows the components of driving axle are abnormal in terms of technical condition fit relation
49. w framework oil seal shall be adopted Fig 3 102 1 Framework oil seal 1 piece 5 Mount the flange gasket and nut and tighten the nut Screw thread sealant 1262 2 3 Fig 3 103 1 Flange 1 piece 2 Nut piece 3 Gasket 1 piece ol A W ZR lS T SDLG ZF AP 410 DK Axle Service Manual Fig 3 104 1 Bearing outer ring 0s a 2 Differential TR Fig 3 105 1 Bolt 4 pieces 3 Bearing Muas cover 2 Gasket 4 pieces 4 Tension pin Tool Torque wrench 24 1 Adjusting nut 2 pieces 2 Bolt 4 pieces Fig 3 106 52 6 Mount the bearing outer ring on the two ends of differential and then mount the differential on driving axle box body 7 Firstly jack the tension pin out of bearing upper cover to prevent it affecting the next procedure and then mount the bearing upper cover bolt and gasket on box body amp CAUTION Much attention shall be paid to the previous mark to prevent disordering the bearing upper covers at two sides 8 Slightly tighten the fixing bolt of bearing cover and then tighten the adjusting nut It is necessary to screw in the adjusting nuts at two sides toward the center amp CAUTION The torque used to tighten the adjusting nuts at two sides shall not be large excessively It should be noted that the bearing outer ring cannot be extruded because this will cause the abrasion of roller during operation and thus reduce the service life of bearing
50. y goggles helmet and appropriate protective clothes 4 Before the transmission and torque converter assembly is disassembled the pollutant on the assembly surface shall be cleaned off to prevent polluting part and component during disassembling 5 It is necessary to wear safety shoes and safety helmet during operation It is not allowed to wear the working clothes that are not as required It is necessary to do up the buttons of working clothes A WRIST ZF AP 410 DK Axle Service Manual It is necessary to wear goggles when knocking at the part and component with cooper bar 6 It is allowed to use the gasoline coal oil and water based cleanser to clean the disassembled part and component 7 It is necessary to firstly check the relevant sling for damage when travelling crane or other hoisting equipment is used It is necessary to use the hoisting equipment with adequate hoisting capacity During hoisting operation it is necessary to slowly hoist any part at specified hoisting position to avoid collision between parts Never work under the hoisted part and component 8 For the operation to be done by two persons or more at the same time the operating procedure to be followed jointly shall be agreed in advance to avoid the occurrence of accident due to inconsistent step 9 It is necessary to properly keep all the tools and know well their operating method 10 Do not insert your finger into hole when aligning with two holes For the pa

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