ZF AP 410 DK Axle Service Manual rvd center

Zf Ap 410 Dk Axle Service Manual Rvd Center-Free PDF

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ZF AP 410 DK Axle Service Manual,FOREWORD 1,1 INTRODUCTION 2. 1 1 SAFETY PRECAUTIONS 2,1 2 DESCRIPTION ON MARK AND SYMBOL 4. 1 3 TABLE FOR TIGHTENING TORQUE OF ORDINARY BOLT THREAD 5. 1 4 TABLE FOR BOLT TIGHTENING TORQUE AND ADJUSTING CLEARANCE OF ZF. DRIVING AXLE 6,2 STRUCTURE AND PRINCIPLE OF ZF DRIVING AXLE 7. 2 1 GENERAL DESCRIPTION ON DRIVING AXLE 7, 2 2 STRUCTURE AND PERFORMANCE PARAMETER OF ZF AXLE 7. 2 2 1 Structure and performance parameter of assembly 8. 2 3 OPERATING PRINCIPLE OF ZF AXLE 8,2 3 1 Differential principle 8.
2 3 2 Torque distribution 10, 2 3 3 Operating principle of limited slip differential 11. 2 3 4 Principle of wet brake 15, 3 DISASSEMBLING AND REASSEMBLING OF ZF DRIVING AXLE 17. 3 1 DISASSEMBLING OF ZF DRIVING AXLE 17,3 1 1 Disassembling of axle accessories 17. 3 1 2 Oil drainage 20,3 1 3 Disassembling of driving axle assembly 21. 3 1 4 Disassembling of wheel reducer 23,3 1 5 Disassembling of wet brake 25.
3 1 6 Disassembling of main actuator 34,3 1 7 Disassembling of differential 40. 3 2 REASSEMBLING OF ZF AXLE 43,3 2 1 Cleaning 43,3 2 2 Reassembling of differential 44. 3 2 3 Reassembling of main actuator 50,3 2 4 Reassembling of wet brake 56. 3 2 5 Reassembling of wheel reducer 64, 3 2 6 Reassembling of front and rear swinging brackets 66. 3 2 7 Refilling of gear oil 68, 3 2 8 Reassembling of axle assembly and other components 70.
4 FREQUENT FAULT DIAGNOSIS AND MAINTENANCE OF DRIVING. 4 1 FAULT DIAGNOSIS AND TROUBLESHOOTING OF DRIVING AXLE 73. ZF AP 410 DK Axle Service Manual,4 1 1 Abnormal sound of driving axle 73. 4 1 2 Heating of driving axle 74,4 1 3 Oil leakage of driving axle 75. 4 2 MAINTENANCE OF ZF DRIVING AXLE 76,4 2 1 Inspection on oil level 76. 4 2 2 Replacement of oil 76, 4 2 3 Measurement of wear extent of friction plate 76. 4 2 4 Inspection on sealing performance of brake hydraulic system 78. 4 2 5 Operating temperature 78,4 2 6 Lubricating grease 78.
4 2 7 Inspection on tightening torque 78,ZF AP 410 DK Axle Service Manual. 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 maintenance 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.
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. ZF AP 410 DK Axle Service Manual,1 Introduction,1 1 Safety precautions. Important safety precautions, It is very important for safe operation of vehicle to conduct maintenance and repair This manual. describes the technology in relation to how to disassemble and reassemble the driving axle. assembly correctly, In order to avoid the occurrence of personal injury 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 safety. 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. 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 part 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. 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. Mark Item Remarks, The operation is in process and a special attention shall be.
paid to safety, A special attention shall be paid to internal pressure during. Much attention shall be paid to technical requirement during. operation to ensure the operating quality is up to standard. Weight of part or device and disassembling and reassembling. 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, Coating The position where the adhesive and grease shall be applied. Oil and water Add a certain amount of engine oil water or fuel oil. The position where the oil or water shall be drained and. drainage capacity,ZF AP 410 DK Axle Service Manual. 1 3 Table for tightening torque of ordinary bolt thread. Table 1 2 Table for tightening torque,Yield Nominal diameter of bolt.
Strength grade of,strength 6 8 10 12 14,N mm2 Tightening torque N m. 4 6 240 4 5 10 12 20 25 36 45 55 70,5 6 300 5 7 12 15 25 32 45 55 70 90. 6 8 480 7 9 17 23 33 45 58 78 93 124,8 8 640 9 12 22 30 45 59 78 104 124 165. 10 9 900 13 16 30 36 65 78 110 130 180 210,12 9 1080 16 21 38 51 75 100 131 175 209 278. Yield Nominal diameter of bolt,Strength grade of,strength 16 18 20 22 24.
N mm2 Tightening torque N m,4 6 240 90 110 120 150 170 210 230 290 300 377. 5 6 300 110 140 150 190 210 270 290 350 370 450,6 8 480 145 193 199 264 282 376 384 512 488 650. 8 8 640 193 257 264 354 376 502 521 683 651 868,10 9 900 280 330 380 450 540 650 740 880 940 1120. 12 9 1080 326 434 448 597 635 847 864 1152 1098 1464. Yield Nominal diameter of bolt,Strength grade of,strength 27 30 33 36 39. N mm2 Tightening torque N m,4 6 240 450 530 540 680 670 880 900 1100 928 1237.
5 6 300 550 700 680 850 825 1100 1120 1400 1160 1546. 6 8 480 714 952 969 1293 1319 1759 1694 2259 1559 2079. 8 8 640 952 1269 1293 1723 1759 2345 2259 3012 2923 3898. ZF AP 410 DK Axle Service Manual, 10 9 900 1400 1650 1700 2000 2473 3298 2800 3350 4111 5481. 12 9 1080 1606 2142 2181 2908 2968 3958 3812 5082 4933 6577. 1 4 Table for bolt tightening torque and adjusting clearance of ZF driving. Table 1 3 Table for bolt tightening torque and adjusting clearance of ZF driving axle. Torque Adjusting clearance,No Part Mounting position Part specification. 1 Bracket locking nut 700,Rear M14 1 5 40,2 Bracket connecting bolt 265. 3 Wheel locking nut 800 1000,4 Wheel supporting axle bolt M18 60 10 9 390. Rear Planet wheel carrier,5 M14 40 10 9 180,axle connecting bolt.
Rear Adjusting clearance of wheel,axle friction plate. Rear Adjusting clearance of sun,axle gear shaft,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. different speed,Front axle Rear axle,Limited slip Parking Limited slip. differential brake differential,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. 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. 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,AP410 DK AP410 HK. Maximum static load t 21 8 25 0,Maximum dynamic load t 13 3 15 3. Output torque,Normal N m 81030 101140,Peak N m 145850 182050.
Brake torque N m 39548 3 discs 52732 4 discs,Tire 20 5 25 23 5 25. 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. 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 dif. ZF AP 410 DK Axle Service Manual 3 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

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