ZF-AXLE AP-9 ZF-differential carrier HK DK-7 DKZ-7 Repair Manual 5871218002 - PDF DOWNLOAD

Order-no.: 5871 218 002

ZF-AXLE AP-9 ZF-differential carrier Type: HK Type: DK-7 Type: DKZ-7

ZF Passau GmbH Donaustr. 25 - 71 D-94034 Passau

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ZF – AXLE AP-9 ZF-DIFFERENTIAL CARRIER Type: HK Type: DK-7 Type: DKZ-7 Information: Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit.

This documentation has been developed for specialized staff trained by ZF for repair work to be made on ZF units.

Continuous technical upgrading of the ZF units and extensions concerning design options may require both deviating work steps and differing setting and testing data.

This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of issue of the manual.

ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise which edition is the latest one.

For maintenance work always observe the lubrication and maintenance instructions (ZF-order no: 5871 218 902) and the ZF-list of lubricants TE-ML 05!

The list of lubricants is continuously being updated and can be obtained or viewed as follows: - In all ZF-plants - In all ZF-service organizations - Internet http://www.zf.com/ Service / Techn. Information ---------------------------------------------------------------------------------------------------------------------------------For service and maintenance work on the brake system always observe the brake manufacturer’s and vehicle manufacturer’s instructions.

ATTENTION: Observe the vehicle manufacturer’s instructions and specifications for the installation and commissioning of the unit!

ZF Passau GmbH Donaustr. 25 - 71 94034 Passau Dept.: ASDM Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted!

Subject to technical modifications!

Konstruktionsstand / Design level : 2005/11 2. Edition: 2006/02

CONTENTS Preface General and important information on industrial safety Examples of gear-tooth-contact patterns for the gleason gear-tooth system (bevel gear set) Conversion table Denomination of standard dimensions Tightening torques for screws

Chapter/page 0/1 0/2 ... 0/3 0/4 … 0/5 0/6 0/7 0/8

SPECIAL TOOLS List of tools Tools – illustrated tables

W /1 ... W /15 WB/01 ... WB/12

1.

OUTPUT UNIT

1/1 … 1/15

1.1

DISASSEMBLY

1/1 … 1/5

1.2 1.2.1

REASSEMBLY Installation of brake

1/5 … 1/15 1/15

2.

ZF – DIFFERENTIAL CARRIER / Type: HK

2/1 … 2/18

Version: With limited slip differential DL-1600 (45% locking value)

2.1

DISASSEMBLY

2/1 … 2/5

2.2 2.2.1 2.2.2

RE-ASSEMBLY Input pinion Differential

2/6 … 2/18 2/6 … 2/10 2/11 … 2/18

3.

ZF – DIFFERENTIAL CARRIER / Type: DK-7 Version: With limited slip differential DL-1000 (45% locking value)

3/1 … 3/31

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

DISASSEMBLY Removal of reduction gear housing Removal of axle drive housing Removal of flange shaft Disassembly of reduction gear housing Disassembly of axle drive housing

3/1 … 3/8 3/2 3/2 3/3 3/4 … 3/6 3/7 … 3/8

3.2 3.2.1 3.2.2 3.2.3 3.2.3.1

RE-ASSEMBLY Installation of flange shaft Reduction gear Axle drive housing Differential DL-1000

3/9 … 3/31 3/9 … 3/10 3/11 … 3/20 3/21 … 3/31 3/22 … 3/27

4.

ZF – DIFFERENTIAL CARRIER / Type: DKZ-7 Version: With limited slip differential DL-1000 (45% locking value)

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

DEMONTAGE Removal of reduction gear housing and interaxle differential Removal of axle drive housing Removal of flange shaft Disassembly of reduction gear housing and interaxle differential Disassembly of axle drive housing

4/1 … 4/43 4/1 … 4/13 4/2 4/2 4/3 4/4 … 4/11 4/12 … 4/13

CONTENTS 4.2 4.2.1 4.2.2 4.2.3 4.2.3.1

RE-ASSEMBLY Installation of flange shaft Reduction gear Axle drive housing Differential DL-1000

Chapter/page 4/14 … 4/43 4/14 … 4/15 4/16 … 4/32 4/33 … 4/43 4/34 … 4/39

Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

PREFACE This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be made on ZF units.

This documentation describes a ZF series product with a design level valid at the date of edition Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both deviating work steps and differing setting and testing data.

We would therefore recommend you to entrust masters and servicemen with the work on your ZF product whose practical and theoretical training is constantly updated in our training school.

The Service Stations established by ZF Friedrichshafen all over the world offer you:

1. Permanently trained staff 2. Specified equipment, e.g. special tools 3. State-of-the-art genuine ZF spare parts All work is done there with utmost care and reliability.

In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms of the currently applicable contractual conditions.

Any damage resulting from work which is done in an improper and unprofessional manner by third parties and any consequential costs incurred shall be excluded from this contractual liability.

This shall also be applicable if other than genuine ZF spare parts are used.

ZF Passau GmbH Service Department

5871 218 002

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

General The Service Manual covers all work required for disassembly and the relating reassembly.

When repairing the unit, ensure utmost cleanliness and that the work is done in a professional manner.Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar.

Carry out disassembly and reassembly work on a clean working place. Use special tools which have been developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings, thrust washers etc. will be reinstalled.

Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with worn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.

Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation:

NOTE:

Only a heating furnace (oil bath) or an electric drier is permitted to be used for heating up parts such as bearings, housings, etc.!

Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.

CAUTION When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual.

Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.

The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible malfunction.

Never wash discs having organic friction linings (e.g. paper discs - adverse effect on lining adhesion).

Only dry cleaning is permitted (leather cloth).

DANGER When using detergents, observe the manufacturer’s instructions regarding their handling.

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

Structure of the Service Manual The structure of this repair manual reflects the sequence of the work steps for completely disassembling the dismantled unit.

Special tools required for carrying out the repair work are listed in the current text as well as in chapters “W” (List of special tools) and “WB” (illustrated tables).

Important information on industrial safety As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully responsible for industrial safety.

The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding any damage to persons and products during maintenance and repair work.

Repair workshops must familiarize themselves with these regulations prior to starting any work.

A suitably trained and skilled staff is required for a proper repair of these ZF products.

The repair workshop shall be responsible for the training.

The following safety references are used in this manual:

CAUTION

This symbol serves as a reference to special working procedures, methods, information, use of auxiliaries etc... indicated in this repair manual.

DANGER

This symbol identifies situations in which lacking care may lead to personal injury or damage to the product.

NOTE:

Thoroughly study this manual before starting any tests or repair work.

NOTE:

Figures, drawings and parts in this manual do not always represent the original; they show the working procedure.

Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on size and weight (not even within one and the same illustration.)

Carry out work according to the legend.

NOTE:

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After repair work and tests, the expert staff must verify that the product is perfectly functioning again.

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM EXEMPLES POUR LA DENTURE GLEASON Ideales Tragbild d.h. die Ritzeldistanz stimmt Ideal tooth-contact pattern i.e. pinion distance is correct L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte

Bild / Figure 1/3/5

Bild / Figure 1

Schubflanke (Konkav) Coast side (concave) Côté poussé (concave)

Bild / Figure 2/4/6

Bild / Figure 2

Zugflanke (Konvex) Drive side (convex) Côté entraîné (convexe)

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

Ritzeldistanz muß größer werden

Ritzeldistanz muß kleiner werden

Pinion distance must be increased

Pinion distance must be decreased

La distance du pignon doit être augmentée

La distance du pignon doit être diminuée

(+)

(-)

Bild / Figure 3

Bild / Figure 5

Bild / Figure 4

Bild / Figure 6

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION

25,40 mm

=

1 in ( inch)

1 kg ( Kilogramm )

=

2.205 lb ( pounds )

9,81 Nm ( 1 kpm )

=

7.233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm )

=

1 lbf x ft ( pound force foot )

1 kg / cm

=

5.560 lb / in ( pound per inch )

1 bar ( 1,02 kp/cm2 )

=

14.5 psi (pound force per square inch lbf/in2 )

0,070 bar ( 0,071 kp/cm2 )

=

1 psi ( lbf/in2 )

1 Liter

=

0.264 Gallon ( Imp. )

4,456 Liter

=

1 Gallon ( Imp. )

1 Liter

=

0.220 Gallon ( US )

3,785 Liter

=

1 Gallon ( US )

1609,344 m

=

1 Mile ( land mile )

0° C ( Celsius )

=

+ 32° F ( Fahrenheit )

0 ° C ( Celsius )

=

273.15 Kelvin

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DÉNOMINATION DES DIMENSIONS STANDARDISÉES Hinweis :

längenbezogene Masse in kg/m;

flächenbezogene Masse in t/m2

Note :

linear density in kg/m;

areal density in t/m2

Nota :

densité linéaire en kg/m;

densité superficielle en t/m2

Begriff Unit Unité

Formelzeichen Neu Symbol New Symbole Nouveau

Masse Density Masse Kraft Force Force Arbeit Work Travail Leistung Power Puissance Drehmoment Torque Couple Kraftmoment Moment (Force) Moment (Force) Druck (Über-) Pressure (Over-) Pression (Sur-) Drehzahl Speed Nombre de Tours

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Alt Old Vieux

Umrechnung Conversion Conversion

Bemerkungen Note Nota

m

kg (Kilogramm)

kg

F

N (Newton)

kp

1 kp = 9.81 N

A

J (Joule)

kpm

0.102kpm = 1J = 1Nm

P

KW (Kilowatt) (DIN)

HP

1 HP = 0.7355KW 1 KW = 1.36 HP

T

Nm (Newtonmeter) kpm

1 kpm = 9.81 Nm

T (Nm) = F (N) . r (m)

M

Nm (Newtonmeter) kpm

1 kpm = 9.81 Nm

M (Nm) = F (N) . r (m)

pü

bar

1.02 atü = 1.02 kp/cm2 = 1 bar = 750 torr

n

min -1 rpm tr/min

atü

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Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

TIGHTENING TORQUES FOR SCREWS (IN Nm) ACC. TO ZF STANDARD 148 Friction coefficient: μ tot.= 0.12 for plugs and nuts without rework, as well as phosphated nuts Tighten manually!

Take tightening torques from the following chart, unless otherwise specified

Metric ISO standard thread DIN 13, page 13 Dimension M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39

8.8 2.8 5.5 9.5 15 23 46 79 125 195 280 390 530 670 1000 1350 1850 2350 3000

10.9 4.1 8.1 14 23 34 68 115 185 280 390 560 750 960 1400 1900 2600 3300 4300

12.9 4.8 9.5 16.5 28 40 79 135 215 330 460 650 880 1100 1650 2250 3000 3900 5100

Metric ISO fine thread DIN 13, page 13 Dimension M8x1 M9x1 M 10 x 1 M 10 x 1.25 M 12 x 1.25 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 18 x 2 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 24 x 2 M 27 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M33 x 1.5 M 33 x 2 M 36 x 1.5 M 36 x 3 M 39 x 1.5 M 39 x 3

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8.8 24 36 52 49 87 83 135 205 310 290 430 580 760 730 1100 1050 1550 1500 2050 2000 2700 2500 3450 3200

10.9 36 53 76 72 125 120 200 300 440 420 620 820 1100 1050 1600 1500 2200 2100 2900 2800 3800 3500 4900 4600

0/8

12.9 43 62 89 84 150 145 235 360 520 490 720 960 1250 1200 1850 1800 2550 2500 3400 3300 4450 4100 5700 5300

Repair Manual

Corporate Division Off-Road Driveline Technology and Axle Systems

LIST OF TOOLS FOR DISASSEMBLY AND REASSEMBLY ZF – AXLE AP- 9/ HK 4464 001 464 OUTPUT UNIT: Disassembly Reassembly Designation and application chapter/figure chapter/figure

1/01

Part number

Assembly truck assy with tilting device Fixture 1 Set = 2 Pcs. 1 Set = 2 Pcs. Clamping brackets Universal use.

For clamping the complete axle AP-9 on the assembly truck.

5870 350 000 5870 350 077 5870 350 075

1/04

1/53

M 14 Adjusting screws For aligning and positioning the planetary carrier on the hub.

5870 204 022

1/04 1/12

1/29

Lifting bracket Facilitates removal and reinstallation of planetary carrier and hub.

5870 281 043

1/05

1/48

A1-A2-A3-A4 Set of external pliers Universal use.

To snap externally clamped retaining rings out and in.

5870 900 015

Two-armed puller Universal use.

To push planetary gears out of planetary carrier.

5870 970 003

Slotted nut wrench # Centering bracket# To loosen and tighten slotted nut 0737 503 059 on hub carrier.

5870 401 110 5870 912 012

1/13

1 Pc. Pry bar Universal use Facilitates removal and separation of components.

5870 345 071

1/15

Two-armed puller Universal use.

To pull the brake disc off the hub.

5870 970 006

1/06

1/10

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1/31 1/35 1/41

W/1

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