ASSEMBLY of ZF-axle AP-R 715

Transcription

1 ASSEMBLY of ZF-axle AP-R DIFFERENTIAL/INPUT PINION: 6 If the bevel gear or the input pinion is damaged both parts (bevel gear set) must be renewed! Bevel gear set = bevel gear and input pinion, both parts must have identical pair numbers! Fig Legend to sketch: 1 = Bevel gear/differential 2 = Axle drive housing 3 = Input pinion 4 = Diff.-lock (100%) 5 = Axle bridge half 6 = Axle bridge half (bevel gear side) 7 = Oil control screw a 4.1 DIFFERENTIAL: VERSION "A" VERSION "DZ 250" or "D 250": (DZ = multi-disc self-locking diff. / D = standard diff.) Fig. 2 b VERSION "B" Legend to sketch: VERSION "A" = multi-disc self-locking differential "DZ 250" (e.g. 45 % interlock value) a = disc packs (outer clutch discs optionally) VERSION "B" = standard differential "D 250" (without discs / no interlock value) b = spacer rings (spacer ring optionally) Axial clearance = 0.2 mm, to be set per disc pack or spacer ring (Fig.-No No. 7). To achieve a correct measuring result for the disc clearance (axial clearance), the individual components must first be mounted without lubricant. Fig. 3 Position pressure discs (2), external (3, s = optionally) and internal discs (4) above the axle bevel gear as shown in the adjacent illustration. The coated surface of the pressure discs (2) shows towards the external disc (3). Number and arrangement of the individual discs see representation in the respective spare parts list! For version D 250, the external and internal discs are substituted by spacer rings (per pack 1 unit) also see perspective drawing in the spare parts list! Insert pre-assembled axle bevel gear into the differential case. Fig /1

2 Insert both differential bevel gears (1) with buffer disc (2) and fix with differential axle )3). Ensure radial installation position of the buffer discs as well as correct installation position of the differential axle (fixing with clamping pins)! Fig. 5 Check axial clearance of the individual disc pack! Completely and repeatedly rotate mounted axle bevel gear / with discs into both directions (settling of the individual components). Axial clearance = 0,2 mm If the axial gap should deviate from the specified value, it must be corrected with suitable external discs or a spacer ring! Ensure identical thickness and arrangement of the second disc pack or spacer ring! Fig. 6 (S) Dial gage (S) Magnetic stand Disassemble again individual components after the adjustment. Oil all individual components of the differential use oil as per ZF list of lubricants TE-ML 05 and mount them again into the differential case, (Sketch No Fig. No. 6). Fix differential axle with clamping pin. Fig. 7 Mount second disc pack of identical thickness and arrangement Fig /2

3 Observing the assembly instructions, see Sketch No. 10, mount clamping pins into the differential case half. Fig. 9 X Assembly instructions: Position clamping pin(s) with the slot showing into the direction of force (arrow)! For double clamping pins offset slots by 180 towards each other. Fig To sketch: 1 = Differential case 2 = Clamping pin 3 = Clamping pin (only for double clamping pin version) X = Direction of force Press bevel gear onto differential case, until it is in close contact. Fig. 11 Fasten bevel gear with cylindrical screws. Secure cylindrical screws with Loctite (Type No. 243)! Tightening torque (M10/10.9)... M A = 68 Nm Fig /3

4 Bring both tapered-roller bearings into contact. Fig VERSION "DHK": (DHK = Diff. - hydraul. engagable) Fig. 14 Observing the assembly instructions see Sketch No. 16, mount clamping pins into the differential case half. Fig. 15 Fig. 16 X Assembly instructions: Position clamping pin(s) with the slot showing into the direction of force (arrow)! For double clamping pins offset slots by 180 towards each other! To sketch: 1 = Differential case 2 = Clamping pin 3 = Clamping pin (only for double clamping pin version) X = Direction of force /4

5 Place ring e.g. s = mm (empirical value) into the differential case. Fig. 17 Insert buffer disc (s = 1.90 mm) and axial bevel gear. Fig. 18 Insert both differential bevel gears with buffer discs into the differential case and fix with differential axle. Ensure installation position of the buffer disc place strap (arrow) into the recess of the differential case! Fig. 19 Check axial clearance of the axial bevel gear! Completely and repeatedly turn mounted axle bevel gear into both directions (settling of the individual components). Axial clearance = 0.2 mm If the axial clearance should deviate from the specified value, correct with a suitable spacer ring (s = optionally 13.0/13.1/13.2 mm)! Fig. 20 (S) Dial gage (S) Magnetic stand /5

6 Align differential axle and fix with clamping pin. Fig. 21 Insert second axle bevel gear with buffer disc e.g.. s = 1.80 mm (empirical value) into the differential case. Fig. 22 Check axial clearance = 0.20,, of the second axle bevel gear (difference from flanged surface of the differential case/bevel gear to buffer disc). Completely and repeatedly turn axle bevel gear into both directions (settling of the individual components). If the axial clearance should deviate from the specified value, correct with a suitable buffer disc (s = 1.70, s = 1.80, s = 2.00 or s = 2.10 mm)! (S) Digital depth gage Fig. 23 Press bevel gear onto the differential case, until it is in close contact. Fasten bevel gear with cylindrical screws. Tightening torque (M10x1.25/12.9)... M A = 84 Nm Fig /6

7 Press both bearing inner rings, until they are in contact. Fig S-2 5 S Determine adjusting spacer for the backlash bevel gear set (S-1) and the bearing rolling moment/differential bearing (S-2): At the machining measure indicated on the axle drive housing (punched in) (see Fig.-No. 42/page 4/12) for determining the adjusting spacer S-3, the differential (with determination of the adjusting spacers) must be mounted after the assembly of the input pinion see Fig.-No Fig.-No. 54 (this renders the preliminary assembly and subsequent disassembly of the differential unnecessary)! 3 2 Legend to sketch: 1 4 S-3 1 = Axle drive housing 4 = Input pinion 2 = Axle casing (Part I) 5 = Differential 3 = Axle casing (Part II) 6 = Hydr. engagable Diff.- (bevel gear side) lock (100%) Fig. 26 S-1 = Adjusting spacer for backlash/bevel gear set S-2 = Adjusting spacer for rolling moment/diff. bearing S-3 = Adjusting spacer for contact pattern /bevel gear set Fig.-No. 27 only for new part assembly: Oil O-ring and insert it into annular groove of axle casing. Fasten axle drive housing to axle casing. Tightening torque (M14/10.9)... M A = 185 Nm Fig /7

8 Bring axle into a vertical position. Insert adjusting spacer(s), (S-1, e.g. s = 2.80 mm empirical value) and insert bearing outer ring, until it is in contact. (S) Support (S) Grip Fig. 28 Insert pre-assembled differential. Fig S-2 A B 1 S-1 Legend to sketch: 1 = Axle drive housing 2 = Axle casing/part I 3 = Axle casing/part II A = Flange surface/axle drive housing to front face/bearing outer ring B = Flange surface/axle casing (Part II) to bearing support/bore S-1 = Adjusting spacer for backlash/bevel gear set S-2 = Adjusting spacer for rolling moment/differential bearing Fig Position bearing outer ring at the bearing inner ring, until all rollers are in contact without clearance. For the following dimension determination, ensure the exact contact of the bearing outer ring and the correct position of the differential! Fig /8

9 Determine dimension "A" of flange surface/axle casing/(part I) to front surface of bearing outer ring. (also see Sketch-No. 30/page 4/8). Dimension A e.g mm (S) Measuring ledge (S) Abutting blocks (S) Digital depth gage Fig. 32 Determine dimension "B" from flange surface (axle casing/part II) to bearing support/bore. Dimension B e.g mm (S) Measuring ledge (S) Abutting blocks (S) Digital depth gage Fig. 33 CALCULATION EXAMPLE. Dimension B e.g mm Dimension A e.g mm Difference mm Bearing preload (0,15 mm ^ 3,0...4,0 Nm) mm Result adjusting spacer (s) = 0.90 mm A bearing preload of 0.15 mm corresponds to a bearing rolling moment of about Nm when using new tapered-roller bearings. Insert determined adjusting spacer (S-2, e.g. s = 0.90 mm) into the bore of the axle casing/part II. Fig /9

10 Insert bearing outer ring, until it is in close contact. (S) Support (S) Grip Fig. 35 Mount axle casing/part II (without O-ring) onto axle drive housing (observe installation position) and fasten it temporarily (completely and repeatedly turn differential in both directions roller settling). Tightening torque (M14/10.9)... M A = 185 Nm Check the backlash ( mm) - see page 4/16, Fig.-No. 59! Fig INPUT PINION: Fig S-3 II D C 5 A I B Determine adjusting spacer to position the pinion for an optimal contact pattern at the bevel gear set also see contact pattern examples on page 0/07 and 0/08: Legend to sketch: 1 = Axle casing/part I 2 = Axle drive housing 3 = Axle casing/part II 4 = Differential 5 = Input pinion 6 = Adjust. spacer/pin. support I = Machining dimension II = Basic distance + bearing width A = Bore/bearing contact up to outer diameter/differential B = ½ diameter/differential C = Bearing width D = Pinion dimension see data on front surface/pinion S-3 = Adjusting spacer (s = optionally) VERSION "without" SPECIFICATION OF MACHINING DIMENSION "I" (Sketch-No. 37): (If specified punched in on the axle drive housing - see Fig.-No. 42/page 4/12) Determine dimension A, (see Sketch-No. 37) of bore/bearing support to external diameter/differential case Fig. 38 Dimension A e.g ,80 mm Make measurements at various points of the external diameter/ differential (turn differential) and determine average value /10

11 Disassemble differential. Determine dimension B (1/2 diameter/differential) Dimension B e.g mm Make measurements at various points and determine average value! Fig. 39 Determine dimension C (bearing width). Dimension C e.g mm (S) Abutting blocks (S) Digital depth gage Fig. 40 Fig ,05 Determine dimension D of the pinion. Pinion dimension (basic distance) e.g mm if a ± distance deviation is specified e.g mm Dimension D e.g mm Pair number/pinion e.g must be identical to pair number/bevel gear (bevel gear set)! CALCULATION EXAMPLE: Dimension I (Dim. A + B ) e.g mm Dimension II (Dim. C + D ) e.g mm Result Spacer disc(s) = 1.25 mm Required adjusting spacer (Item S-1 see Sketch-No. 37) e.g.. s = 1.25 mm. Continue the assembly with Fig.-No.: 45/page 4/13! /11

12 VERSION "with" SPECIFICATION OF THE MACHINING DIMENSION "I" (also see Sketch-No. 37): Read dimension I, (machining dimension also see Sketch-No 37) from axle drive housing (punching in position see arrow). Dimension "I e.g mm Fig. 42 Determine dimension C (bearing width). Dimension C e.g mm (S) Abutting block (S) Digital depth gage Fig ,05 Pair number/pinion e.g must be identical to pair number /bevel gear (bevel gear set)! Read dimension D from pinion. Pinion dimension (basic distance) e.g.. if a ± distance deviation is specified e.g. Dimension D e.g. CALCULATION EXAMPLE: mm mm mm Fig Dimension C (bearing width) e.g... Dimension D e.g.... Result Dimension "II" mm mm = mm Dimension I (machining dim.) e.g mm Dimension II (dim. C + D ) e.g mm Result Adjusting spacer thickness (s) = 1.25 mm Required adjusting spacer (Item S-1 see Sketch-No. 37), e.g. s = 1.25 mm /12

13 4.2.2 Set ROLLING MOMENT of the PINION SUPPORT Nm (without shaft sealing ring) Insert adjusting spacer (S-3, e.g. s = 1.25 mm) into the bearing bore. Fig. 45 Supercool bearing outer ring (arrow) and bring it into contact using a device. Version - tapered-roller bearing, type "32 209" (e.g. ZF-No.: ) (S) Assembly device Version - tapered-roller bearing, type "HM 88610" (e.g. ZF-No.: ) (S) Assembly device Fig. 46 Supercool second bearing outer ring and insert it, until it is in contact. Version - tapered-roller bearing, type "32 208" (e.g. ZF-No.: ) (S) Support (S) Grip Fig. 47 Version - tapered-roller bearing, type "HM 86610" (e.g. ZF-No.: ) (S) Support (S) Grip Heat up tapered-roller bearing and bring it into contact. Reset tapered-roller bearing after cooling down! Fig /13

14 Line up spacer ring (s = optional). It is recommended to install again the spacer ring found during the disassembly (e.g. s = 5.90 mm). If however the required rolling moment of Nm (without shaft sealing ring) is not achieved, the bearing rolling moment must be corrected with a suitable spacer ring! Fig. 49 Insert pre-assembled input pinion and fix it with heated up bearing inner ring. Fig. 50 Line up flange or spur gear (for version with axle transmission case) and fix with disc and hexagon bolt or cylindrical screw (depending on the version). Fig. 51 Fasten flange or spur gear (for version with 1 axle transmission case-150) with disc and hexagon bolt or cylindrical screw (depending on the version). During tightening, completely and repeatedly turn input pinion into both directions roller settling! Tightening torque (M 20x1,5/10.9)... M A = 400 Nm (S) Clamping fork Fig /14

15 Check rolling moment of the input pinion support! Bearing rolling moment (without shaft sealing ring Aim at upper value Nm If the required rolling moment should deviate from the specified value, correct with a suitable spacer ring (see Fig.-No. 49/page 4/14)! Fig. 53 (S) Torque wrench (S) Reduction ¼ ½ (S) Reduction ½ ¾ Disassemble again input flange and spur gear, respectively. If for the version "with" specified machining dimension to determine the adjusting spacer of S-3, the adjusting spacers S-1 and S-2 were not yet determined, Section 4.1.3, page 4/7... 4/10, this must be done here! Fig Check BACKLASH and CONTACT PATTERN of the BEVEL GEAR SET: Wet some tooth flanks of the bevel gear set with touching-up ink (determination of contact pattern). Fig. 55 Insert pre-assembled differential. Fig /15

16 Position axle case/part II (O-ring) onto axle drive housing (observe installation position) and temporarily fasten it (completely and repeatedly turn differential into both directions roller settling). Tightening torque (M14/10.9)... M A = 185 Nm Fig. 57 Mesh pinion via bevel gear into both directions (engagement of driving flank and non-driven flank) (contact pattern). Fig. 58 Through the oil drain bore, rectangularly position dial gage at one tooth flank of the bevel gear set and check backlash. Backlash mm If the required backlash should deviate from the specified value, correct with a suitable adjusting spacer (see Fig.-No. 28, page 4/8)! Fig. 59 Disassemble differential again. Compare contact pattern (see arrow) with contact pattern examples on page 0/6 and 0/7. If a major contact pattern deviation should be noticed, upon the determination of the adjusting spacer (S-3, Fig.-No. 45 page 4/13), a meausring mistake was made which must be corrected.. Fig /16

17 Insert plug-in shaft. Fig. 61 Insert pre-assembled differential. Fig Mount LOCKING SLIDE (100% lock): Legend to sketch: 1 = Axial needle cage 2 = Locking slide 3 = Pressure spring Fig. 63 Insert pressure spring and locking slide. Position axial needle cage. Fig /17

18 Oil both 4-lip sealing rings and insert them into the annular grooves (arrows) of the axle case/part II. Fig. 65 Introduce piston, until it is in close contact. Oil O-ring (arrow) and insert it into the annular groove. Fig. 66 Place pre-assembled axle case/part II and finally fasten it. Tightening torque (M14/10.9)... M A = 185 Nm Fig Check FUNCTIONING and TIGHTNESS of the 100% LOCK : Check control function of the 100% lock: - Switching on function (with compressed air) - Shutting down function (resetting via pressure spring) Fig /18

19 Check tightness: Establish test pressure p = 25 bar and close connection to the high-pressure pump via shut-off valve. During a test period of 5 minutes, a pressure drop is inadmissible!! Test media: Engine oils SAE 10-W, ATF-oils Fig. 69 (S) High-pessure pump (S) Screw-type connection M12x1, SHAFT SEALING RING/INPUT FLANGE X The represented shaft sealing ring / input flange assembly (Sketch-No Fig.-No. 73) shows the procedure for the "Standard version". For axle versions "with" flange brake or axle transmission case the assembly of the shaft sealing ring/input flange is described under the respective flange brake or under the axle transmission case assembly! 3 Legend to sketch: Fig = Shaft sealing ring 2 = Tapered-roller bearing 3 = Input flange 4 = Axle drive housing 5 = Input pinion X = Install. dimens. 19,0-0,5 mm Apply sealing compound (Loctite No. 574) to the contact surface (external diameter) of the shaft sealing ring and drive ring in observing the installation dimension X see Sketch-No. 70. Grease shaft sealing ring near dust and sealing lip (Grease = PETAMO, ZF-ordering No. : )! The use of the specified support ensures an exact installation position of the shaft sealing ring! Fig. 71 (S) Support Mount stud bolt with securing compound (Loctite No. 262) into the flange. Tightening torque (M8/12.9)... M A = 11 Nm Fig /19

20 Fasten flange with disc and hexagon bolt or cylindrical screw or hexagon nut (depending on the version). During tightening, completely and repeatedly turn input pinion into both directions roller settling! Hexagon bolt / cylindrical screw Tightening torque (M20x1,5/ M A = 400 Nm Hexagon nut Tightening torque... M A = 800 Nm Fig. 73 (S) Clamping fork /20

21 5. OUTPUT: Mount bushes into axle casing. Fig HUB: Insert wheel bolt into the hub, until it is in contact. (S) Wheel bolt extractor basic tool (S) Insert M18x Fig. 2 Press in both bearing outer rings, until they are in contact. Here, the hub must not be supported on the wheel bolt. (S) Support (S) Grip Fig. 3 Heat up and insert bearing inner ring. To avoid cooling down of the bearing inner ring, mounting of the shaft sealing ring (Fig. 5) and lining up of the hub (Fig. 7) must take place directly after having inserted the heated up bearing inner ring. Fig /1

22 Apply sealing compound (Loctite No. 574) to contact surface shaft sealing ring/hub and press shaft sealing ring into the hub, the lettering "LUFT SEITE/OUTSIDE" showing to the outside (upwards) duly considering the installation dimension "X" see sketch No. 6. The use of the specified support ensures the exact installation position. (S) Support (S) Grip Fig. 5 X 2 Legend to sketch: 1 = Shaft sealing ring 2 = Roller bearing 3 = Hub X = Installation dimension mm 3 Fig. 6 Directly prior to mounting the hub, wet contact surface shaft sealing ring/joint housing with spirit (assembly aid)! Line up hub and fix it with heated up bearing inner ring. Fig INTERNAL GEAR: Bring internal gear into position at the axle and temporarily tighten them uniformly using the old locking bolts which were removed during the disassembly. Observe installation position of the internal gear mount internal gear with the lettering "TOP" (see arrow) in 'noon' clock position. Then, remove again all bolts. Fig /2

23 Finally fasten internal gear with new locking bolts. Tightening torque (M10/12.9)... M A = 90 Nm Insert locking bolts with Loctite (Type-No. 262)! Locking bolts are permitted to be used only once! Fig Legend to sketch: 1 = Plug shaft 2 = Sleeve 3 = Retaining ring 4 = Sun gear shaft 4 Fig. 10 Insert retaining ring into the annular groove of the sleeve, line up plug shaft and sun gear shaft. Fig. 11 Mount complete plug shaft into the axle casing, until the gearing in the differential (axle bevel gear) has engaged. Fig /3

24 Line up thrust disc and fix with retaining ring. Fig Set AXIAL PLAY of the SUN GEAR SHAFT to mm : Bring sun gear shaft into contact. Determine dimension II from the front face (sun gear shaft) up to the flange surface (hub/planetary carrier). Dimension II e.g mm Fig. 14 (S) Measuring ledge (S) Digital depth gage Determine dimension I from the flange surface (planetary carrier/hub) to the contact surface (thrust disc). Dimension I e.g mm (S) Abutting blocks (S) Digital depth gage Fig. 15 CALCULATION EXAMPLE: Dimension I mm Dimension II mm Difference mm Axial play ( mm) - average e.g mm Result 2.05 mm Required thrust disc e.g. s = 2.00 mm Fig. 16 Insert determined thrust disc (e.g. s = 2.00 mm) into the planetary gear. Secure thrust disc by staking! /4

25 Legend to Picture: 3 1 = Planetary gear 2 = Bearing inner ring with cyl. rollers 3 = Plastic ring 4 = Angle ring (Assembly ring) Fig Pre-assemble planetary gear. Insert bearing inner ring (with cylindrical rollers) into the planetary gear and fix with angle rings. The stepped plain surfaces of the angle rings must always show outwards! Heat up bearing inner ring and line up planetary gear, until it is in contact. The large radius of the bearing inner ring is showing towards the planetary carrier base (downwards)! Fig. 18 Fix planetary gear with retaining ring. Analogously mount residual planetary gears. Oil O-ring (arrow) into the annular groove of the planetary carrier. (S) External pliers set Fig. 19 Line up planetary carrier and fasten with cylindrical bolt. Tightening torque (M10/12.9)... M A = 32 Nm Fig /5

26 6. AXLE EQUIPMENT - "with" FLANGE BRAKE or axle transmission case: For demonstration purposes, the adjacent sketch shows an axle of standard design "without" flange brake or axle transmission case). Fig. 1 Fig. 2 1 Legend to sketch: 1 = Input flange 2 = Axle drive housing 3 = Axle casing 6.1 DESIGN "with" HYDR. SIMPLEX-BRAKE: Axle with flange brake. "Hydraulic - Simplex Brake" Type. 160 x 40 (25704) Works at the brake must be performed duly considering the original "Function- and/maintenance instructions as well as the setting and Resetting instructions for the Hydraulic - Simplex Brake of the component manufacturer see Section 6.1.1, page 6/5... 6/10! To support the assembly, below some working steps are illustrated! 3 X 2 1 Legend to sketch: 1 = Axle drive housing 5 = Input flange 2 = Shaft sealing ring 6 = Brake drum 3 = Brake carrier 7 = Hexagon bolt/washer 4 = Brake 4 X = Installation dimension mm 6 Fig Apply sealing compound (Loctite No. 574)to the contact surface of the shaft sealing ring and drive in shaft sealing ring considering the installation dimension X see sketch No. 3. Grease shaft sealing ring near the dust- and sealing lip (Grease = PETAMO, ZF ordering-no.: )! The use of the specified support ensures the exact installation position of the shaft sealing ring! (S) Support Fig /1

27 Line up brake carrier and fasten it with cylindrical screw. Tightening torque (M14/8.8)... M A = 125 Nm Fig Nm Pre-assemble brake anchor plate Nm Nm Tightening torques: Wheel brake cylinder M A = 8-12 Nm Venting plug M A = 3-5 Nm Pressure connection M A = Nm X X 42,4 mm Adjust resetting unit "X" to dimension mm prior to the assembly of the brake shoes. Fig. 6 Individual components of the Hydraulic Simplex Brake. Fig. 7 Line up pre-assembled brake anchor plate and fasten it. Tightening torque (M12/10.9)... M A = 115 Nm Fig /2

28 Insert both bolts (support). Fig. 9 Introduce brake cable, fix it with spring disc (arrow) and suspend it into the yoke of the brake shoe. Observe installation position of the spring disc the concave side must show towards the feed bore! Fig. 10 Insert tappet, fix brake shoes with down-holder (compression spring) and suspend recoil springs. Fig. 11 Mount stud bolt with securing compound (Loctite No. 262) into the input flange. Tightening torque (M8/12.9)... M A = 11 Nm Fig /3

29 Line up flange and fix disc with hexagon bolt. Fig. 13 Finally fasten flange. Tightening torque (M20x1.5/12.9)... M A = 400 Nm (S) Clamping fork Fig. 14 Line up brake drum and fasten it.. Tightening torque (M6/8.8)... M A = 9.5 Nm Fig. 15 Setting of the brake see Function- and Maintenance instructions of the component manufacturer (brake) in Section page 6/5... 6/10. Fig /4

30 Section Hydraulic-Simplex-Brake Type 160 x 40 (Messrs. Knott) REFERENCE: The present assembly instructions are the non-modified reprint of the original assembly instructions of the component manufacturer. In this respect, the ZF Passau GmbH will not be liable for mistakes in these assembly instructions and is, in particular, not responsible for the positive knowledge of a new edition on the side of the user of these instructions. ZF Passau GmbH Donaustr D Passau 6/5

31 Technical Information 37/88 Functioning- and Maintenance Instructions Hydraulic-Simplex-Brakes 1 Functioning of the Hydraulic-Simplex-Brake. Functioning of this brake is based on it that, after expanding of the wheel cylinder, both brake shoes are brought into contact with the interior of the brake drum. Due to the rigid support, the engaging brake shoe (primary shoe) is pressed against the brake drum in the sense of rotation and the disengaging brake shoe (secondary shoe) opposite to the sense of rotation. Such, the braking effect is nearly identical in both driving directions. Legend: Vorwärtsfahrt = Forward driving 1 Slack adjuster In the case of these brakes, a resetting screw is arranged on the rear of the brake carrier via which the brake shoes can be steplessly reset using a resetting wedge. 2 Wheel cylinders The pressure generated via the control system is transmitted onto the brake shoes by the pistons of the wheel cylinders. 6/7

32 2.1 Maintenance Upon every periodical brake check, the wheel cylinder and its connection elements must be checked for leakages. 2.2 Repair instructions After having disassembled the cylinder, all individual components as well as housings must be subject to a thorough visual inspection. To renew the individual components, repair kits are available. Here, it is urgently recommended to replace them completely and not only partly. Important! Make sure, when using mineral oil or synthetic brake fluid as operating medium, that accordingly resistant sealing sets are installed as otherwise proper functioning of the wheel cylinder is no more ensured. For cleaning the cylinder and its individual components, only use methylated spirit. By no means, detergents are permitted to be used which contain mineral oil. Upon assembly, ensure the correct sequence of the parts using a suitable assembly paste or liquid. If, during the visual inspection of the cylinder liner, defects such as corrosion pits, grooves or other damage should be noticed in the housing, the wheel cylinder must be replaced as complete unit, which must be obtained from the respective manufacturer of the vehicle or the brake indicating the ordering number. After the completion of the works on the hydraulic system, check the brake liquid level in the reservoir and refill, if necessary. Then, carefully bleed at the main cylinder or the wheel cylinders as directed by the vehicle manufacturer. 3 Brake shoes 3.1 Maintenance and checks Normally, the brake shoes are maintenance-free; here, only a check for damaged parts should be made and the unhindered movement of the locking lever (if existing) be made sure. Depending on the vehicle application, the brake lining thickness must be checked at regular intervals, at the latest every half year. In case of a small residual lining thickness, these intervals must be accordingly reduced to avoid major damage to brakes or drum. As, depending on the application, brake linings are glued or riveted, different lining thickness must be considered. Brake lining riveted: min. residual thickness mm above the rivet head at the weakest lining point. Brake lining glued: min. residual thickness 1.0 mm at the weakest lining point. When these thickness are reached, the brake lining must be renewed as directed below. 6/8

33 3.2 Repair or replacement of the brake shoes Upon contamination, irregular wear, insufficient braking effect and reaching of the residual thickness, brake linings or shoes must be renewed or replaced. Note: Here, in any case, all shoes or linings at one axle must be renewed to avoid the risk or non-uniform braking behaviour. Riveted linings can be riveted and unriveted in suitably equipped workshops observing the common regulations. Important! To that end, however, genuine spare linings of Messrs. Knott must be procured and used. When using other spare parts, a warranty or guarantee for the brake and its functioning is not granted. In the case of glued brake linings, the renewal can be realised by replacing the brake shoes. Note! For the replacement, a genuine Knott spare part ready for installation is supplied by the vehicle or brake manufacturer with indication of the ordering number. Important! When using foreign parts or using other linings than directed, any warranty for the brake will expire. After the installation of new brake shoes or a repair, the brake must be properly set as directed by the manufacturer Messrs. Knott. 4 Brake drum If a check should reveal major grooves at the drum surface, the brake drum can be hollowed out by turning as directed by the vehicle manufacturer. If no instructions in this respect should exists, use the following table duly considering the wall thickness. Max. admiss. turning measures for brake drums Brake size Drum ø new (mm) max. turning ø (mm) 160 x x x 30/ x 40/ Here, it must be ensured that always both brake drums of one axle are re-worked to the same measure. Note: For re-worked brake drums, brake linings of overmeasure must be used. 6 General Defects or damage found at parts not mentioned must, of course, be eliminated or genuine spare parts installed. Missing information or more precise instructions must be obtained from the vehicle or brake manufacturer. 6/9 TM3788.DOC

34 Setting instructions: TECHNICAL INFORMATION 58/96 Setting- and resetting instructions Brake Hydr. Simplex applicable to brake size: 160x40, 180x40, 200x30, 200x50, 203.2x40 Setting of the brake is necessary after the installation of new brake shoes and brake drums of any repair stage, upon an insufficient braking effect as well as in case of an excessively large path of the actuating element. The setting procedure must generally be performed with cold brake. Moreover, generally all brakes at the vehicle must be set. When performing setting works at the lower slack adjuster, the locking device must be released, i.e. the control cables must not be tensioned. Perform setting and resetting of the brake as follows: 1. Jack up vehicle brake drum or wheel must permit unhindered turning. 2. Tighten self-locking bolt (WAF 17) in the expansion wedge with a suitable box spanner or socket spanner (no open-end wrench), until the brake drum can no more be turned by hand. Resetting direction clockwise seen onto the bolt head. Important: After the brake shoes are in contact with the drum, do not apply excessive force to the box spanner as this could entail damage to the slack adjuster and the brake shoes. 3. Then, unscrew hexagon bolt, until the wheel can be turned without audible dragging of the brake shoe in the brake drum. If this procedure should not be possible due to the installation position of the brake (e.g. driveline), prior to setting the brake, the brake drum must be withdrawn and the brake shoes be set to the dimension as per assembly drawing. Check the shoe radius related to the rotation axis using a slide gage. To ensure a uniform wear of the brake linings, it is recommended to also set the locking device. 4. Set brake control cables such that the brake shoes do not drag in the brake drum when turning the wheel. 5. Tighten hand brake lever according to the engaging instructions of the vehicle manufacturer. In this position, the wheels must permit uniformly heavy turning. Attention: A correction of non-uniformly heavy rotating wheels is only permitted to be made at the brake control cables and not at the slack adjuster of the brake. 6. Remove jacks from vehicle check braking behaviour of the vehicle. 6/ TM5869.DOC

35 6.2 EXECUTION "with" HYDRAULIC SERVO-BRAKE: Fig. 20 "Hydraulic Servo-Brake" Type: 203 x 60 (100716) Works at the brake are only permitted to be performed considering the original "Functioning- and/maintenance instructions as well as the Setting and Resetting instructions for the Hydraulic Servo-Brake of the component manufacturer see section 6.2.1, page 6/17! For supporting the assembly, below some working steps are shown in the pictures. 1 3 X Legend to sketch: 1 = Axle drive housing 5 = Resetting device 2 = Shaft sealing ring 6 = Input flange 3 = Brake carrier 7 = Hexagon bolt/disc 4 = Brake 8 = Brake drum X = Installation dimension mm Fig Apply sealing compound (Loctite No. 574) to the contact surface (external diameter) of the shaft sealing ring and drive in shaft sealing ring considering the installation dimension X see sketch No. 21. Grease shaft sealing ring near dust- and sealing lip (Grease = PETAMO, ZF ordering No.: )! The use of the specified support ensures the exact installation position of the shaft sealing ring! Fig. 22 (S) Support Line up brake carrier and fasten it with cylindrical bolts. Tightening torque (M14/8.8)... M A = 125 Nm (S) Socket spanner (S) Torque spanner Fig /11

36 2,5-4 Nm Nm 8-10 Nm 8-10 Nm Pre-assemble brake anchor plate. Tightening torques: O Wheel br. cylinder M A = 8 10 Nm Spring holder M A = 8-10 Nm Venting plug M A = Nm Pressure connection M A = Nm Resetting device M A = Nm Wheel brake cyl. M A = 115 Nm D Nm X 115 Nm X = Setting mm D = Resetting sense O = Opening for lining wear measurement Fig. 24 Pre-assemble brake anchor plate also see Sketch-No.. Mount screw neck with sealing ring. Tightening torque... M A = 25 Nm Fig. 25 Single components of the Hydraulic Simplex - Brake Fig. 26 Introduce control cable. Retract compression spring and insert spring disc. Observe installation position of the spring disc concave side must show towards the pass through bore! Fig /12

37 Fasten pre-assembled brake anchor plate with cylindrical bolts. (S) Tightening torque (M 12/10.9)... M A = 115 Nm Fig. 28 Suspend control cable to the yoke of the brake shoe (see arrow). Fig. 29 Position brake shoe and fix it with pressure spring (downholder). Fig. 30 Position tappet, line up pressure spring and disc. Observe installation position of the tappet! Fig /13

38 Position second brake shoe (here, insert tappet with pressure spring and disc) and fix with pressure spring. Fig. 32 Suspend lower coil spring. (S) Spring hook Fig. 33 Hook both coil springs in the brake shoes and suspend to spring holder. (S) Spring hook Fig. 34 Only required upon the assembly of new parts: Insert stud bolts into the flange. Insert stud bolts with securing compound - Loctite No. 262! (S) Tightening torque (M 10/10.9)... M A = 17 Nm Fig /14

39 Line up flange. Fig. 36 Fasten flange with disc and hexagon bolt. Insert hexagon bolt with securing compound - Loctite No. 262! Tightening torque... M A = 400 Nm (S) Clamping fork Fig. 37 Line up brake drum and fasten with cylindrical bolts. (S) Tightening torque (M6/8.8)... M A = 9.5 Nm Fig. 38 Adjustment of the resetting device/brake see functioning and maintenance instructions of the component manufacturer (brake) in section 6.2.1, page 6/ /26! Fig /15

40 Section Function-, Maintenance- and Assembly Instructions Setting instructions Hydraulic-Servo-Brake Type: 203 x 60 (Messrs. Knott) INFORMATION: The present assembly instructions are the non-modified reprint of the original assembly instructions of the component manufacturer. On that basis, the ZF Passau GmbH will not be liable for mistakes in these assembly instructions and is, in particular, not responsible for the positive knowledge of a new edition on the side of the user of these instructions. ZF Passau GmbH Donaustr D Passau 6/17

41 1 Functioning of the Hydraulic-Servo-Brake. Technical Information 25/82 Function- and Maintenance Instructions Hydraulic-Servo-Brakes Functioning of the this brake is based on it that, after expanding of the wheel cylinder, two brake shoes are brought into contact with the interior of the brake drum; one brake shoe (primary shoe) is carried in the rotation direction of the brake drum, while the other brake shoe (secondary shoe) is supported against a fixed point on top of the brake carrier or wheel cylinder due to the lower, floating suspension. By the additional force of the overrunning brake shoe, the so-called self-energising effect (servo effect) of the brake is achieved. The braking effect is nearly identical in both driving directions. Legend: Vorwärtsfahrt = Forward driving Resetting device The lower, floating suspension is mostly designed as resetting device, optionally using a mechanical or automatic version. Note: For maintenance purposes or handling for a setting procedure, the separate instructions of the manufacturer Messrs. Knott must be observed and performed. 2 Wheel cylinders The pressure generated via the control system is transmitted onto the brake shoes via the pistons of the wheel cylinders. continuation next page 6/19

42 2.1 Maintenance Upon every periodical brake check, the wheel cylinder and its connection elements must be checked for leakages. 2.2 Repair instructions After having disassembled the cylinder, all individual components as well as housings must be subject to a thorough visual inspection. To renew the individual components, repair kits are available. Here, it is urgently recommended to replace them completely and not only in part. For cleaning the cylinder and its individual components, only us methylated spirit. By no means, detergents are permitted to be used which contain mineral oil. Upon assembly, ensure the correct sequence of the parts using a suitable assembly paste or liquid. If, during the visual inspection of the cylinder liner, defects such as corrosion pits, grooves or other damage should be noticed in the housing, the wheel cylinder must be replaced as complete unit, which must be obtained from the respective manufacturer of the vehicle or of the brake indicating the ordering number. After the completion of the works on the hydraulic system, check the brake liquid level in the reservoir and refill, if necessary. Then, carefully bleed at the main or the wheel cylinders as directed by the vehicle manufacturer. 3 Brake shoes 3.1 Maintenance and checks Normally, the brake shoes are maintenance-free; here, only a check for damaged parts should be made and the unhindered movement of the locking device be made sure. Depending on the vehicle application, the brake lining thickness must be checked at regular intervals via the wear control bore by a visual inspection at the latest, every half year. In case of a small residual lining thickness, these intervals must be accordingly reduced to avoid major damage to brake or drum. As, depending on the application, brake linings are glued or riveted, different lining thicknesses must be observed. Brake lining riveted: min. residual thickness mm above the rivet head at the weakest lining point. Brake lining glued: min. residual thickness 2.0 mm at the weakest lining point. When these thicknesses are reached, the brake lining must be renewed as directed below. 3.2 Repair or replacement of the brake shoes Upon contamination, irregular wear, insufficient braking effect and reaching of the residual thickness, brake linings or shoes must be renewed or replaced. Note: Here, in any case, all shoes or linings at one axle must be renewed to avoid the risk of non-uniform braking behaviour. continuation next page 6/20

43 Riveted linings can be riveted and unriveted in suitably equipped workshops observing the common regulations. Important! To that end, however, genuine spare linings of Messrs. Knott must be procured and used. When using other spare parts, a warranty or guarantee for the brake and its functioning is not granted. In the case of glued brake linings, the renewal can be realised by replacing the brake shoes. Note! For the replacement, a genuine Knott spare part ready for installation is supplied by the vehicle or brake manufacturer with indication of the ordering number. Important! When using foreign parts or linings other than directed, any warranty for the brake will expire. After the installation of new brake shoes or a repair, the brake must be properly set as directed by the manufacturer Messrs. Knott. 4 Brake drum If a check should reveal major grooves at the drum surface, the brake drum can be hollowed out by turning as directed by the vehicle manufacturer. If no instructions in this respect should exists, use the following table duly considering the wall thickness. Max. admiss. turning measures for brake drums Brake size Drum ø new (mm) max. turning ø (mm) 180 x x x 40 and x x x 40 and x x 60 and x x x x ,5 432 x Here, it must be ensured that always both brake drums of one axle are re-worked to the same measure. Note: For re-worked brake drums, brake linings of overmeasure must be used. 6 General Defects or damage found at parts not mentioned must, of course, be eliminated or genuine spare parts installed. Missing information or more precise instructions must be obtained from the vehicle or brake manufacturer.. TM2582.DOC 6/21

44 Technical Information 24/82 Mechanical resetting device for Hydraulic - Servo - Brakes. These hydraulic Servo-Brakes comprise a central resetting device for both brake shoes (see Fig. 2). 1. Maintenance instructions Upon every periodical brake check, the resetting device (see Fig. 1) must be checked for damaged parts. 2. Note: Repairs at the resetting device are not admissible; if required, the entire resetting device must be replaced. Fig. 1 The resetting device is largely maintenance-free, only the thread of the resetting bolts 1 must be slightly greased with a heat-resistant grease upon the disassembly of the brake shoes. 2. Setting instructions Setting of the brake is necessary after the installation of new brake shoes and brake drum, any repair stages, an insufficient braking effect as well in case of an excessive path of the control element. The setting procedure must generally be performed with cold brake; service brake and locking brake should only be commonly set. The brake must be reset or basically set as follows: 3. Basic setting During this setting, the locking brake must be released, i.e. the control cable must not be tensioned. 3.1 Jack up vehicle the brake drum or wheel must freely rotate. 3.2 Unfix brake control cables at the compensating beam. 3.3 Remove plastic closure cap 2 from the bore which is arranged on the opposite side of the wheel cylinder in the brake carrier. 3.4 Unscrew self-locking hexagon bolt 3 for fastening the resetting device (WAF-19). 3.5 Tension resetting gear 4 introducing a screw driver or suitable resetting device and applying leverage, until the brake drum can no more be manually turned.. By this setting, at the same time, the brake shoes and the resetting device, respectively, are centered in the brake drum. continuation next page 6/22

45 3.6 Tighten self-locking hexagon bolt 3 with the specified tightening torque of 115 Nm 3.7 Then, turn back resetting wheel 4, until the wheel can be turned without audible dragging of the brake shoes in the brake drum. 3.8 Adjust brake control cables such that the brake shoes do not drag in the drum when rotating the wheel. 3.9 Activate locking brake lever according to the detent instructions of the vehicle manufacturer. In this position, the wheels must rotate uniformly heavy. Attention! A correction of non-uniformly heavy rotating wheels is only permitted at the brake cables and not at the slack adjuster Mount closure cap Remove jack.- check braking behaviour of the vehicle. 4. Resetting procedure 4.1 Jack up vehicle. 4.2 Remove closure cap 2 at the rear of the brake carrier. 4.3 Tension resetting wheel 4 with a suitable tool, until the wheel can no more be turned through. 4.4 Then, turn back resetting wheel 4, until the wheel can be turned without audible dragging of the brake shoes in the brake drum. 4.5 Mount closure cap Remove jack and check braking behaviour of the vehicle. Fig. 2 Generally, all brakes of the vehicle must be set or reset. TM2482.DOC 6/23

46 Technical Information 36/87 Assembly Instructions Hydr. -Servo Brake 1. On the brake anchor plate (1), introduce the complete wheel cylinder (2) into the bore according to Fig. B. and fasten it from the rear with two retaining rings (3) and two cylindrical bolts (4) using an Allen wrench size 6 with a tightening torque of max. 25 Nm. 2. Then, place down-holder (5) according to Fig. C onto the armature web (6) and fasten it with two retaining rings (7) and two hexagon bolts (8) using a box spanner or socket spanner size 10 with a tightening torque of max. 10 Nm. Note: Important: Do not use an open end wrench as this would entail damage to the bolt or to the hexagon if not properly used. Absolutely make sure that the down-holder (5) is always mounted such that, upon the assembly of the left and right brake in the vehicle, the offset bore (9) is always showing into the direction 'forward driving'. continuation next page 6/24

47 3. Press the two round plugs (10) from the rear of the brake anchor plate (1) into the provided openings. 4. Insert the complete slack adjuster (11) and fasten it with shim (12), retaining ring (13) and hexagon bolt (14). Make sure that the toothed resetting wheel (16) is always on the left side seen from the front Bring brake shoes (17) and (18) into contact on top underneath the down-holder (5) laterally to the armature web (6). Make sure that the two pressure bolts (19) of the wheel cylinder (2) are within the calotte guide of the brake shoes. At the same time, according to Fig. E, introduce the brake shoes at the slack adjuster on either side into the slots of the threaded bolts (20). 6. Introduce the two pressure springs (21) through the bores in brake shoes and brake anchor plate and press them through so that spring saddle (22) can be suspended in the spring yoke. Then, relieve pressure spring and check, whether the curvature of the spring yoke (22) is fitting in the bore of the brake anchor plate. 7. Introduce the upper tension springs with the bent hook into the bore of the brake shoe and suspend it into the opening of the down-holder (5) using a suitable tool, e.g. spring pliers Suspend the lower tension spring (24), too, into the bore of the brake shoe using a suitable tool. 9. After the completion of the above working steps, check the proper execution and correct assembly of all parts. 10. Setting of the brake shoes: The pre-condition for a proper setting is that the brake shoes are centred following the procedure described below. continuation next page 6/25

48 Slide brake drum over the brake shoes. Through the rectangular opening (25), tension the toothed resetting wheel from the rear of the brake anchor plate using a screw driver or suitable resetting tool applying leverage, until the brake drum can no more be turned by hand. Such, the brake shoes are centred in the drum. In this condition, tighten the hexagon bolt (15), width across flanks 22 mm, with the specified Nm. Important: This tightening torque must absolutely be observed to avoid that, due to vibrations during driving or similar, the resetting is not affected. Then, turn back resetting wheel (16), until the brake drum can be turned without audible dragging of the brake shoes. 11. Press both rectangular plugs (26) from the rear of the brake anchor plate into the provided opening (25). 12. The further assembly of the brake such as connection of the hydraulic line to the wheel cylinder, bolt connection of the brake anchor plate etc. is subject to the directions of the axle or vehicle manufacturer Ra/Gn 6/26

49 6.3 VERSION "with" BHF - BRAKE: 1 3 BHF = Service- and hydraul. releasable locking brake (Multi-disc flange brake) Legend to sketch: 1 = Piston service brake 2 = Piston locking brake 3 = Emergency release device Fig Fasten disc to the axle with a hexagon bolt. Insert hexagon bolt with Loctite (Type-No. 243)! Tightening torque (M6/8.8)... M A = 9,5 Nm Fig. 41 Only for version "with" insert O-ring (see arrow 1) into the annular groove and grease it. Wet flange surface (see arrow 2) with Loctite (Type-No. 574). Fig. 42 Mount two adjusting screws and bring brake housing into contact with the axle casing. Observe installation position (see adjacent picture)! (S) Adjusting screws Fig /27

50 Fasten brake housing with cylindrical bolts. Insert cylindrical bolts with Loctite (Type-No. 243)! Tightening torque (M14/ M A = 185 Nm Fig. 44 Heat up both support rings in the oil bath and insert them into the recesses of the piston. Then, mount grooved ring and oil it (use W-10 oils). Observe installation position, see sketch No. 46! Fig Legend to sketch: 1 = Disc carrier 2 = Support ring 3 = Grooved ring Fig. 46 After cooling down of the support rings, line disc carrier into the brake housing. Observe installation position see marking/disassembly page 1/12, Fig. 37! Fig /28

51 Line support (see arrow) onto the input pinion or into the disc carrier, mount disc and screw on hexagon nut. Then, press disc carrier into contact using an assembly lever. (S) Support (S) Assembly lever Fig. 48 Setting the disc clearance mm: (Fig ) Line end disc into the disc carrier, until it is in contact. Observe installation position, see following sketch! Fig. 49 Legend to sketch: 1 = End disc 2 = Disc carrier 3 = Brake housing Fig. 50 Line up spline bush (S), until it is in contact. Lining up of the spline bush (S) is necessary to permit the subsequent assembly of the input flange! (S) Spline bush Fig /29

52 Alternatingly mount inner and outer disc starting with an outer disc. According to experience, the required disc clearance results when mounting 5 outer discs of thickness s = 3.0 mm and 1 outer disc of thickness s = 2.8 mm! However, measuring of the disc clearance is nevertheless necessary to ensure proper functioning of the multi-disc brake! When mounting outer discs of different thickness, the weaker outer discs must generally be mounted on the side of the end shim! Fig. 52 Fix disc clearance with preloading strips. (S) Preloading strips Fig. 53 Determine measure from the front face of the brake housing up to the plane face of the outer disc. Measure I e.g mm (S) Measuring ledge (S) Digital depth gage Fig. 54 Place piston onto the spring casing. Temporarily mount individual components (Fig.-No. 55 and 56) without sealing elements! Fig /30

53 Place spacer ring. Fig. 56 Measure dimension II from the front face of the piston up to the flange surface of the spacer ring. Dimension II e.g ,85 mm (S) Measuring ledge (S) Digital depth gage Fig. 57 CALCULATION EXAMPLE: Dimension I... Dimension II... - Difference = disc clearance mm mm 1.60 mm In case of a deviation from the required disc clearance ( mm), correct with suitable outer discs (s = 2.8, s = 3.0 or s = 3.2 mm)! Oil disc use oil as per ZF list of lubricants TE-ML 05! Mount stud bolt. Insert stud bolt with Loctite (Type-No. 262)! Tightening torque... M A = 46 Nm Fig /31

54 Insert grooved ring (see arrow) into the annular groove of the piston and oil it. Observe installation position, see sketch No. 60! Fig. 59 Legend to sketch: 1 1 = Grooved ring 2 = Piston 2 Fig. 60 Insert four-lip ring (see arrow) into the annular groove of the spacer ring and oil it. Fig. 61 Insert piston into the intermediate ring and carefully press it into contact using a hand press. Observe radial installation position of the piston, see adjacent picture! (S) Support Fig /32

55 X Workshop Manual Press shaft sealing ring (part 1) into the spring casing. When using the specified support, the exact installation position will result (see following sketch)! Directly prior to mounting it, wet outer diameter of the shaft sealing ring with spirit and grease the area dust-/sealing lip (grease = PETAMO, ZF-ordering-No.: )! The shaft sealing ring comprises 2 parts, part 2 is subsequently pressed onto the input flange (see Fig. 73)! Fig. 63 (S) Support Legend to sketch = Shaft sealing ring part = Shaft sealing ring part 2 2 = Spring casing X = Installation dimension mm (S) Support Fig. 64 Insert O-ring (see arrow) into the annular groove and grease it. Fig. 65 Insert pressure springs (2 units, each/bore) into the spring casing. Fig /33

56 Place pre-assembled spacer ring. Observe radial installation position! Fig. 67 Insert pressure springs into the bores using grease. Inset O-ring (see arrow) into the annular groove and grease it. Fig. 68 Mount two adjusting screws and line up pre-assembled spacer ring including spring casing. (S) Adjusting screws Fig. 69 Uniformly tighten piston or spacer ring, until it is in contact, first using the old locking nuts which were removed upon the disassembly. Fig /34

57 Uniformly tighten spring casing including spacer ring, until it is in contact with the axle casing using cylindrical bolts. Then, remove again old locking nuts. Tightening torque (M12/8.8)... M A = 79 Nm Fig. 71 Press part 2 of the shaft sealing ring (see dimension "X" Fig.- No. 73) onto the input flange. Wet contact surface of the sheet with Loctite (Type-No. 243)! When using the specified support, the exact installation position will result! (S) Support Fig. 72 X X = Installation dimension - part 2 of the shaft sealing ring (see Fig.-No. 72). Mount stud bolts. Insert stud bolts with securing compound (Loctite-No. 262)! Tightening torque... M A = 11 Nm Fig. 73 Withdraw splined bush (S) from the disc pack.. (S) Splined bush Fig /35

58 Maß X Maß I Workshop Manual Line input flange into the disc pack, until it is in contact. Fig. 75 Fasten input flange with disc and hexagon nut or cylindrical bolt depending on the version. Insert hexagon nut or cylindrical bolt with securing compound (Loctite No. 262)! Cylindrical bolt Tightening torque (M 20x1,5/12.9)... M A = 400 Nm Hexagon nut... M A = 600 Nm Fig. 76 Einschraubdistanz 2,9-0,5 mm Setting the screw-in distance " mm" of the emergency release nut: (Fig ) The measuring procedure must be performed on either side or at both locking nuts! Fig. 77 Determine dimension I (see sketch 77) from the front face up to the bore base. Dimension I e.g mm (S) Digital depth gage Fig /36

59 Measure dimension II (thickness of the locking nut). Dimension II e.g mm CALCULATION EXAMPLE: Dimension I mm Dimension II mm mm Screw-in distance mm e.g mm results in dimension X (see sketch 77) mm Fig. 79 Turn locking nut, until dimension X e.g mm is achieved. Check again dimension X e.g mm. Only new locking nuts are permitted to be used! Fig. 80 Line up spare discs (1 unit, each/bore or resetting device). The spare disc serves for a possible subsequent resetting (after wear) of the brake! Fig. 81 Mount sleeves (see arrow). Tightening torque... M A = 46 Nm Fig /37

60 Maß II Maß I Lüftspiel 1,0...1,4 mm Workshop Manual Setting the release play mm: (Sketch-No ) The measuring procedure must be performed on either side or at both resetting devices1 Fig. 83 Determine dimension I (see sketch 83) from the contact surface of the locking bolt up to the plane surface of the sleeve. Dimension I e.g ,20 mm Fig. 84 Determine dimension II (see sketch 72), (Fig. 85 and 86): Measure dimension "A" from the front face of the locking bolt up to the bore base. Dimension A e.g mm Fig. 85 Determine dimension "B" from the front face of the locking bolt up to the collar. Dimension B e.g.... CALCULATION EXAMPLE: Dimension A e.g.... Dimension B e.g results in dimension II e.g mm mm mm 1.80 mm CALCULATION EXAMPLE: Fig. 86 Dimension I e.g.... Dimension II e.g mm mm 4.00 mm Release play mm e.g mm Result spacer s = 3.00 mm /38

61 Insert spacers e.g. s = 3.00 mm into the locking bolt. Analogously perform measuring procedure at the second resetting device or locking bolt! The difference of the release play between left and right end stop is permitted to be max mm! Fig. 87 Mount locking bolts with new O-ring and install it. Tightening torque... M A = 80 Nm Fig. 88 Mount locking bolts (see arrow 1) with new O-ring and install them. Then, mount vent (see arrow 2). Tightening torque... M A = 35 Nm Fig. 89 Checking hydraulic brake system of the service brake for tightness: Mount pressure connection. Prior to starting the check, vent hydraulic brake system and repeatedly operate it (min. 10 times)! (S) High-pressure pump (S) Screw-type coupling (S) Breather bottle Fig /39

62 Check: Establish test pressure p = 120 bar and close connection to high-pressure pump via shut-off valve During a testing time of 5 minutes, a pressure drop of max 2% (p = 117 bar) is admissible. Test media: Engine oils SAE 10-W corresponding to, MIL-L 2104C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils Type A, Suffic A Dexron of II D. Checking the hydraulic braking system of the locking brake for tightness: Mount pressure connection. Prior to starting the check, vent hydraulic brake system and repeatedly operate it (min. 10 times). Check: Establish test pressure p = 25 bar and close connection to the high-pressure pump via shut-off valve Fig. 91 During a test time of 5 minutes, a pressure drop of max 2% (p = 24.5 bar) is admissible! Test media: Engine oils SAE 10-W corresponding to, MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils Type A, Suffic A Dexron of II D. Only for version "with" hexagon nut: Secure hexagon nut against jamming. Fig /40

63 6.3.1 INFORMATION on DISPLACEMENT or EMERGENCY TOWING of the VEHICLE The parking brake is preloaded (engaged) by spring power. If pressure for venting the hydraulic parking brake cannot be built up in the vehicle (e.g. engine stop), for towing or displacing the vehicle, the mechanical emergency venting system must be activated as follows Maß I Legend to sketch: 1 = Locking bolt 2 = Spacers 3 = Sleeve 4 = Spare disc 5 = Retaining nut 6 = Brake piston 7 = Disc pack Fig Unscrew both locking bolts. Observe spacers becoming free! Mark installation position of the locking bolts with the pertaining spacers to the spring casing. Fig. 94 Unfix both sleeves and remove spare discs becoming free. Fig /41

64 Determine dimension I (see sketch No. 93) from the front face of the spring casing up to the plane surface of the retaining nut at both emergency release devices or on either side. Dimension I e.g mm Then, uniformly screw in both retaining nuts, until the preload force of the pressure springs is eliminated or the disc pack is released. Fig. 96 After having displaced the vehicle, proper functioning of the brake must be ensured again! To that end, uniformly screw back again both retaining nuts into their original position (as determined in Fig.-No. 96)! If dimension I (see Fig.-No. 96) was not determined prior to releasing the brake, the complete measuring procedure (setting the screw-in distance of the emergency release nut see page 6/36) must be performed! Fig. 97 Line up spare disc (1 unit, each/bore) and mount sleeves again. Tightening torque... M A = 46 Nm Fig. 98 Mount locking bolts with the pertaining spacers. Tightening torque... M A = 80 Nm Observe installation position see marking Fig. 94! If the installation position of the locking bolts with the pertaining spacers was not marked, the complete measuring procedure (setting the release play see page 6/38) must be performed. Fig. 99 For the admissible towing speed as well as the distance of the admissible towing path, the data given by the vehicle manufacturer are binding considering the legal regulations! /42

65 6.3.2 BRAKE LINING WEAR MEASUREMENT A measurement of the brake lining wear gives restricted information on the overall condition of the brake disc pack without disassembling the brake. The measurement must be performed in particular in case of changed braking behaviour such as: - Braking noise - Changed deceleration - Changed brake oil level - Changed brake pressure as well as at least once per year. Perform wear measurement on either side or at both resetting devices! Release play new condition: Limit value release play with max. wear mm 2.0 mm Perform wear measurement: Maß a Maß b - Unscrew locking bolt Observe spacers becoming free! - Determine dimension a (front face/spring casing plane surface/sleeve). - Determine dimension b (plane surface/spacers collar/locking bolt). - Determine the difference between both dimensions. Dimension a - dimension b = actual value (release play + wear) If the admissible limit value ( 2.00 mm ) is exceeded, the release play can be reset once by inserting the spare disc (see arrow)! If no spare disc should be available, the brake has already been reset. If the admissible limit value (2.00 mm) is reached or exceeded a second time, the lining discs must be renewed! /43

66 6.4 VERSION "with" 1 axle transmission case 150: Wet flange surface (see arrow) with sealing compound (Loctite No. 574). Fig. 100 Mount two adjusting bolts (S) and bring housing into contact with the axle. (S) Adjusting bolts (M14) Fig. 101 Fasten housing with cylindrical bolts. Insert cylindrical bolts with securing compound (Loctite No. 574)! Tightening torque (M10/8.8) M A = 46 Nm Fig. 102 Line up screening plate, until it is in contact. Observe installation position, the opening of the screening plate (see arrow) must show upwards ('noon' clock position)! Fig /45

67 Mount stud bolts. Insert stud bolts with securing compound (Loctite No. 262)! Tightening torque (M8/12.9)... M A = 11 Nm Fig. 104 Line up spur gear on the input pinion, until it is in contact. Fig. 105 Line up disc. Fig. 106 Fasten spur gear with hexagon nut or cylindrical bolt depending on the version. Hexagon nut Tightening torque... M A = 800 Nm Fig. 107 Cylindrical bolt Tightening torque (M20x1.5/12.9)..... M A = 400 Nm Insert cylindrical bolt with securing compound (Loctite No. 262)! (S) Clamping fork /46

68 Only for version with hexagon nut: 1 Fig. 108 X Legend to sketch: 1 = Hexagon nut 2 = Pinion 3 = Washer 4 = Spur gear X = 3 4 threads to be continuously wetted with Loctite Continuously wet the first 3-4 threads of the hexagon nut with Loctite (Type-No.: 2701) (also see the following sketch)! Plane surfaces of hexagon nut and washer must be free from Loctite!. Press ball bearing onto the drive gear, until it is in contact. Fig. 109 Insert drive gear into the housing bore, until it is in contact. (S) Plastic mallet Fig. 110 Mount shaft sealing ring with the sealing lip showing towards the oil compartment. (S) Support Apply sealing compound (special type 1108, ZF-ordering No ) to the contact surface shaft sealing ring/housing and fill area of dust- and main sealing lip with grease. (Grease = PETAMO, ZF-orderingNo )! Fig. 111 When using the specified support, the exact installation position will result! /47

69 Mount two adjusting screws (S) and bring drive housing into contact with the housing. (S) Adjusting screws (M10) Wet contact surfaces of both housing halves with sealing compound (Loctite-No. 574)! Fig. 112 Temporarily screw housing halves manually together using cylindrical bolts. Insert cylindrical bolts with sealing compound (Loctite-No.: 574)! Fig. 113 Drive cylindrical pins (2 units, see arrows) into the housing bores. Observe installation position, see following sketch! Fig Legend to sketch: 1 = Housing 2 = Cylindrical pin 3 = Drive housing Fig /48

70 Finally fasten cylindrical bolts. Tightening torque (M10/8.8) M A = 46 Nm Fig. 116 Line up dust shield, until it is in contact with the spur gear. Fig. 117 Grease O-ring (see arrow) and mount it. Then, provide all locking bolts with new O-rings and mount them. Fig. 118 Prior to starting up the system, fill in oil as per lubricating instructions, page 0/4...0/5! /49