ZF AV 133 Setup guide

REPAIR INSTRUCTIONS
AV 133
Bus axle with compact bearing
BUSES

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

1Preface ....................................................................................................................... 5
1.1 Document overview .......................................................................................................................... 5
2Safety Instructions ...................................................................................................... 6
2.1 General safety instructions .............................................................................................................. 6
2.2 Signal words and symbols .............................................................................................................. 9
3Notes on Repairs and Assembly ................................................................................. 10
3.1 General notes ...................................................................................................................................... 10
3.2 Cleaning the ZF product .................................................................................................................. 10
3.3 Dismantling the ZF product ............................................................................................................ 10
3.4 Assembling the ZF product ............................................................................................................ 10
3.5 Cleaning parts .................................................................................................................................... 11
3.6 Reusing parts ...................................................................................................................................... 11
3.7 Replacing parts .................................................................................................................................. 11
3.8 Reworking parts ................................................................................................................................. 12
4Technical Data ............................................................................................................ 13
4.1 Oil grade .............................................................................................................................................. 13
4.2 Type plate ............................................................................................................................................. 13
5Setting Data ............................................................................................................... 14
6Tightening Torques ..................................................................................................... 15
7Workshop Equipment ................................................................................................. 17
7.1 Special tools ........................................................................................................................................ 17
7.2 Standard tools and fixtures ............................................................................................................. 30
7.3 Operating supplies and auxiliary materials ................................................................................. 35
8Dismantling ................................................................................................................ 36
8.1 Clamp the axle ................................................................................................................................... 36
8.2 Drain oil ................................................................................................................................................ 36
8.3 Remove mounting parts ................................................................................................................... 38
8.4 Removal of brake ............................................................................................................................... 39
8.5 Remove and dismantle hub. ........................................................................................................... 42
8.5.1 Remove hub ........................................................................................................................................ 42
8.5.2 Dismantling hub ................................................................................................................................. 44
8.6 Remove tachometer .......................................................................................................................... 47
8.7 Remove and dismantle left portal drive ....................................................................................... 48
8.7.1 Remove left portal drive ................................................................................................................... 48
8.7.2 Dismantling left portal drive ........................................................................................................... 48
8.8 Remove breather ................................................................................................................................ 57
8.9 Remove and dismantle right portal drive. ................................................................................... 58
8.9.1 Remove right portal drive ................................................................................................................ 58
8.9.2 Dismantle right portal drive ............................................................................................................ 58
Table of Contents
EN 4472.751.001 - 2015-11 3

8.10 Dismantle differential. ...................................................................................................................... 68
8.11 Remove input ...................................................................................................................................... 70
9Assembly .................................................................................................................... 74
9.1 Install input .......................................................................................................................................... 74
9.2 Assemble differential ........................................................................................................................ 79
9.3 Setting backlash and differential bearing rolling torque and checking axial run-out and
contact pattern. .................................................................................................................................. 81
9.4 Install shaft seal onto the drive ...................................................................................................... 86
9.5 Assemble and install left portal drive ........................................................................................... 88
9.5.1 Assemble left portal drive ............................................................................................................... 88
9.5.2 Install left portal drive ....................................................................................................................... 102
9.6 Assemble and install right portal drive ........................................................................................ 103
9.6.1 Assemble right portal drive ............................................................................................................. 103
9.6.2 Install right portal drive .................................................................................................................... 116
9.7 Install breather neck ......................................................................................................................... 117
9.8 Install breather .................................................................................................................................... 118
9.9 Install tachometer .............................................................................................................................. 118
9.10 Assemble and install hub ................................................................................................................ 120
9.10.1 Assembling hub ................................................................................................................................. 120
9.10.2 Install hub ............................................................................................................................................ 124
9.11 Install brake ......................................................................................................................................... 127
9.12 Install mounting parts ....................................................................................................................... 129
9.13 Filling oil ............................................................................................................................................... 131
10 Testing, Measuring, Adjusting ..................................................................................... 133
10.1 Check contact pattern ...................................................................................................................... 133
10.1.1 Contact pattern on crown wheel shifted towards the root ..................................................... 134
10.1.2 Contact pattern on the crown wheel shifted towards the tip ................................................ 135
11 Annex ......................................................................................................................... 136
11.1 Overview of revisions ........................................................................................................................ 136
Table of Contents
4EN 4472.751.001 - 2015-11

1 Preface
This documentation was developed for specialized staff trained in the operation of ZF products by
ZF Friedrichshafen AG (hereinafter referred to as "ZF").
Object of documentation is a ZF product. State of design acc. to date of issue.
The figures serve to illustrate the operation or the workflow and may deviate from your ZF product.
Illustrations and figures are not drawn to scale; therefore, no conclusions about size and weight can be
drawn.
The work described below may be performed by authorized, trained, and instructed specialized staff only.
It is the responsibility of the company that performs repair, assembly, or maintenance tasks to ensure that
their specialized staff is properly trained and that current documents are made available.
ZF Friedrichshafen AG
1.1 Document overview
The specifications listed in these documents must be observed because they are a prerequisite for fault-
free operation of the product and for the warranty granted by ZF Friedrichshafen AG. Please speak with
your contact if you need binding documents.
Document no. Designation Technical information
4472.758.101 Operating Instructions AV 110/AV 133
Tab. 1
Preface
EN 4472.751.001 - 2015-11 5

2 Safety Instructions
2.1 General safety instructions
Please read all safety instructions. Failure to comply with safety information and instructions may lead to
property damage, serious injuries, or death.
Intended use
The ZF product is exclusively intended for the application as defined in the contract and as agreed on
delivery. Any other or extended form of use does not comply with this definition of intended use. The
intended use includes compliance with this documentation and other applicable documents, in order to
avoid malfunctions and damage in operation.
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate.
However, this ZF product may pose dangers if improperly used by unauthorized, untrained, and
uninstructed specialized staff or if not used according to its intended use.
Repair, assembly, maintenance, and commissioning
Perform repair, assembly, and maintenance work exclusively according to this documentation on hand and
other applicable documents paying particular attention to the points mentioned below:
▪ Work must be performed in a professional manner and according to the technical provisions.
▪ Work must only be performed by trained, instructed, and authorized specialized staff.
▪ Only original ZF spare parts may be used.
▪ Only original ZF accessories may be used.
▪ Only original ZF special tools may be used.
▪ Changes and modifications of the ZF product may lead to the expiry of the operator's license, warranty,
or guarantee.
In case of damage, immediate action is mandatory in order to restore or guarantee full functionality and
safety / operational safety of the ZF product and to minimize the extent of damage.
In case of damage, contact ZF Services and have the following information ready:
▪ Product type, product parts list number, and serial number
▪ Total mileage [km]
▪ Progress of the damage
▪ Damage pattern
To avoid personal injury and damage to third-party products and the ZF product, this safety information,
all valid safety regulations, and legal requirements must be observed.
Country-specific safety, accident prevention, and environmental regulations apply irrespective of the
information provided in this document.
Safety-relevant workwear must be worn for all work. Depending on the type of work, additional protective
equipment, e.g. protective goggles, protective gloves, hard hat, and apron must be used. The workwear
must fit tightly so that it cannot get caught in turning or protruding parts.
Safety Instructions
6EN 4472.751.001 - 2015-11

After completion of repair, assembly, and maintenance work, as well as inspections, the specialized staff
must ensure that the ZF product is once more functioning perfectly and is safe to operate.
The user/operator is responsible for assigning the corresponding section of the documentation to the
correct target group. The former must ensure that the corresponding section of the documentation is kept
in close proximity to the ZF product and remains accessible to the concerned target group.
Using ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the ZF
product's operational safety.
Unless explicitly permitted, no repair, assembly, and maintenance work may be performed while the
engine is running. Secure the engine against an unintentional start and the vehicle against unintentional
movements. Attach a "Do not operate" sign which is visible for everyone! Keep uninvolved parties away.
Prior to starting work, always secure the ZF product properly using suitable means. Do not work on ZF
products that are only held with lifting equipment or a crane. Risk of injury from tilting or falling parts
and/or tools.
▪ Do not walk under suspended loads.
▪ Keep distance.
Lifting and moving heavy parts without tools may lead to health damage or serious injury.
▪ Only use permitted means of transport, lifting tools with a sufficient load capacity, and suitable lifting
technology.
▪ Observe safety regulations.
Increased risk of injury in the event of contact with cooled down or heated parts. Only touch parts when
wearing suitable protective gloves.
Noise
Wear suitable ear protection at all workplaces with a sound pressure level above 85 dB(A). The country-
specific safety regulations and the accident prevention regulations apply irrespective of this. Noise can
lead to a higher risk of accidents if the noise affects the perception of acoustic signals, warning calls, or
other sounds alerting to danger.
Handling operating supplies and auxiliary materials
Increased risk of injury at contact with heated, cooled down, or caustic operating supplies and auxiliary
materials (e.g. lubricants, cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources – do not smoke.
Store operating supplies and auxiliary materials in suitable and correctly labeled containers.
Use suitable protective clothing, protective gloves, and protective goggles/face protection.
Pay attention to the manufacturer's regulations and accident prevention regulations.
Safety Instructions
EN 4472.751.001 - 2015-11 7

Immediately seek medical assistance after contact with heated, cooled down, or caustic operating
supplies and auxiliary materials.
Environment
Operating supplies and auxiliary materials may not be allowed to enter the soil, groundwater, or sewage
system.
▪ Request material safety data sheets for the corresponding ZF products from your responsible
environmental protection authority, and observe them.
▪ Collect operating supplies and auxiliary materials in a sufficiently large container.
▪ Dispose of operating supplies and auxiliary materials, waste, containers, soaked cleaning cloths,
contaminated filters, etc. in accordance with the regulations of the environmental protection laws.
▪ Pay attention to the manufacturer's regulations and accident prevention regulations.
When selecting operating supplies and auxiliary materials, pay attention to health risks, environmental
compatibility, disposal regulations, and your country-specific opportunities to dispose of such materials
properly.
Safety Instructions
8EN 4472.751.001 - 2015-11

2.2 Signal words and symbols
This document contains particularly highlighted safety instructions which start with one of the following
signal words depending on the severity of the danger.
DANGER
The signal word DANGER indicates a dangerous situation that, if not prevented, will lead to a severe
injury or death.
ðInformation as to how the danger can be prevented.
WARNING
The signal word WARNING indicates a dangerous situation that, if not prevented, can lead to a severe
injury or death.
ðInformation as to how the danger can be prevented.
CAUTION
The signal word CAUTION indicates a dangerous situation that, if not prevented, can lead to a slight or
moderate injury.
ðInformation as to how the danger can be prevented.
The signal word NOTICE indicates a situation that, if not prevented, can lead to property damage.
ðInformation as to how the property damage can be prevented.
The following symbols are additionally used:
This symbol refers to additional, safety-relevant information.
This symbol indicates information concerning special workflows, methods, application of aids, etc.
Safety Instructions
EN 4472.751.001 - 2015-11 9

3 Notes on Repairs and Assembly
3.1 General notes
▪ Please read this documentation prior to starting repair or assembly work.
▪Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF
product is available. ZF Service Information may contain tests or supplements to the product or to
repair processes, which may not be included in this documentation. ZF Service Information is available
from all ZF Services Partner or from the ZF-ServiceLine.
▪ In cases of doubt, always contact the relevant expert departments of ZF Services.
▪ Please ensure that all work on the ZF product is performed expertly and under clean conditions.
▪ Use the specified special tools and equipment intended for the working procedures described.
▪ Please perform all work according to the working procedure described.
▪ Cover opened ZF products to prevent entry of foreign matter.
▪ Cover parts that have been removed and that are reusable, and protect them against dirt and damage.
▪ After completion of work and inspections, specialized staff must ensure that the ZF product is again
functioning perfectly and is safe to operate.
3.2 Cleaning the ZF product
Clean the ZF product with an appropriate cleaning agent prior to repair or assembly works.
Possible damage to ZF product due to water infiltration.
ðBe careful when using a pressure washer on the ZF product.
3.3 Dismantling the ZF product
▪ To avoid mixing up parts, the parts must be clearly assigned to the disassembled ZF product. In
particular, this applies to gear parts, reusable spacer washers or shims, electronic components, etc.
▪ Assemblies which must not be disassembled or are only available as spare parts assembly are
described accordingly. Please refer to the spare parts catalog for the ZF product.
▪ Inspect the parts during disassembly in order to find a potential cause of damage.
3.4 Assembling the ZF product
Assemble the ZF product at a clean workplace. The order of work steps, configuration data, and
tightening torques must be retained. Use the special tools specified in the work steps.
Bearings
The provisions for assembly of the bearings are described in the respective work step. Each bearing
integrated must be lubricated with operating oil after assembly.
Notes on Repairs and Assembly
10 EN 4472.751.001 - 2015-11