Golden Dragon XML6125CLE Repair Manual Download | Manualshive

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R e p a i r M a n u a l

Corporate Division

Off-Road Driveline

Technology and Axle Systems

5871 214 102

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PREFACE

This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair
and maintenance work to be done on ZF units.

This manual 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 different 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 AG 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 are excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.

This manual is based on the state-of-the-art at the time of printing.
It was prepared with utmost care in order to avoid errors.
However, we shall not be liable for any possible errors in figures or descriptions.

ZF Friedrichshafen AG

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Summary of Contents for XML6125CLE

Page 1: ......

Page 2: ...cifications or procedures in this catalogue may not be in accordance with specific objects Golden Dragon has the right to modify them without notification in advance Any detail should be subject to the modified parts should there be any modification Please contact with our After sales Service Center if you need to know more details about our repair data and other data or hope to further check the ...

Page 3: ...of bus systems Chapter Model XML6125CLE GI General Instructions GI XML6125CLE 01 ED Electric drive system EN XML6125CLE 01 PP Transmission shaft PP XML6125CLE 01 FA Front axle FA XML6125CLE 01 RA Rear axle RA XML6125CLE 01 SU Air suspension system SU XML6125CLE 01 SR Steering system SR XML6125CLE 01 BR Brake system BR XML6125CLE 01 WT Wheel and tyre WT XML6125CLE 01 1 2 ...

Page 4: ...ꞏꞏꞏꞏꞏꞏꞏGI 8 1 Disassembly procedure requirements 2 Assembly procedure requirements 3 Pipeline connecting 4 Sealant application specifications 5 Thread sealant adhesive application specifications 6 Seal tape winding specifications Troubleshooting flow chart ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏGI 11 Introduction of bus oils and fluidsꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ...

Page 5: ...ended to remove the key from the switch In order to avoid severe scalds the operator shall avoid touching hot metal parts like engine exhaust manifold radiator muffler exhaust pipe and tail pipe Do not smoke while working on the bus because the engine s fuel and the gases discharged from the battery are both inflammables Take special care while working on the battery because it contains corrosive ...

Page 6: ...rential or rear axle shaft is in trouble please remove both left and right rear axle shafts and seal the openings of the wheel hubs to avoid losses of lubricating oils in the axles and ingress of dusts or foreign matters Use heavy duty cables to tow a vehicle Fasten the cable securely to the hook of the frame Connect the cable to the hook so that the angle between the towing direction and the trav...

Page 7: ... alkali solution cleaning neutral medium cleaning trichloroethylene cleaning Magnus solution cleaning etc For instance rubber parts shall not be cleaned with mineral oils Use alcohols or dry fabrics to remove sludge Carry out cleaning work strictly according to the Instructions Manual of detergents or cleaning equipment Take proper anticorrosive and antirust measures Remove the used grease coating...

Page 8: ...idance on troubleshooting during operation 4 There is a dedicated tools section in some chapters Please use the dedicated tools for repair 5 Please confirm the numbers of the dedicated tools as specified in the applicable list of components while placing an order for such dedicated tools 2 Definitions of directions 1 Definitions of left and right sides of the bus Left side and right side refer to ...

Page 9: ...del 最大总质量 Max total mass 发动机型号 Engine model 整备质量 Curb weight 额定功率 Rated power 制造年月 Manufacture date 厦门金龙旅行车有限公司 Xiamen Golden Dragon Bus Co Ltd 3 Chassis S N chassis S N is engraved on the frame close to the right front wheel 4 Engine S N engine model and S N are engraved on the engine set Please refer to the corresponding Engine Operation Manual Please refer to the corresponding Engine Operation ...

Page 10: ...rements Thoroughly clean all the components that need to be assembled Do not allow ingress of any dust and foreign matter into the transmission Otherwise unnecessary losses may be caused Take the following precautions during assembly Fastening bolts fasten the bolts with the required torque apply lubricating oils and other sealants if required Reassemble in the correct sequence Initial lubrication...

Page 11: ... installation requires vertical pipe tip cutting against the pipe center line the tip shall be round and complete and the cutting sleeve shall be properly fitted Bushing is needed when installing nylon pipe Flared connecting Seal by the sealing face formed by flare Pipe thread connector Seal by thread 4 Sealant application specifications Sealant designation Loctite 545 thread sealant Evenly apply ...

Page 12: ...th the sealant adhesives Check the threads of the two bolts to see if there is any part that has no sealant adhesive thereon Apply additional sealant adhesives if any Install the bolts after the requirements are satisfied 6 Seal tape winding specifications Seal tape specifications tetrafluoroethylene seal tape 26mm 01mm 20m Remove the first 3 to 4 threads that enter the casing firstly of the pipe ...

Page 13: ...sake of effective repairs 2 Routine system inspections check the system in order to confirm if the system works properly Then carry out other diagnosis in orders 3 Read and check relevant technical documents fully utilize relevant technical documents and other repair information and compare with the routine system inspection results 5 1 The phenomena and causes of troubles can be identified in the...

Page 14: ...it is necessary to appraise the symptoms and conditions as described by the user and refer to existing repair information for a diagnosis thereof 5 4 User reported conditions may fit in with the bus design and therefore are part of the proper working conditions of the bus Or the conditions may be caused by user s improper operations In that case please explain the identified problems and system op...

Page 15: ...e recycled together with the lubricating oils and removed by the filter f Resistance to abrasion the lubricating oil s ability to prevent the oil film from being damaged 2 Designation and variety of commonly used lubricating oils Variety Viscosity and designation SC 5W 20 10W 30 15W 40 30 40 SD SD CC 5W 30 10W 30 15W 40 30 40 SE SE CC 5W 30 10W 30 15W 40 20 20W 30 40 SF SF CD 5W 30 10W 30 15W 40 3...

Page 16: ...rd for the pump to feed oils with a high viscosity after the engine is started and thus the engine abrasion may be increased the oil film will be easily damaged to dwarf the effects of lubrication if the viscosity is too low b Lubricating oils with a higher grade can be a substitute of those with a lower grade and it is not cost effective in this case merely However lubricating oils with a lower g...

Page 17: ...General Instructions GI 6126J12 01 GI 14 1 16 ...

Page 18: ...General Instructions GI 6126J12 01 GI 15 1 17 ...

Page 19: ...r lubrication sealing vibration reduction and noise reduction but will easily cause higher internal friction forces and thus reduce transmission efficiency It is also bad for lubrication at a low temperature Gear oils with a low viscosity help to reduce rotational resistances of mechanical parts increase transmission efficiency and achieve better cooling and cleaning effects However the loading ca...

Page 20: ...case the surface contact pressure of gears is below 3 000Mpa sliding speed is below 10m s and working conditions are not severely rough For instance medium duty vehicle gear oils may be adopted for the rear driving axle of Dongfeng EQ1090 trucks even if it is driven by hyperbolic gears because the load is not particularly heavy General vehicle gear oils are normally adopted for general helical gea...

Page 21: ...and properties of lubricating greases a Basic makeup of lubricating greases Normally lubricating greases include 80 to 90 lubricating oils as the basic oils and 10 to 20 thickeners A small quantity of additives is also added to further improve their properties Thickeners mainly consist of various types of soaps generated in saponification of fat and alkali There are calcium sodium and lithium base...

Page 22: ...eration of the brake fluid will be affected This is called vapor lock In order to guarantee the proper and effective operation of the brake system it is necessary to ensure that the brake fluid has a high boiling point and resistance to vapor locks b Good low temperature fluidity and temperature viscosity characteristic in order to guarantee that the brake system works properly within the variatio...

Page 23: ... freezing point and the operating cost is high c Glycol type Glycol has a boiling point of nearly 200 C 197 4 C and is not easily volatile when mixed with water Mixtures of glycol and water have an apparently reduced freezing point 68 C at the lowest Glycol has a high thermal capacity good fluidity and high chemical stability and can substantially improve the effects of antifreeze fluids However g...

Page 24: ...8 0 56 0 75 113 106 158 M12 1 25 30 0 48 0 40 0 60 0 78 115 108 161 M14 2 46 8 75 0 62 0 95 0 122 185 141 200 M14 1 5 56 0 92 0 68 0 105 0 146 205 178 235 M16 2 73 0 115 0 98 0 150 0 182 245 200 310 M16 1 5 76 0 133 0 101 0 160 0 199 270 240 335 M18 2 5 107 4 178 0 161 0 220 0 229 298 380 467 M18 1 5 124 5 190 0 165 0 230 0 287 346 397 507 M20 2 5 135 0 230 0 190 0 272 0 389 470 450 568 M20 1 5 14...

Page 25: ...definitions Various parts of the bus model code are defined as follows Model XML 6 12 6 J12 Self defined code of Golden Dragon Product series Main data code nominal length 12m Bus type code 6 indicates passenger bus Factory brand Golden Dragon XML 1 24 ...

Page 26: ......

Page 27: ...sites installation by ODIN 14 6 2 2 Installation of ODIN 17 6 2 3 Software license installation 21 6 2 4 CAN interface driver installation 26 6 3 Use of ODIN 29 6 3 1 Location diagram of Odin in E drive system framework 29 6 3 2 Device connection 30 6 3 3 Fault records reading 33 6 3 4 GDD file collection 34 6 3 5 Logging of CAN messages 36 6 3 6 Data collection 38 6 3 7 Graph collection 40 6 3 8 ...

Page 28: ...d of maintenance parts of MD series 6 phase motor 60 9 2 3 1 Operation specifications for flanges and related parts replacement 60 9 2 3 2 Operation specifications for lifting bracket and related parts replacement 60 9 2 3 3 Operation specifications for nameplates and related parts replacement 61 9 2 3 4 Operation specifications for signal cables and related parts replacement 61 9 2 3 5 Operation ...

Page 29: ...alling positive and negative cables 77 10 2 2 1 5 Tools for use 78 10 2 2 1 6 CO200 MCU consumable parts list 78 10 2 2 2 Replacement of other maintenance parts of CO200 MCU 79 10 2 2 2 1 Replace the water pipe joint 79 10 2 2 2 2 Replace the grounding screw 79 10 2 2 2 3 Replace the warning sign 79 10 2 2 2 4 Tools for use 80 10 2 2 2 5 List of other consumable parts of CO200 80 10 2 3 CO200 MCU ...

Page 30: ... items 87 11 2 MCU maintenance items 88 11 3 VMUmaintenance items 88 11 4 Maintenance items for high voltage power line phase line 89 11 5 High voltage power line DC bus maintenance items 90 11 6 Maintenance items for motor and MCU ground wires 91 11 7 Low voltage signal line maintenance items 92 11 8 Cooling system maintenance items 93 11 9 Insulation test items 94 12 E drive system service tools...

Page 31: ...ctric vehicle 2 Towing Method 1 Disassemble the drive shaft or half shaft of the vehicle After disassembly The motor does not rotate following the wheel and the trailer can run normally at unlimited speed Method 2 The trailer runs at the required speed limit and the motor does not need to disconnect the drive shaft half shaft or phase cable The speed limit driving requirements are shown as follows...

Page 32: ...l with high voltage wiring harness or high voltage components please bring high voltage insulation shoes gloves and other insulation protective equipment On fire Turn off the Key and cut off the 24V low voltage main power supply In case of fire use carbon dioxide or dry powder fire extinguisher recommended method or use high pressure water gun to put out fire at a long distance alternative method ...

Page 33: ...so it is necessary to operate in accordance with this safe operation guide to avoid personal injury or death Before disassembling or disassembling the products of our company you must undergo Dana safety training and hold a state recognized low voltage electrician certificate the maintenance personnel must wear safety gear such as insulated gloves insulated anti smash shoes protective glasses hard...

Page 34: ...p prohibited 5 After unplugging or turning off the high voltage emergency switch of the vehicle use a multimeter to measure whether the voltage is greater than 1V on the DC cables of the MCU if more than 1V wait After 10 minutes if there is still a voltage inform the vehicle manufacturer to check the circuit and confirm that there is no voltage on the DC cables of the MCU before the next step 6 Th...

Page 35: ...rofessionals The customer is responsible for ensuring that all operators have received professional training and wear protective gear to ensure personal safety The safety precautions are shown in the figures below Safety warning signs are affixed to the eye catching position of the E drive products Please read it carefully before operating the product and ensure that the safety regulations are obs...

Page 36: ...ial attention should be paid to the use of coolant as follows 1 Coolant composition requirements 40 deionized water and 60 glycol which shall conform to the NB SH T 0521 2010 standard 2 When adding coolant it is prohibited to add tap water mineral water and distilled water and it is prohibited to mix coolants of different brands or specifications 3 Coolant should be replaced once every 2 years or ...

Page 37: ...e derating mode If the temperature exceeds the limit seriously the system will automatically shut down Note If the cooling water pipe needs to be removed during maintenance it is necessary to confirm that the current cooling system temperature has dropped to room temperature before operation During operation please pay attention to that removing the pipeline will cause the coolant to gush out Use ...

Page 38: ...s sent to the VMU The VMUsends commands to the MCUand BMS at the same time The BMS commands the battery group to transmit power to the MCUand other vehicle equipments according to the VMU command After receiving the VMU command and the BMS message the MCU commands the motor to work forward or reverse The rotation of the motor is transmitted to the wheels through the drive axle to realize the forwa...

Page 39: ...theMCU The MCU controls the forward or reverse rotation of the motor to drive the vehicle forward D position or reverse R position In this process the electric energy of the battery is converted into the kinetic energy of the vehicle Braking There are two forms of braking electric braking and mechanical braking as shown in the figure below When the vehicle is running the brake pedal is depressed t...

Page 40: ...IN v4 22 5 42400 6 1 1 Supported CAN interfaces Kvaser USB cable interfaces PEAK System PCAN USB and PCAN USB Pro interfaces Vector Vector XL Interface family for example CANcaseXL CANboardXL CANcardXLe and CANcardLe and the VN16XX series are all supported by TM4 ODIN 6 2 Installation steps 6 2 1 ODIN required installation environment Double click the new ODIN installer to install it The figure ab...

Page 41: ... 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd Select all the content that says Installed can be left unselected click Next as shown in the figure above Install the components we just selected click Next as shown in the figure above Select I accept the license agreement and click Next as shown in the figure above 2 15 ...

Page 42: ...tric Motor Co Ltd Click the Next button to install the component If other prompts or a component is not successfully installed in this process you can skip it temporarily After the installation is complete the completion interface pops up as shown in the figure above Click Finish to complete the component installation As shown in the figure above 2 16 ...

Page 43: ... Co Ltd 6 2 2 Installation of ODIN Now start to install ODIN After the Installation Environment is completed the following dialog box appears Click Next to start installing ODIN as shown in the figure above Select all the functional components of ODIN some components can be selected according to the actual situation click Next as shown in the figure above 2 17 ...

Page 44: ...8 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd When the license association and installation page occurs click Skip as shown in the figure above The associated operation will be performed later by a specialist after the installation is complete Click Next to continue installing ODIN as shown in the figure above 2 18 ...

Page 45: ...ongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd Click Install to begin installation of TM4 ODIN4 as shown in the figure above Select Automatically close applications and attempt to restart after setup is complete and click OK as shown in the figure above 2 19 ...

Page 46: ...k OK As shown in the figure above The installation of the software license will performed later The installation of ODIN continues and creates 2 shortcuts on the desktop Then it will prompt No matching feature found 4 times continuously as shown in the figure above and below Click OK It pops up the Installation Complete interface indicating that the installation is completed Click Close to end the...

Page 47: ...e now You can find all the details of installation and ues from TG 0001 TM4 ODIN 4 Technical Guide pdf Double click the ODIN icon on the desktop to open ODIN either odin1 or 2 is OK The system prompts a missing Sentinel Key and reports an error then Click OK to go to the license management interface as shown in the figure above Click the Associate button to copy the fingerprint code to the clipboa...

Page 48: ...ctric Motor Co Ltd Send the copied content to Dana TM4 Beijing by email and wait for the reply from DEMCO Save the attached file in the email on your PC return to the License Manager interface and install the newly downloaded license Select the Install button on the left and select the license location from the right as shown in the figure above 2 22 ...

Page 49: ...德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd Click Open to locked the license to install as shown in the figure above Finally click Install to finish as shown in the figure above The system prompts The license is valid and the software license installation is successful till this time as shown in the figure above 2 23 ...

Page 50: ...zhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd Close the License Manager interface open ODIN and check whether ODIN is activated as shown in the figure above Find the Options button from the toolbar click it as shown in the figure above 2 24 ...

Page 51: ...18 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd You can change the system language between Chinese and English After selecting Click OK to load As shown in the figure above Then we do some configuration in the system file column check the box in front of Display error and warning displayed on the message panel 2 25 ...

Page 52: ...机有限公司 Dana Beijing Electric Motor Co Ltd 6 2 4 CAN case driver installation Find the CAN case driver Kvaser software package and double click to start loading Click Next inside the pop up dialog box as shown in the figure below The dialog window Kvaser CAN Drivers Setup pops up and selects Next as shown in the figure below 2 26 ...

Page 53: ...tric Motor Co Ltd The dialog window Kvaser CAN Drivers Setup pops up and selects NEXT as shown in the figure below The dialog window Kvaser CAN Drivers Setup pops up then select Install as shown in the figure below When the dialog window Kvaser CAN Drivers Setup pops up after the progress bar is full then click Close as shown in the figure below 2 27 ...

Page 54: ...电机有限公司 Dana Beijing Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd CAN case driver installation is complete 2 28 ...

Page 55: ...ing Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 6 3 Use of ODIN 6 3 1 Odin s position in the E drive system architecture 2 29 ...

Page 56: ...r the box is connected correctly and the CAN cable of the vehicle is connected correctly Please see the next step if there is no problem As shown in the figure below Device connection operation method Click Configuration in the toolbar of the TM4 ODIN interface and then click Device Configuration The dialog window Device Communication Configuration pops up Check if the CAN Port is None If so indic...

Page 57: ...age dialog window After you find the required program click Apply If there is no required program in the arrow under the Device Package Configuration dialog window go to the required software folder provided by DEMCo find the required program and double click to install it Restart ODIN4 Server 1 or 2 and continue with the steps described above After the update the required package version will app...

Page 58: ...德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 2 32 ...

Page 59: ...erating procedures Find the fault log in the Sysfile at the bottom right of the ODIN interface as shown in the figure below If the interface is too small you can drag it to the blank area of the interface and select the drag area as shown in the figure below Make a preliminary judgment of the fault according to the fault code description and time in the fault record and then troubleshoot according...

Page 60: ...sinfo as soon as possible When collecting Csinfo it is best to collect it when the fault recurs GDD includes the following Sysfile Item Blackbox SystemInfo Operation steps After opening ODIN click on Diagnostic in the toolbar of the software to find Gather Diagnostic Data as shown in the figure below The dialog window Gather Diagnostic Data pops up Save the path in the File Path option as shown in...

Page 61: ... 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd The generated compressed file is added to the fault report summary form and a template of the fault report summary form is provided by the after sales department 2 35 ...

Page 62: ...ges and save them in BLF format Import and view blf format message files Switch the data display mode and manually send message to the bus Can be connected to the vehicle CAN to confirm the following Whether a specific CAN message is on the bus Does the CAN bus have a lot of error frames causing unstable communication Operation steps Connect the CAN case to the DBC port to communicate with devices...

Page 63: ...18 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd Select Continuous Log in the bottom of the TM4 CAN Spector interface set Msg Per File value to more than 30 000 and select the save path in Destination As shown in the figure below After confirming the above configuration click the Play button to start collection 2 37 ...

Page 64: ...d Graph Size The number of data points displayed in the currently collected image Interval time interval ms between two collection points Max File Size Maximum number of line saved in a single file The collected data is generally used for energy calculations Operation steps Open ODIN and click on Tools then choose Data Logger and click on it as shown in the figure below Pop up the dialog window to...

Page 65: ...na Beijing Electric Motor Co Ltd Right click on the blank space below Name to add Axis as shown in the figure below In the TM4 Data Logeger interface find the items you want to monitor under the Items Explorer as shown in the figure below Drag the selected item into the established Axis and click Start as shown in the figure below 2 39 ...

Page 66: ...according to requirements Trigger Related parameters 1 Frequency collection frequency 2 SubSample Actual collection frequency Frequency Subsample 3 Trigger collection started trigger point Common triggers 1 FirstErrorCode 2 MotorSpeedRpm 3 HighpowerVoltage Codition Condition value Presample For example when set to 50 it will collect 50 of the data before the trigger and 50 of the data after the tr...

Page 67: ...e trigger conditions at the bottom left of ODIN and adjust Frequency to the maximum You needs to find the trigger item from the bottom right of Items Explorer and drag it into the trigger Select the trigger conditions as shown in the figure below Is not equal to Condition Value Presample as shown in the figure below After all the settings are finished click Start to start the collection A window G...

Page 68: ... 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd After the trigger use the mouse right button to click the curve part and click the last item Save Image And Csv Data As below to save as shown in the figure below 2 42 ...

Page 69: ...e switch to power on and off Operating procedures Please double click the package from the email to install it and the pop up dialog window Package Self Extractor proves successful as shown in the figure below Click on the TM4 ODIN interface to find the Flash Program Manager in the Configuration configuration as shown in the figure below A window Flash Program Manager pops up Check before Erasing ...

Page 70: ...roubleshooting of common problems 7 1 Circuit control principles of high voltage pre charge circuit 7 2 Relay function and name K1 pre charge relay K2 high voltage main positive contactor K3 high voltage main negative contactor optional 7 2 1 Power on sequence 1 Close K3 2 Close K1 3 Wait for the end of pre charge 5 RC 4 Close K2 5 Disconnect K1 6 MCU starts to work 2 44 ...

Page 71: ...heating switch panel and low voltage wiring harness If the measured DC bus voltage is about 0V first measure the battery voltage separately If there is no problem please check whether the fuse above the DC bus in the high voltage distribution cabinet is conductive if open circuit needs to be replaced If there is no problem check whether the pre charge relay is sticked pre charge relay needs to be ...

Page 72: ...normally after the key switch is restarted the vehicle manufacturer is required to use an insulation resistance meter to measure the insulation resistance value of the high voltage parts one by one Supplier personnel arrived at the site to troubleshoot Measure the MCU Remove the DC bus from the MCU use the insulation resistance meter to test the positive pole to ground and the negative pole to gro...

Page 73: ...nce between the measured values is too large which proves that there is a problem with this group of temperature sensors You need to ask the company to confirm whether there is a joint inside motor on the 6 wires If there is you need to remove the rear cover to measure again If there is not you need replace a motor Dynamic failure Touch the MCU motor case with your hands to verify if it is really ...

Page 74: ...ctuates Verify that the pre charge timing is correct Check whether the pre charge resistance is damaged Dynamic failure Verify that the power battery voltage is too high or fluctuates In operation status verify whether the main positive relay is suddenly open and closed 7 5 5 Troubleshooting method of resolver Fault code and name 0x3109 Error Motor Control Inverter 0x09 Position sensor hardware fa...

Page 75: ... the high voltage power distribution cabinet one by one according to the frequency of faults reported by the vehicle such as defrost heater air conditioner oil pumps and air pump then proceed the road tests road tests can only be performed when the vehicle is safe to drive After the above equipment road test no longer has insulation faults it can be judged that the entire line of the equipment has...

Page 76: ...and so on Its scale unit is expressed in Megohms MΩ Use of insulation resistance meter The resistance test can only be performed on the circuit that is not energized If the test is performed on the circuit that is energized the insulation tester may be damaged 1 Insert the test probe into the V and COM common input terminals on the meter 2 Turn the rotary switch to the required test voltage range ...

Page 77: ...y of the motor resolver base and count the A B C D E F pins from the direction of the flange to the left 2 Using a multimeter ohm range measure the resistance between A B C D E F 3 The cold state resistance is about 1 1K ohms The hot state resistance is slightly larger than the cold state 4 V pin is grounded the resistance to ground should be OL continuity state 8 4 IGBT measurement method 1 Use a...

Page 78: ...010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 9 Maintenance Manual on motor spare parts replacement 9 1 MD series 3 phase motor 9 1 1 MD series 3 phase motor structure diagram Figure 1 2 52 ...

Page 79: ...sign 1 Used to alert users to the danger of high voltage 13 3316 0565 Junction box cover 1 For sealed junction boxes 14 BNAEB048 Hex flange bolts 4 For fastening the terminal box cover 15 3310 0001 seal ring 1 For sealed junction boxes 16 HW 2316 Combination screws 3 For fixing phase cables 17 Cable assembly Cable holder base 3 For fixing phase end cable head 18 Cable gland cover 3 For fixing phas...

Page 80: ... and sleeve to remove the lifting bracket Step 2 Install the new lifting bracket on the motor middle cover The screw tightening torque is16 2Nm 2 Tools for use Fixed value torque wrench 0 10Nm outer hexagon wrench ratchet wrench No 13 sleeve Figure 3 3 List of maintenance parts No Part number of maintenance part Name of maintenance part Quantit y per unit Maintenance part replacement standard 5 33...

Page 81: ...middle cover figure 5 The bolt tightening torque is 20 2Nm 2 Tools for use Fixed value torque wrench 0 10Nm ratchet wrench No 13 sleeve 3 List of maintenance parts No Part number of maintenance part Name of maintenance part Quantit y per unit Maintenance part replacement standard 6 HW 1742 Hex flange bolts 1 No damage to the thread and corrosion 7 HW 3485 Signal line clip 1 No damage or deformatio...

Page 82: ...e figure 7 Step 10 Install the cover on the junction box by 4 hexagon flange bolts with a torque of 9 1Nm Before installation make sure there is no foreign matter in the junction box Step 11 After the replacement is completed perform an insulation test on the motor Figure 6 Figure 7 2 Tools for use Fixed value torque wrench 0 10Nm outer hexagon wrench ratchet wrench 10mm sleeve special socket wren...

Page 83: ...hten the new grounding screw The tightening torque is 17 2Nm Step 3 Use a ratchet wrench to remove the air valve and use a fixed torque wrench to tighten the new air valve with a tightening torque of 16 2Nm 2 Tools for use Torque wrench 5 20Nm ratchet wrench 13mm sleeve 18mm sleeve 3 List of maintenance parts No Part number of maintenance part Name of maintenance part Quantit y per unit Maintenanc...

Page 84: ...ectric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 9 2 MD series 6 phase motor 9 2 1 MD series 6 phase motor structure diagram Figure 1 2 58 ...

Page 85: ...e clip 1 For fixing signal lines 10 Signal line 1 For transmitting signal lines 11 FM 0011 Signal line interface protective sleeve 1 Dust proof and waterproof for signal cable joint with 90 bend FM 0009 1 Dust proof and waterproof for signal cable joint straight 12 NP 0041 High voltage sign 2 Used to alert users to the danger of high voltage 13 3316 0565 Junction box cover 2 For sealed junction bo...

Page 86: ...for use Figure 2 Fixed value torque wrench 10 50Nm ratchet wrench 13mm sleeve 3 List of maintenance parts No Part number of maintenance part Name of maintenance part Quantit y per unit Maintenance part replacement standard 1 Plate 15 Upper baffle 1 Severe deformation and damage 2 Plate 16 Lower baffle 1 Severe deformation and damage 3 HW 1742 Hex flange bolts 4 Thread damage and corrosion 9 2 3 2 ...

Page 87: ... signal cables and related parts replacement 1 Steps see the diagram figure 5 Step 1 Use a ratchet wrench and sleeve to remove the signal cable fixing clip and check whether it is damaged or deformed Step 2 Turn the lower edge of the protective cover of the signal line interface up to reveal the signal line buckle and then twist the signal line joint to remove the signal line Step 3 Put the protec...

Page 88: ...o the junction box with a torque of 25Nm Step 7 Install the new cable to the junction box and tighten the screw HW 2316 with a torque of 20Nm Step 8 Use a cable socket wrench to fasten the cable gland cover on the new cable with a torque of 12Nm Step 9 Install the seal ring opening upward to the junction box as shown in the figure 7 Step 10 Use a fixed value torque wrench to install the cover on t...

Page 89: ...the diagram Figure 8 Step 1 Replace the damaged warning sign and paste a new warning sign Step 2 Use a ratchet wrench to remove the grounding screw Use a fixed torque wrench to tighten the new grounding screw The tightening torque is 17 2Nm Step 3 Use a ratchet wrench to remove the air valve and use a fixed torque wrench to tighten the new air valve with a tightening torque of 16 2Nm 2 Tools for u...

Page 90: ...g Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 9 3 HD series 9 phase motor 9 3 1 HD series 9 phase motor structure diagram 2 64 ...

Page 91: ... protective sleeve 1 Dust proof and waterproof for signal cable joint with 90 bend 13 3354 0002 Warning sign 2 Warn the user of high voltage danger 14 HW 1928 Phase cable gland assembly 9 For fixing phase end cable head 16 Phase cable assembly Phase cable 9 For motor and controller current and voltage transmission 17 HW 1742 Ground screw 1 For fixing the ground wire 18 HW 2322 Air valve 1 For air ...

Page 92: ...d or deformed Step 2 Use brush and blower to clean the dust outside of the protective sleeve then turn the lower edge of the sleeve up to expose the signal cable lock ring then turn the lock ring to remove it Step 3 Put the protective sleeve on new signal cable joint and then align key of the signal cable with the keyway of the motor base and then turn it to the motor interface Step 4 Turn down th...

Page 93: ...ep 7 After the replacement is completed perform a motor insulation test Use an insulation resistance meter by the 500Vdc or 1000Vdc voltage range The positive test lead touches each phase of the motor and the negative test lead touches the frame Press the test button wait for the value to stabilize and record it Step 8 Tighten the cable screw cover the tightening torque is 20 2Nm 2 Tools for use F...

Page 94: ... 5 20Nm fixed value torque wrench 20 100Nm ratchet wrench 13mm sleeve 18mm sleeve 3 List of maintenance parts No Part number Name of part Quantity Maintenance part replacement standard 13 3354 0002 Warning sign 1 The handwriting is not clear and legible 17 HW 1742 Hex flange bolts 1 Thread damage and corrosion 18 HW 2322 Air valve 1 Regular maintenance for replacement 4 HW 0025 Rings 3 Thread dama...

Page 95: ... Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 10 Maintenance manual on MCU spare parts replacement 10 1 CO300 MCU 10 1 1 Structure diagram of CO300 MCU Figure 1 2 69 ...

Page 96: ...rning sign 1 pcs Remind users to operate safely 5 None Positive and negative cables 1 pcs each Powering the MCU 6 HW 0311 01 Phase cable 9 pcs Power transit between MCU and motor 7 AM 0014 Water pipe joint 2 pcs Connect the cooling pipes to circulate coo 10 1 2 CO300 9 phase MCU maintenance parts replacement method Summary MCU maintenance work is divided into two levels Maintenance level 1 Mainten...

Page 97: ...ten the cable fixing base to ensure the tightening torque 25 3Nm Step 5 Take the positive cable insert the terminal into the controller and then use the hexagonal wrench to fix the two HW 1944 combination screws to fix the terminal Step 6 Use a torque wrench to tighten the two HW 1944 combination screws to ensure a torque of 10 2Nm Step 7 Tighten the cable gland and base tightening torque 15 2Nm S...

Page 98: ...torque wrench tightening torque 25 3Nm Note After the water pipe joint is replaced the vehicle water cooling system needs to be operated under normal conditions Check that there is no leakage of cooling water in the replacement place 10 1 2 2 2 Replace the grounding screw Step 1 Use a socket wrench to remove the hexagonal flange bolt that fixes the ground wire and check that the surface of the bol...

Page 99: ...y 4 HW 1742 Hex flange bolts 1 Damage to surface threads no rust or corrosion on the surface 5 NP 0039 Warning sign 1 Damage on the surface and clear writing 10 1 2 3 CO300 MCU service tools list No Tool name Model Quan tity Purpose 1 Sleeve 12 5mm Metric Hexagonal Sleeve Size 36 1 pcs Loosen and tighten HW 1734 2 Sleeve adapter 12 5mm to 10mm adapter 1 pcs 36mm sleeve connected with fixed torque ...

Page 100: ... Dana Beijing Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 10 2 CO200 MCU 10 2 1 Structure diagram of CO200 MCU 2 74 ...

Page 101: ... safely 6 HW 3311 Hex flange bolts 1 For fixing the ground wire 7 HW 2316 Combination screws 8 Phase cable terminal DC cable terminal fixing 8 None HV cable assemblies 2 Controller positive and negative cable 9 AM 0012 Water pipe joint assembly 2 Connect cooling liquid through external water pipe to circulate cooling inside the controller 10 WH 0537 01 Phase cable holder 6 Fix with the controller ...

Page 102: ...the phase end cover is not scratched the seal is not damaged and it is not deformed Step 3 Use a hex wrench to remove the HW 2316 combination screw which fixes the cable terminal Note Do not drop the screw into the controller case when removing the screw Step 4 Use a special tool for removing the phase cable loosen the cable gland cover and remove the phase cable Step 5 Use a special tool for remo...

Page 103: ...hase end cover 10 2 2 1 3 Steps for removing positive and negative cables see the diagram Figure 5 Step 1 Using a socket wrench remove the 6 HW 3311 hexagon flange bolts which fixes the DC junction box cover Step 2 Check that the surface of the DC junction box cover is not scratched the seal is not damaged and not deformed Step 3 Using a hexagon wrench loosen the two HW 2316 combination screws fix...

Page 104: ... and negative cable is not produced by our company If you need to replacethem the customer should contact the positive and negative cable manufacturer and purchase it separately 10 2 2 1 5 Tools for use Fixed value torque wrench 10 50Nm hexagonal screwdriver sleeve ratchet wrench 14mm sleeve sleeve adapter cable sleeve 10 2 2 1 6 CO200 MCU consumable parts list No Part number of maintenance part N...

Page 105: ...rench tightening torque 25 3Nm Note After the water pipe joint is replaced the water cooling system needs to be operated under normal conditions Check that there is no cooling water leakage at the replacement place 10 2 2 2 2 Replace grounding screw Step 1 Use a socket wrench to remove the hexagonal flange bolt that fixes the ground wire and check that the surface of the bolt is not damaged and th...

Page 106: ...Apply the O ring surface evenly each time 4 HW 3311 Hex flange bolts 1 No damage to surface threads no rust or corrosion on the surface 10 2 3 CO200 controller service tools list No Tool name Model Quanti ty Purpose 1 Sleeve 10mm 3 8 Metric Hex Sleeve Size 14 1 pcs Loosen and tighten the phase cover DC cover fixing screw and ground screw 2 Sleeve adapter 12 5mm to 10mm adapter 1 pcs No 14 sleeve i...

Page 107: ...Dana Beijing Electric Motor Co Ltd 10 3 CO150 MCU 10 3 1 Structure diagram of CO150 MCU Figure 1 Combination screwsHW 2227 Stuffy cover HW 1896 Phase cable WH 0537 01 Hex flange bolts HW 3311 Positive and negative cables Combination screws HW 2102 DC side cover 3327 0209 Hexagon socket head cap screws HW 3144 Warning sign NP 0039 2 81 ...

Page 108: ... flange bolts 1 For fixing the ground wire 8 None High voltage cable assemblies 2 Controller positive and negative cable 9 AM 0012 Water pipe joint assembly 2 Connect external water pipe to circulate cooling inside the controller 10 WH 0537 01 Phase cable holder 3 Fix with the controller cable 11 Phase cable fixing base 3 12 Phase end cable 3 10 3 2 CO150 3 phase MCU related maintenance parts repl...

Page 109: ...ation screw that fixes the lug Step 6 Use a torque wrench to tighten one HW 2227 flat disc combination screw to ensure a tightening torque of 9Nm Step 7 Tighten the cable gland and base tightening torque 12 2Nm Step 8 Repeat steps 1 7 to complete the installation of the remaining two cables Step 9 Check whether any foreign matter in the phase end enters the controller cavity Step 10 If the stuffin...

Page 110: ... 7 to complete the installation of the negative cable Step 9 Check if there is any foreign matter in the DC DC side cover entering the controller cavity Step 10 If the cover is deformed or damaged replace it with a new DC side cover Step 11 Place the DC side cover assembly on the controller pass 8 hexagon sleeve flat head screws part number HW 3144 through the DC side cover and screw it in first b...

Page 111: ...ystem needs to be operated under normal conditions Check that there is no cooling water leakage at the replacement place 10 3 2 2 2 Replace the grounding screw Step 1 Use a socket wrench to remove the hexagonal flange bolt that fixes the ground wire and check that the surface of the bolt is not damaged and the surface is free of rust and corrosion Step 2 Pass the hexagon flange bolt through the gr...

Page 112: ... to surface threads no rust or corrosion on the surface 10 3 3 CO150 controller service tools list No Tool name Model Quanti ty Purpose 1 Sleeve 10mm 3 8 Metric Hex Sleeve Size 14 1 pcs Loosen and tighten the ground screw 2 Sleeve adapter 12 5mm to 10mm conversion head 1 pcs No 14 sleeve is connected with fixed torque wrench 3 Plum joint Plum T25 1 pcs Removing the DC side cover 4 Sleeve 19mm Metr...

Page 113: ...ns of breakage or unweld If there are above signs replace the mounting plate Every 20 000 KM No signs of aging cracking crushing and rubber peeling Visual inspection Visual inspection and touch to check the cushion had no signs of aging cracking crushing and rubber peeling Every 20 000 KM a The bolts of flanges are tightly The torque value meets the designed requirements a Visual inspection a Visu...

Page 114: ...led and the torque value meets the design requirements of the vehicle manufacturer Torque wrench and sleeve hexagonal combination kit Use tools review and adjust and tighten according to the design requirements of the vehicle manufacturer Every 20 000 KM No signs of aging cracking and crushing Visual inspection Every 20 000 KM 11 3 Vehicle controller maintenance items No Maintenance content Techni...

Page 115: ...leaner to remove surface ash impurities and foreign matter Every 5 000 KM The wiring harness should be tied firmly and not loose Vehicle wiring and fastening must meet the design requirements of the vehicle manufacturer Visual inspection and touching with hands Visual inspection and actual tape measure to check if the bending radius of the wire harness is 8 times or more the diameter Every 5 000 K...

Page 116: ...es or more the diameter Every 5 000 KM The wiring harness should be tied firmly and not loose Vehicle wiring and fastening must meet the design requirements of the vehicle manufacturer Visual inspection and touching with hands Visually and manually check the binding of the wiring harness For example check whether the bandage is lost the fixing clips are loose the fixing glue is detached and the th...

Page 117: ... measure Every 50 000 KM 2 Installation b The insulation resistance between the ground point of the motor and the motor controller case and the chassis ground point is not greater than 0 1Ω Visual inspection and touching with hands Visually and manually check the binding of the wiring harness For example check whether the bandage is lost the fixing clips are loose the fixing glue is detached and t...

Page 118: ...ge damage b The air around circulates and is easy to dissipate heat no spikes or sharp objects around c The bending radius of cable is 8 times or more than the diameter d The wire harness should be tied firmly The wiring and fastening must meet the design requirements e The wiring harness cannot be bundled with high voltage wiring harness gas oil water etc f The connectors at both ends of the wiri...

Page 119: ...evel in the expansion tank Every 3 000 KM No clogging on the radiator grill Visual inspection Visual inspection to check whether there is clogging in the radiator grill Every 5 000 KM 2 Installation The cooling pump fan assembly and expansion tank are installed firmly and the torque meets the design requirements Visual inspection and torque wrench and sleeve outer hexagonal Cooperate with correspo...

Page 120: ...the test lead is touching the frame Press the start test button wait for the value to stabilize and record the value Every 60 000 KM 2 Insulation test The insulation resistance of the motor is no less than 20MΩ under any circumstances Insulation resistance meter Use insulation resistance meter with 500Vdc or 1000Vdc voltage range The test leads touches each phase of the motor and the test leads to...

Page 121: ...d with the frame 8 Sockets 1 Set For removing the motor output shaft flange and drive shaft flange nut M6 M24 For removing the motor frame suspension mounting bolts associated with the frame 9 Sockets 1 pcs For removing the DC bus plug of the motor controller M36 10 Sockets 1 pcs For removing spline flange fastening nuts M50 11 Extractor 1 pcs Used to disassemble motor end resolver pins 12 Lappgro...

Page 122: ...庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 12 2 Pictures of tools 1 Pneumatic wrench 2 Diagonal pliers 3 Hexwrench 4 Needle nose pliers 5 Magnetic picker 6 Phillips screwdriver 7 Open end wrench M6 M24mm 8 Socket M6 M24mm 2 96 ...

Page 123: ... 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 9 10 Socket M36mm M50mm 11 Extractor tool 12 Lappgroup cable gland tool 13 Percussion ring spanner 14 Multimeter 15 Insulation resistance meter 2 97 ...

Page 124: ...r Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 16 Torque wrench 5 25Nm 17 Torque wrench 20 100Nm 18 Torque wrench 40 200Nm 19 Single arm lifting machine 2 98 ...

Page 125: ...Dana Beijing Electric Motor Co Ltd 电话 Tel 010 69596333 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 德纳北京电机有限公司 Dana Beijing Electric Motor Co Ltd 20 Mobile hydraulic lift 21 Hydraulic lifting trolley 2 99 ...

Page 126: ......

Page 127: ...nt of common troubles ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP 4 1 Drive shaft vibration 2 Drive shaft abnormal noise Drive shaft disassembly and assemblyꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP 5 1 Drive shaft disassembly 2 Drive shaft assembly Examination and repairing ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP 9 3...

Page 128: ...dition the frame will also be distorted and deformed during traveling Therefore a slide fork with spline shaft lining is adopted for the transmission shaft to compensate for the axial displacement of the transmission shaft A universal joint is adopted to satisfy working requirements in case of angle changes 安全阀 Safety valve 油封 Oil seal 滚针 Needle 套筒 Sleeve 螺栓锁片 Bolt lock 轴承盖 Bearing cover 万向节滑动叉 Un...

Page 129: ...ed arrange the two universal joint forks connected to the drive shafts within the same plane and ensure the same angle for the universal joints so that outputs at a constant angular velocity can be realized However it is necessary to keep the two shafts of the cross shaft universal joint at a moderate angle Otherwise the working life of needle bearing inside will be affected Normally the angle bet...

Page 130: ...PP 4 Propeller shaft 1 传动轴 Drive shaft 2 六角螺栓 Hex bolt 3 螺母 Nut 4 弹垫 Spring washer 5 万向节总成 Universal joint assy 3 4 ...

Page 131: ...eed vibration transmission at high gear Lower the gear 7 Excessive axial clearance of cross shaft Clearance adjustment 8 Excessive play of sliding fork spline Replace 2 Abnormal noises of drive shaft No Cause Solution 1 Startup or coasting flange coupling bolt is loosened Fasten with the required torque 2 Coupler needle roller bearing worn out Replace 3 Excessive play of sliding fork spline Replac...

Page 132: ...alancing unit 万向节盖 Universal joint cover 3 Remove the universal joint 4 Remove the universal joint bearing and cross shaft from the joint fork a Place the joint fork under the manual press and push part of the universal joint out from the joint fork lug The bearing inner race shall project from the joint fork now b Place the drive shaft assembly on a bench vice and clamp the projecting bearing wit...

Page 133: ...ng Apply supramoly containing lubricating greases on needle roller the lips of sealing ring and on both sides of thrust washer Install the cross shaft and universal joint bearing into the joint fork 1 Select the thickness T of projecting part of the universal joint cover In this way measurements of B and A are equivalent Use universal joint covers of the same thickness at both ends if possible Uni...

Page 134: ... install universal joint bearing on the joint fork Caution pay attention to the position of the yellow lubrication fitting while installing the universal joint cross shaft onto the joint fork Point it towards the inner side of the joint fork lug as indicated in the figure 3 8 ...

Page 135: ...he universal joint cover 6 Bend the locking piece so that it clings closely to both sides of the bolt after fastening the universal joint cover Ensure that there is no clearance between the locking piece and the bolt After the locking piece and the bolt are closely engaged check the bent part of the locking piece and ensure that there is no crack or clearance 相位箭头 Phase arrow 7 Use a spring balanc...

Page 136: ...and bent 0 0 6 1 0 0 0393 Replace Welding seam crack Replace Sliding spline damaged Replace Sliding spline clearance 0 62 0 174 0 0025 0 0068 0 25 0 0098 Replace Clearance between universal joint cross shaft and needle bearing C C A B 0 02 0 054 0 0008 0 0021 0 1 0 0039 Replace needle bearing sub assembly or universal joint cross shaft 3 10 ...

Page 137: ......

Page 138: ...Repair Instructions AVN 75 RL 75 A RL 75 E RL 75 EC RL 80 A RL 80 E RL 82 A RL 82 EC RL 85 A RL 85 E RL 85 EC Buses 4 1 ...

Page 139: ...ted 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 4 2 ...

Page 140: ... 1 Clamping ZF product 37 8 1 1 Clamping independent wheel suspension 37 8 1 2 Clamping RL 85 38 8 1 3 Clamping axle variant with axle bridge 38 9 Dismantling 39 9 1 Removing and dismantling attachments 39 9 1 1 Removing attachments independent wheel suspension variant 39 9 1 2 Dismantling the steering arms RL 75 EC and RL 82 EC 39 9 1 3 Removing tie rod variant with axle bridge 41 9 1 4 Dismantli...

Page 141: ...t with axle bridge and steering knuckle as an example without web 74 10 3 Assemble and install hub 80 10 3 1 Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit 80 10 3 2 Installing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit 84 10 3 3 Assembling the hub RL 85 adjustable bearing 87 10 3 4 Installing hub RL 85 adjustable mounting 89 10 4 Installing tachometer an...

Page 142: ...nits 114 11 1 3 Conversion of force units 115 11 1 4 Conversion of pressure units and units of stress 115 11 1 5 Conversion of torque units 116 11 1 6 Conversion of temperature units 117 11 2 Overview of Revisions 117 Table of Contents EN 4474 751 104a 2018 06 5 4 5 ...

Page 143: ...he 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 as they are a prerequisite for fault free operation of the product and for the warranty granted by ZF Friedrichshafen AG Please...

Page 144: ...d can lead to a severe injury or death ð Information 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 ð Information as to how the danger can be prevented The signal word NOTICE indicates a situation that if not prevented can lead to property damage ð Information as to how the property...

Page 145: ...awn with regard to size and weight Installation commissioning maintenance and repair Perform assembly commissioning maintenance and repair work exclusively according to this documentation and other applicable documents Observe the following points Employ authorized trained and instructed staff Observe technical provisions Only use genuine ZF spare parts Only use genuine ZF accessories Only use gen...

Page 146: ...rques Protect cables against mechanical damage Noise Noise might cause irreversible damage to hearing The perception of acoustic signals warning calls or sounds warning of impending danger is impaired by noise Observe the following when working on the ZF product Avoid noise Wear ear protection Operating supplies and aids Operating supplies and aids might cause permanent damage to health and enviro...

Page 147: ...st 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 ð Be 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 ...

Page 148: ...d clutch disks with a lint free cloth only Remove sealing compound residues on sealing faces or retaining agent residues e g in tapped holes or on splines Clean joining surfaces Clean blind holes and blind hole threads Lubricating bores oil bores oil ducts bores for oil press fits and lubricating grooves must be free from dirt preservatives and foreign matter Check for free passage Hose assemblies...

Page 149: ...is not impaired Minor damage includes Indentation marks on sealing faces Score marks or burs caused by the disassembly of the ZF product Frictional corrosion Damage caused by paint or corrosion If rework is needed on spacer washers or shims because of clearance settings ensure that the reworked surface is level with the starting face and has the same surface quality Debur all edges that can cause ...

Page 150: ...1 Type plate 1 Product designation 2 Parts list number 3 Serial number 4 Customer spec number if known to ZF 5 Number of List of Lubricants 6 Features The following data should be quoted when making inquiries or undertaking repairs 1 2 3 Technical Data EN 4474 751 104a 2018 06 13 4 13 ...

Page 151: ... bridge and steering knuckle as an example without web page 74 Rolling moment of hub without shaft seal 2 Nm to 5 Nm Spring balance Value without shaft seal Check shaft seal approx 1 Nm Installing hub RL 85 adjustable mounting page 89 Rolling moment of the control arm bearing 8 Nm to 15 Nm Torque wrench with scale dial gage Measure without scraper Installing the upper control arm page 99 Rolling m...

Page 152: ...23 Nm Torque wrench Installing hub RL 85 adjustable mounting page 89 M16 x 1 5 10 9 lock nut 130 Nm Torque wrench Installing tachometer and mounting steering stop page 92 M16 x 1 5 10 9 stop screw 300 Nm Torque wrench Installing tachometer and mounting steering stop page 92 M16 x 1 5 10 9 fit bolt 270 Nm Torque wrench Installing brake page 94 M20 12 9 fit bolt 475 Nm 40 Nm Torque wrench Installing...

Page 153: ...age 105 Hexagon nut M16 x 1 5 90 Nm Torque wrench Assembling axle housing page 105 Fitting attachments variant for independent wheel suspension page 111 M18 10 9 hexagon screw 440 Nm Torque wrench Assembling axle housing page 105 M24 x 1 5 hexagon slotted nut 250 Nm Torque wrench Installing the tie rod variant with axle bridge page 108 M12 x 1 5 clamp 70 Nm to 90 Nm Torque wrench Installing the ti...

Page 154: ...dependent wheel suspension page 104 1 AA02 257 341 Screw coupling Clamping independent wheel suspension page 37 Removing the track lever independent wheel suspension variant page 43 Fitting the track lever all axles with compact bearing units e g independent wheel suspension page 104 1 5870 350 101 Clamping bracket Clamping independent wheel suspension page 37 Removing the track lever independent ...

Page 155: ...L 75 EC and RL 82 EC page 39 Removing the track lever independent wheel suspension variant page 43 Fitting the track lever all axles with compact bearing units e g independent wheel suspension page 104 Assembling axle housing page 105 1 5870 350 094 Fixture Clamping RL 85 page 38 1 5870 350 063 Clamping plate Clamping RL 85 page 38 1 5870 350 098 Fixture Clamping RL 85 page 38 1 Workshop Equipment...

Page 156: ... L 29 mm AA02 244 886 Tapered ring Dismantling the steering arms RL 75 EC and RL 82 EC page 39 1 Ø 29 8 mm L 33 mm 5870 350 110 Supporting plate Dismantling the steering arms RL 75 EC and RL 82 EC page 39 1 5870 400 001 Offset screwdriver Dismantling the steering arms RL 75 EC and RL 82 EC page 39 Removing and dismantling the lower control arm variant with tapered roller bearing page 44 Removing a...

Page 157: ...l arm RL 75 E with molecular joint page 46 1 5870 100 059 Assembly fixture Removing and dismantling the lower control arm variant with tapered roller bearing page 44 Removing and dismantling upper control arm page 47 1 5870 506 134 Press in bush Removing and dismantling the lower control arm variant with tapered roller bearing page 44 Removing and dismantling lower control arm RL 75 E with molecul...

Page 158: ...Removal of brake page 49 Installing brake page 94 1 M16 x 35 5870 204 002 Eyebolt Removal of brake page 49 Installing brake page 94 1 Eyebolt set Consists of two pieces M8 M10 M12 M14 M16 M20 each AA01 266 187 Plug insert Removing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 52 Dismantling hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 54 Assembling the hub RL 7...

Page 159: ...b RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 84 1 AA01 395 095 Load carrying fixture Removing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 52 Removing hub RL 85 adjustable bearing page 57 Installing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 84 Installing hub RL 85 adjustable mounting page 89 1 5870 300 020 Extracting device Dismantling hub ...

Page 160: ...with axle bridge and example of king pin without web page 62 1 5870 287 010 Pump Removing king pin and dismantling steering knuckle independent suspension variant and example of king pin with web page 60 Removing king pin and dismantling steering knuckle variant with axle bridge and example of king pin without web page 62 1 5870 285 027 Pressure plate Removing king pin and dismantling steering knu...

Page 161: ...nd king pin independent wheel suspension variant where king pin does not have a web page 68 1 With king pin installed 5870 260 003 Handle Removing king pin and dismantling steering knuckle independent suspension variant and example of king pin with web page 60 Removing king pin and dismantling steering knuckle variant with axle bridge and example of king pin without web page 62 Assembling steering...

Page 162: ...mple without web page 74 1 AA01 046 851 Assembly fixture Assembling steering knuckle and king pin independent wheel suspension variant where king pin does not have a web page 68 Assembling the steering knuckle and installing the steering king pin variant with axle bridge and steering knuckle as an example without web page 74 1 5870 912 018 Centering bolt Assembling steering knuckle and king pin in...

Page 163: ...hub RL 85 adjustable bearing page 87 1 Use only in connection with insert 5870 610 002 Insert Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 80 Assembling the hub RL 85 adjustable bearing page 87 1 Use only in connection with assembly device M22 x 1 5 5870 050 003 Driver tool Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 80 1 5870 26...

Page 164: ...75 with compact bearing unit page 80 1 5870 260 011 Handle Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 80 1 Length 220 mm M24 fixture 5870 048 317 Driver tool Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 80 1 5870 651 099 Inner installer Installing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 84 1 Workshop Equi...

Page 165: ...sembling the hub RL 85 adjustable bearing page 87 1 Length 160 mm 5870 058 089 Driver tool Assembling the hub RL 85 adjustable bearing page 87 1 5870 651 070 Inner installer Assembling the hub RL 85 adjustable bearing page 87 1 5870 048 295 Driver tool Assembling the hub RL 85 adjustable bearing page 87 1 Workshop Equipment 28 EN 4474 751 104a 2018 06 4 28 ...

Page 166: ...89 1 WAF 8 mm AA00 249 031 alignment part Assembling the control arms variant with retaining ring page 98 1 5870 058 084 Driver tool Installing the upper control arm page 99 Assembling the steering arms RL 75 EC and RL 82 EC page 108 1 5870 345 091 Press in mandrel Installing the upper control arm page 99 Assembling the steering arms RL 75 EC and RL 82 EC page 108 1 Workshop Equipment EN 4474 751 ...

Page 167: ...ling the steering arms RL 75 EC and RL 82 EC page 108 1 AA01 021 368 Alignment fixture Installing the upper control arm page 99 1 5870 000 097 Mounting fixture Installing the upper control arm page 99 Installing lower control arm variant with tapered roller bearing page 102 Assembling the steering arms RL 75 EC and RL 82 EC page 108 1 7 2 Standard tools and fixtures To repair this ZF product use t...

Page 168: ...70 203 039 Torque wrench 80 Nm to 400 Nm 5870 203 016 Torque wrench 140 Nm to 800 Nm 5870 203 011 Torque wrench 750 Nm to 2 000 Nm 5870 203 048 Torque wrench 1 500 Nm to 3 000 Nm Fig 3 5870 900 013 Set of internal pliers Contains the sizes I1 I2 I3 I4 Fig 4 5870 900 014 Set of internal pliers 90 angled contains the sizes I11 I21 I31 I41 Fig 5 5870 900 015 Set of external pliers Contains the sizes ...

Page 169: ...at depth 300 mm to 500 mm 5870 970 026 Two armed extractor Jaw width 250 mm Throat depth 200 mm 5870 970 028 Two armed extractor Jaw width 380 mm Throat depth 200 mm Fig 8 5870 971 001 Three armed extractor Jaw width 85 mm Throat depth 65 mm 5870 971 002 Three armed extractor Jaw width 130 mm Throat depth 105 mm 5870 971 003 Three armed extractor Jaw width 230 mm Throat depth 150 mm 5870 971 004 T...

Page 170: ...ty 2 000 kg Effective length 2 m Fig 11 5870 281 047 Lifting chain Fig 12 5870 221 500 Hot air blower 230V 5870 221 501 Hot air blower 115V Fig 13 5870 345 071 Pry bar Fig 14 5870 280 004 Plastic hammer 5870 280 006 Nylon insert Spare part Workshop Equipment EN 4474 751 104a 2018 06 33 4 33 ...

Page 171: ...870 200 055 Magnetic holder Fig 17 5870 200 057 Dial gage Fig 18 5870 200 066 Set of parallel gage blocks Consisting of two pieces Height 70 mm 5870 200 067 Set of parallel gage blocks Consisting of two pieces Height 100 mm Workshop Equipment 34 EN 4474 751 104a 2018 06 4 34 ...

Page 172: ...ydraulic press Hydraulic actuation Tab 3 Other Equipment Comment Requirement Socket wrenches open end wrenches box wrenches hammers screw drivers pliers front cutting pliers Various sizes respectively in a set Commercial Sand paper In different grit sizes to clean surfaces Flat scraper For removal of sealing compound Whetstone For removal of minor damage and smoothing of plane faces Polishing clot...

Page 173: ...790 033 Sealing compound Loctite 574 Installing hub RL 85 adjustable mounting page 89 0671 190 065 Silicone grease UNIREX N3 Installing tachometer and mounting steering stop page 92 0666 690 112 Jointing compound Loctite 649 Installing brake page 94 0666 690 022 Jointing compound Loctite 262 Installing the upper control arm page 99 Installing lower control arm variant with tapered roller bearing p...

Page 174: ... of gravity ð Lift load slowly and observe whether the load tilts or swivels out laterally If required immediately put down load and modify attachment ð Keep distance ð Do not walk under suspended loads ð Only ever move load under supervision 8 1 1 Clamping independent wheel suspension Special tools 5870 505 012 Test device AA02 257 341 Screw coupling 5870 350 101 Clamping bracket 5870 350 000 Ass...

Page 175: ...3 Clamping plate on 5870 350 000 Assembly truck Fix RL 85 E with 5870 350 098 Fixture on 5870 350 000 Assembly truck Fig 22 8 1 3 Clamping axle variant with axle bridge Special tools 5870 350 093 Fixture 5870 350 000 Assembly truck 1 Fix axle with 5870 350 093 Fixture on 5870 350 000 Assembly truck 2 Support axle from below Fig 23 Preparatory Activities 38 EN 4474 751 104a 2018 06 4 38 ...

Page 176: ... and remove air spring Fig 24 2 Unfasten hexagon nut and remove releasing parts Fig 25 9 1 2 Dismantling the steering arms RL 75 EC and RL 82 EC Special tools AA02 244 885 Tapered ring AA02 244 886 Tapered ring 5870 350 110 Supporting plate 5870 350 000 Assembly truck 5870 400 001 Offset screwdriver Dismantling EN 4474 751 104a 2018 06 39 4 39 ...

Page 177: ...0 Supporting plate on 5870 350 000 Assembly truck Fig 26 3 Heat hexagon nut 4 Loosen hexagon nut 5 Press out and remove bearing bolt with two armed extractor Fig 27 6 Remove scrapers with 5870 400 001 Offset screwdriver 7 Remove releasing parts 8 Force out bearing outer rings Fig 28 Dismantling 40 EN 4474 751 104a 2018 06 4 40 ...

Page 178: ...t with axle bridge Special tools AA01 312 325 Press out device 5870 080 052 Press out device 1 Secure tie rod with crane 2 Remove cotter pin Fig 29 3 Unfasten hexagon slotted nut Fig 30 Dismantling EN 4474 751 104a 2018 06 41 4 41 ...

Page 179: ...870 080 052 Press out device and remove it Fig 31 9 1 4 Dismantling axle bridge 1 Unfasten hexagon nut and remove releasing parts Fig 32 2 Fasten two hexagon nuts to the air spring and lock them 3 Unfasten and remove the air spring Fig 33 Dismantling 42 EN 4474 751 104a 2018 06 4 42 ...

Page 180: ...xle bridge to crane 8 Unfasten hexagon screws and remove axle bridge Fig 35 9 2 Removing the track lever 9 2 1 Removing the track lever independent wheel suspension variant Special tools 5870 505 012 Test device AA02 257 341 Screw coupling 5870 350 101 Clamping bracket 5870 350 000 Assembly truck Dismantling EN 4474 751 104a 2018 06 43 4 43 ...

Page 181: ...e the track lever Fig 36 9 2 2 Removing the track levers and the steering arm variant with axle bridge 1 Unfasten hexagon screws and remove track lever and steering arm Fig 37 9 3 Removing and dismantling the control arms 9 3 1 Removing and dismantling the lower control arm variant with tapered roller bearing Special tools 5870 100 059 Assembly fixture 5870 506 134 Press in bush AA02 293 799 Compr...

Page 182: ...100 059 Assembly fixture and two armed extractor and remove it Fig 39 5 Preload joint with hydraulic press 5870 506 134 Press in bush and AA02 293 799 Compression sleeve 6 Disengage retaining ring 7 Release press 8 Remove retaining ring 9 Remove joint Fig 40 Dismantling EN 4474 751 104a 2018 06 45 4 45 ...

Page 183: ... Fig 41 9 3 2 Removing and dismantling lower control arm RL 75 E with molecular joint Special tools 5870 080 052 Press out device 5870 506 134 Press in bush AA02 293 799 Compression sleeve 1 Remove cotter pin 1 2 Secure control arm with crane 3 Unfasten hexagon slotted nut 2 Fig 42 Dismantling 46 EN 4474 751 104a 2018 06 4 46 ...

Page 184: ... 1 8 Release press 9 Remove retaining ring 10 Remove joint 11 Preload ball joint 4 with hydraulic press 5870 506 134 Press in bush and AA02 293 799 Compression sleeve 12 Disengage retaining ring 3 13 Release press 14 Remove retaining ring 15 Remove ball joint Fig 44 9 3 3 Removing and dismantling upper control arm Special tools 5870 100 059 Assembly fixture 5870 506 134 Press in bush AA02 293 799 ...

Page 185: ...wn bolt with 5870 100 059 Assembly fixture and two armed extractor and remove it Fig 46 6 Preload joint with hydraulic press 5870 506 134 Press in bush and AA02 293 799 Compression sleeve 7 Disengage retaining ring 8 Release press 9 Remove retaining ring 10 Remove joint Fig 47 Dismantling 48 EN 4474 751 104a 2018 06 4 48 ...

Page 186: ...roller bearings 13 Force out bearing outer rings Fig 48 9 4 Removal of brake Special tools AA01 137 137 Eyebolt 5870 204 002 Eyebolt Observe the specifications of the brake manufacturer 1 Loosen locknuts 2 Remove brake cylinder Fig 49 Dismantling EN 4474 751 104a 2018 06 49 4 49 ...

Page 187: ...3 Remove the bracket Fig 50 4 Remove metal sheet Fig 51 5 Depending on variant remove steel clip or plastic clip Fig 52 Dismantling 50 EN 4474 751 104a 2018 06 4 50 ...

Page 188: ...ter in counterclockwise direction manually until contact is obtained Fig 53 8 Remove spring split pin 9 Remove disk 1 and pin 2 10 Remove lining bracket 3 Fig 54 11 Remove contacts 1 Fig 55 Dismantling EN 4474 751 104a 2018 06 51 4 51 ...

Page 189: ...ection on brake caliper 15 Remove brake caliper Fig 57 9 5 Remove and dismantle hub 9 5 1 Removing hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit Special tools AA01 266 187 Plug insert 5870 401 136 Slotted nut wrench 5870 912 012 Centering device AA01 395 095 Load carrying fixture Dismantling 52 EN 4474 751 104a 2018 06 4 52 ...

Page 190: ... connection of the brake disk with AA01 266 187 Plug insert and do not remove à The brake disk will be removed later 6 Unlock slotted nut 7 Support hub from below 8 Loosen slotted nut with 5870 401 136 Slotted nut wrench and 5870 912 012 Centering device 9 Remove locking plate Fig 60 Dismantling EN 4474 751 104a 2018 06 53 4 53 ...

Page 191: ...hub from steering knuckle 9 5 2 Dismantling hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit Special tools AA01 266 187 Plug insert 5870 400 001 Offset screwdriver 5870 300 020 Extracting device 5870 300 019 Extracting device 1 Loosen Torx screws with AA01 266 187 Plug insert 2 Remove hub Fig 61 3 Remove O ring Fig 62 Dismantling 54 EN 4474 751 104a 2018 06 4 54 ...

Page 192: ...ove impulse disc with three armed extractor Fig 63 5 Remove inner ring of shaft seal with 5870 400 001 Offset screwdriver Fig 64 6 Remove retaining ring 1 Fig 65 Dismantling EN 4474 751 104a 2018 06 55 4 55 ...

Page 193: ...bearing and shaft seal from the hub Fig 67 10 Do not mix up bearing outer rings Use suitable appliances to tie together bearing outer ring and tapered roller bearing Risk of injury due to parts flying away Slight or moderate injury possible ð Wear protective goggles Force out bearing outer rings 11 Press wheel studs from the hub Dismantling 56 EN 4474 751 104a 2018 06 4 56 ...

Page 194: ...ving hub RL 85 adjustable bearing Special tools AA01 395 095 Load carrying fixture 1 Loosen cap screws 2 Remove cover Fig 68 3 Unfasten cap screw on locking nut Fig 69 Dismantling EN 4474 751 104a 2018 06 57 4 57 ...

Page 195: ...hub off steering knuckle and remove releasing components Fig 70 9 5 4 Dismantling hub RL 85 adjustable bearing Special tools 5870 400 001 Offset screwdriver 5870 300 020 Extracting device 5870 300 019 Extracting device 1 Remove shaft seal with 5870 400 001 Offset screwdriver Fig 71 Dismantling 58 EN 4474 751 104a 2018 06 4 58 ...

Page 196: ...r bearing Fig 72 3 Remove impulse disc with three armed extractor Fig 73 4 Remove the bearing outer rings with 5870 300 020 Extracting device and 5870 300 019 Extracting device Fig 74 Dismantling EN 4474 751 104a 2018 06 59 4 59 ...

Page 197: ...on variant king pin as an example with web Variant with axle bridge king pin as example without web Depending on the variant the king pin does or does not have a web All axles with compact bearing units except for AVN 75 have a web on the king pin RL 85 comes with and without a web Damage due to inappropriate handling possible ð Note that operational steps depend upon the variant being worked upon...

Page 198: ...emove the lower seal holder Fig 77 6 Secure steering knuckle support to the crane 7 Working upwards from bottom press out king pin using 5873 003 007 Clamping cylinder 5870 287 010 Pump 5870 285 027 Pressure plate and 5870 285 028 Pull rod and remove it 8 Remove steering knuckle support and disk Fig 78 Dismantling EN 4474 751 104a 2018 06 61 4 61 ...

Page 199: ...2 Removing king pin and dismantling steering knuckle variant with axle bridge and example of king pin without web Special tools 5870 650 001 Extracting device 5873 003 007 Clamping cylinder 5870 287 010 Pump 5870 285 027 Pressure plate 5870 285 028 Pull rod AA02 042 372 Guidance 5870 260 003 Handle Dismantling 62 EN 4474 751 104a 2018 06 4 62 ...

Page 200: ...asten the lower lubricating nipple Fig 81 3 Remove retaining ring Fig 82 4 Pull seal holder out of bore with 5870 650 001 Extracting device and M10 x 1 screw 5 Remove the lower seal holder Fig 83 Dismantling EN 4474 751 104a 2018 06 63 4 63 ...

Page 201: ...inder 5870 287 010 Pump 5870 285 027 Pressure plate and 5870 285 028 Pull rod and remove it 8 Remove steering knuckle and disk Fig 84 9 Remove the axial roller bearing Fig 85 10 Drive components out of both bores using AA02 042 372 Guidance and 5870 260 003 Handle Fig 86 Dismantling 64 EN 4474 751 104a 2018 06 4 64 ...

Page 202: ... tachometer and steering stop 1 Pull tachometer out of steering knuckle Fig 87 2 Pull bush out of steering knuckle Fig 88 3 Loosen hexagon nut 4 Remove stop screw Fig 89 Dismantling EN 4474 751 104a 2018 06 65 4 65 ...

Page 203: ...9 8 Removing the hub carrier AVN 75 1 Loosen Torx screws 1 and remove hub carrier 2 Remove O ring from hub carrier Fig 90 Dismantling 66 EN 4474 751 104a 2018 06 4 66 ...

Page 204: ...riants of the illustrated ZF units in various combinations The following variants are illustrated in this chapter Independent wheel suspension variant king pin as an example with web Variant with axle bridge king pin as example without web Depending on the variant the king pin does or does not have a web All axles with compact bearing units except for AVN 75 have a web on the king pin RL 85 comes ...

Page 205: ...870 260 003 Handle AA01 046 851 Assembly fixture 5870 912 018 Centering bolt AA02 042 372 Guidance 1 Install needle sleeves with nomenclature facing special tool Install bush with clearance groove pointing upwards Depending on variant drive in the lower needle sleeves or bush with 5870 055 107 Driver tool and 5870 260 003 Handle Fig 93 2 Install the axial roller bearing in the steering knuckle wit...

Page 206: ... on the gage block to zero Fig 95 5 Press the gage block against the upper bore of the steering knuckle 6 Measure dimension from axial bearing to gage block Dimension A e g 81 mm Fig 96 7 Measure height of axle stub Dimension B e g 87 45 mm Fig 97 8 Measure height of gage block Assembly EN 4474 751 104a 2018 06 69 4 69 ...

Page 207: ...mm 87 45 mm 0 07 mm s 2 38 mm 10 Secure steering knuckle to crane 11 Slowly slide steering knuckle over axle stub 12 Slide in calculated shim for axial clearance of steering knuckle On RL 85 slide disk above knuckle On all other axles insert disk below knuckle Fig 98 13 Align bores of all parts with 5870 912 018 Centering bolt Fig 99 14 Wipe king pin with a soft cloth Assembly 70 EN 4474 751 104a ...

Page 208: ...y damage the components ð Heat the axle stub to max 100 C Uniformly heat the axle stub with a hot air blower 16 Super cool the king pin 17 On the king pin with web align the longer end pointing downwards From above quickly slide the king pin until contact is obtained Fig 100 18 Carefully install sealing ring with sealing lip pointing downwards using AA02 042 372 Guidance and 5870 260 003 Handle Fi...

Page 209: ...sert sealing ring with AA02 042 372 Guidance and 5870 260 003 Handle until contact is obtained 21 On variant with bush install bush with recess pointing downwards Fig 103 22 Center needle sleeve 2 with transport sleeve 3 on AA02 042 372 Guidance and 5870 260 003 Handle 1 Fig 104 Assembly 72 EN 4474 751 104a 2018 06 4 72 ...

Page 210: ...le sleeve until contact is obtained 26 Install second needle sleeve Fig 105 27 Install O ring in the seal holder 28 Install seal holder in steering knuckle with tab facing towards tachometer 29 Insert retaining ring 30 Install the lower seal holder Fig 106 31 Screw in the top and bottom lubricating nipples and tighten by hand Fig 107 Assembly EN 4474 751 104a 2018 06 73 4 73 ...

Page 211: ...bush with clearance groove pointing upwards Depending on variant drive in the lower needle sleeves or bush with 5870 055 107 Driver tool and 5870 260 003 Handle Fig 108 2 Install needle sleeves with nomenclature facing special tool Install bush with clearance groove pointing downwards Depending on variant drive in the upper needle sleeves or bush with 5870 055 107 Driver tool and 5870 260 003 Hand...

Page 212: ...earance of the steering knuckle 5 Press gage block against the axial bearing 6 Set the depth gage on the gage block to zero Fig 111 7 Press the gage block against the upper bore of the steering knuckle 8 Measure dimension from axial bearing to gage block Dimension A e g 81 mm Fig 112 Assembly EN 4474 751 104a 2018 06 75 4 75 ...

Page 213: ...Calculate thickness s of shim for axial clearance on steering knuckle 0 05 mm to 0 15 mm Calculation example s dimension A dimension C dimension B axial clearance mean value s 81 mm 8 9 mm 87 45 mm 0 07 mm s 2 38 mm 12 Install 5870 345 092 Press in ring and the seal holder Fig 114 Assembly 76 EN 4474 751 104a 2018 06 4 76 ...

Page 214: ...xle stub 16 Slide in calculated shim for axial clearance of steering knuckle On RL 85 slide disk above knuckle On all other axles insert disk below knuckle Fig 116 17 Align bores of all parts with 5870 912 018 Centering bolt Fig 117 18 Wipe king pin with a soft cloth Assembly EN 4474 751 104a 2018 06 77 4 77 ...

Page 215: ...jury possible ð Wear protective gloves This may damage the components ð Heat the axle stub to max 100 C Uniformly heat the axle stub with a hot air blower 20 Super cool the king pin 21 From above quickly slide the king pin until contact is obtained Fig 118 22 Remove retaining ring 23 Pull seal holder out of bore and remove 5870 345 092 Press in ring Fig 119 Assembly 78 EN 4474 751 104a 2018 06 4 7...

Page 216: ...ig 120 25 Install seal holder in the steering knuckle 26 Insert retaining ring 27 Install the lower seal holder Fig 121 28 Screw in the top and bottom lubricating nipples and tighten by hand Fig 122 Assembly EN 4474 751 104a 2018 06 79 4 79 ...

Page 217: ...26 Driver tool 5870 260 011 Handle 5870 048 317 Driver tool AA01 266 187 Plug insert 1 Use the tools only with hubs where wheel studs have already been installed Use 5870 610 010 Assembly fixture and 5870 610 002 Insert to install the wheel studs Fig 123 2 Do not mix up bearing cups Use 5870 050 003 Driver tool and 5870 260 004 Handle to press both bearing outer rings into the hub until contact is...

Page 218: ...eile into the space between bearing inner ring and bearing cage 40_020226_01 1 2 3 4 Fig 125 1 Grease 2 O ring 3 Retaining ring 4 Compact bearing consisting of two individual tapered roller bearings 4 Place bearing inner ring at the brake disk side onto 5870 345 121 Support arbor Fig 126 Assembly EN 4474 751 104a 2018 06 81 4 81 ...

Page 219: ...aining ring 1 in both bearing inner rings 9 Rotate hub several times in both directions 10 Check whether the retaining ring 1 is completely engaged Once the retaining ring has engaged the bearing unit has a total height of 135 mm 0 4 mm Fig 128 11 Insert outer shaft seal with 5870 345 121 Support arbor 5870 053 026 Driver tool and 5870 260 011 Handle with the open side facing outwards Fig 129 Asse...

Page 220: ... 130 13 Press impulse disc until flush Fig 131 14 Place brake disk on hydraulic press with hub reaching through 15 Put hub onto the brake disk 16 Bolt in Torx screws and tighten manually with AA01 266 187 Plug insert Final tightening of Torx screws after installing the hub Fig 132 Assembly EN 4474 751 104a 2018 06 83 4 83 ...

Page 221: ...nner installer AA01 395 095 Load carrying fixture 5870 401 136 Slotted nut wrench 5870 912 012 Centering device AA01 266 187 Plug insert Operating supplies and auxiliary materials 0671 190 180 Renolit LX NHU 2 1 Apply 0671 190 180 Renolit LX NHU 2 evenly onto both bearing seats 1 2 Bolt 5870 651 099 Inner installer 2 onto the steering knuckle Fig 134 Assembly 84 EN 4474 751 104a 2018 06 4 84 ...

Page 222: ... 5870 401 136 Slotted nut wrench and 5870 912 012 Centering device to tighten the slotted nut Tightening torque 850 Nm 9 Mount locking plate with the tab showing inwards onto the hub carrier 10 Bolt on slotted nut with the chamfer showing inwards 11 Use 5870 401 136 Slotted nut wrench and 5870 912 012 Centering device to tighten the slotted nut Tightening torque 1 200 Nm 12 Support hub on a wheel ...

Page 223: ...re slotted nut with locking plate 1 Fig 136 15 Insert O ring 1 Fig 137 16 Slide cover into hub 17 Screw in and tighten hexagon screws Tightening torque 100 Nm Fig 138 Assembly 86 EN 4474 751 104a 2018 06 4 86 ...

Page 224: ...191 Phoenix spirit 0666 790 060 Stucarit 203 1 Place brake disk on hydraulic press with hub reaching through 2 Put hub onto the brake disk 3 Bolt in Torx screws and tighten manually 4 Place hub on hydraulic press so that the brake disk is not placed on it 5 Risk of crushing due to hydraulic tool Slight to moderate injury possible ð Do not reach into danger area Use press to fix hub 6 Bolt in and t...

Page 225: ...l and 5870 260 002 Handle 9 Press large bearing outer ring into hub until contact is obtained using 5870 058 089 Driver tool and 5870 260 002 Handle Fig 141 10 On the variant with grease in the hub install 200 g of grease in the tapered roller bearing in acc with ZF List of Lubricants TE ML 12 Press grease also from outside into the space between bearing inner ring and bearing cage 11 Place bearin...

Page 226: ...ease chamber using 5870 048 295 Driver tool 15 Press impulse disc on with 5870 048 295 Driver tool Fig 143 16 Apply 0666 790 060 Stucarit 203 to O ring 17 Install O ring 1 in bearing inner ring Fig 144 10 3 4 Installing hub RL 85 adjustable mounting Special tools AA01 395 095 Load carrying fixture 5870 230 005 Spring balance AA02 247 297 Socket wrench Operating supplies and auxiliary materials 066...

Page 227: ...ed tapered roller bearing refer to section Assembling the hub RL 85 adjustable bearing page 87 onto knuckle Fig 146 4 Slide on supporting ring 5 Bolt on and hand tighten the lock nuts 6 Remove AA01 395 095 Load carrying fixture 7 Rotate hub several times in both directions Fig 147 Assembly 90 EN 4474 751 104a 2018 06 4 90 ...

Page 228: ...F N Mtotal 0 1785 x 25 Mtotal 4 46 Nm Mbearing 4 46 Nm 1 Nm experiential value for shaft seal Mbearing 3 46 Nm If rolling moment too low tighten locking nut If rolling moment is too high unfasten locking nut 11 Rotate hub several times in both directions 12 Check rolling moment of hub again Fig 148 13 Bolt in cap screw and tighten with AA02 247 297 Socket wrench and torque wrench Tightening torque...

Page 229: ... of cover Fig 150 15 Fix cover with cylindrical screws Tightening torque 23 Nm Fig 151 10 4 Installing tachometer and mounting steering stop Operating supplies and auxiliary materials 0671 190 065 UNIREX N3 Assembly 92 EN 4474 751 104a 2018 06 4 92 ...

Page 230: ...ained Fig 153 4 On variant with hexagon nut bolt hexagon nut to stop screw On variant without hexagon nut slide disk onto stop screw 5 On variant with hexagon nut turn in stop screw and and lock with hexagon nut Tightening torque 130 Nm On variant without hexagon nut screw in stop screw and tighten down Tightening torque 300 Nm Adjust steering angle before initial operation Fig 154 Assembly EN 447...

Page 231: ...riant with fit bolt fasten fit bolt in front direction of travel and tighten down M16 x 1 5 10 9 fit bolt Tightening torque 270 Nm M20 12 9 fit bolt Tightening torque 475 Nm 40 Nm 3 On variant with four screws apply 0666 690 112 Loctite 649 to the threads 4 Bolt in screws and tighten M16 x 1 5 10 9 hexagon screw Tightening torque 270 Nm M20 12 9 hexagon screw light gray silver colors Tightening to...

Page 232: ...ll contacts 1 in brake linings from outside Fig 157 7 Attach lining bracket 3 into the brake 8 Press lining retainer bracket 3 downwards and push in bolts 2 9 Push disk 1 onto pin 2 10 Fix pin 2 with spring split pin Fig 158 Assembly EN 4474 751 104a 2018 06 95 4 95 ...

Page 233: ...11 Attach steel clips Fig 159 12 Align cable with variant with steel clip 1 or variant with plastic clip 2 Fig 160 Assembly 96 EN 4474 751 104a 2018 06 4 96 ...

Page 234: ...4 Clip in the bracket Fig 162 15 Mount brake cylinder with the connections showing backwards to the brake caliper 16 Fix brake cylinder with new locknuts Tightening torque 195 Nm 15 Nm Fig 163 Assembly EN 4474 751 104a 2018 06 97 4 97 ...

Page 235: ... centrally on joint 3 With AA00 249 031 alignment part align joint flush Fig 164 4 Install retaining ring as far as possible in bore so that opening 45 to shaft of control arm is twisted On variant with open spacer ring align opening of retaining ring opposite opening to spacer ring 5 Preload joint with hydraulic press 5870 506 134 Press in bush and AA02 293 799 Compression sleeve until retaining ...

Page 236: ...acer ring 13 Preload ball joint with hydraulic press 5870 506 134 Press in bush and AA02 293 799 Compression sleeve until the retaining ring can be installed completely 14 Insert retaining ring 15 Release press 16 Check that retaining ring is correctly seated Fig 166 10 6 2 Installing the upper control arm Special tools 5870 058 084 Driver tool 5870 260 003 Handle 5870 345 091 Press in mandrel 587...

Page 237: ...sion sleeve 4 Tighten hex nut on 5870 345 091 Press in mandrel and turn the 5870 345 091 Press in mandrel several times during this tightening process Tightening torque 1 000 Nm Fig 168 5 Rolling moment of the control arm bearing 8 Nm to 15 Nm In case of an insufficient rolling torque install a thinner spacer In case of an excessive rolling torque install a thicker spacer 6 Unfasten hexagon nut an...

Page 238: ...gs the calculated shims and the bush Fig 170 8 Install the scraper with its sealing lip facing outwards using AA01 003 764 Assembly fixture Fig 171 9 Install rings with large radius pointing inwards Fig 172 Assembly EN 4474 751 104a 2018 06 101 4 101 ...

Page 239: ...t to the control arms 15 Remove 5870 000 097 Mounting fixture 16 Apply 0666 690 022 Loctite 262 to thread of the hexagon nut 17 Fit hexagon nut on bolt with flat surface facing inwards and tighten Tightening torque 1 000 Nm 18 Swivel the control arms several times and tighten the hexagon nut Fig 173 10 6 3 Installing lower control arm variant with tapered roller bearing Special tools 5870 000 097 ...

Page 240: ... surface facing inwards and tighten Tightening torque 1 000 Nm 9 Swivel the control arm again and tighten down the hexagon nut Fig 174 10 6 4 Installing control arm RL 75 E with molecular joint 1 Degrease tapered hole and tapered pivot 2 Slide conical peg into tapered bore from below 3 Align joints of lower control arm with joints on upper control arm 4 Bolt on and tighten the hexagon slotted nut ...

Page 241: ...8 bar 2 bar à Hub axle secured to prevent twisting 2 Secure axle half to wheel stud with 5870 350 101 Clamping bracket to 5870 350 000 Assembly truck 3 Secure track lever with hexagon screws Tightening torque 1 050 Nm Fig 176 10 7 2 Fitting the track levers and steering arm RL 85 e g to axle bridge Operating supplies and auxiliary materials 0666 690 022 Loctite 262 1 Apply 0666 690 022 Loctite 262...

Page 242: ...666 690 022 Loctite 262 to thread of hexagon screws 4 Secure axle bridge to bracket M20 x 1 5 10 9 cap screw Tightening torque 620 Nm M20 x 1 5 10 9 hexagon screw Tightening torque 690 Nm Fig 178 5 On variant with damper secure damper to bracket with hexagon screw and hexagon nut Tightening torque 90 Nm 6 Degrease tapered hole and tapered pivot 7 Slide conical peg into tapered bore on track lever ...

Page 243: ...hreads of the cap screws 12 Secure spring carrier to axle bridge with cap screws M20 x 1 5 10 9 cap screw Tightening torque 620 Nm M20 x 1 5 12 9 cap screw Tightening torque 720 Nm Fig 180 13 Fasten two hexagon nuts to the air spring and lock them 14 Bolt on and tighten the air spring Tightening torque 80 Nm Fig 181 Assembly 106 EN 4474 751 104a 2018 06 4 106 ...

Page 244: ...4 and disk 3 at the thread of the shock absorber Fig 182 17 Fix shock absorber with hexagon nut Tightening torque 90 Nm Fig 183 18 Secure struts to axle bridge and spring carrier with hexagon bolts and washers Tightening torque 440 Nm Assembly EN 4474 751 104a 2018 06 107 4 107 ...

Page 245: ... cotter pin along the conical peg 6 Adjust track as specified by the vehicle manufacturer 7 Tighten down the clamp Tightening torque 70 Nm to 90 Nm Fig 185 10 8 3 Assembling the steering arms RL 75 EC and RL 82 EC Special tools 5870 058 084 Driver tool 5870 260 003 Handle 5870 345 091 Press in mandrel 5870 100 060 Compression sleeve AA01 003 764 Assembly fixture 5870 000 097 Mounting fixture Opera...

Page 246: ...leeve 4 Tighten hexagon nut on 5870 345 091 Press in mandrel and turn 5870 345 091 Press in mandrel several times during the tightening process Tightening torque 1 000 Nm Fig 187 5 Rolling moment of steering arm bearing 5 Nm to 12 Nm without scraper In case of an insufficient rolling torque install a thinner spacer In case of an excessive rolling torque install a thicker spacer 6 Unfasten hexagon ...

Page 247: ...gs the calculated shims and the bush Fig 189 8 Install the scraper with its sealing lip facing outwards using AA01 003 764 Assembly fixture Fig 190 9 Install rings with large radius pointing inwards Fig 191 Assembly 110 EN 4474 751 104a 2018 06 4 110 ...

Page 248: ...octite 262 to thread of the hexagon nut 14 Screw hexagon nut onto bearing bolt with flat side pointing inwards and tighten Tightening torque 1 000 Nm 15 Turn the bearing pin several times and retighten the hex nut Fig 192 10 8 4 Fitting attachments variant for independent wheel suspension 1 Fit air spring and secure with hexagon screw Tightening torque 70 Nm to 80 Nm Fig 193 Assembly EN 4474 751 1...

Page 249: ...egs 6 Secure tie rods with hexagon slotted nuts 1 2 4 5 and 7 M24 x 1 5 hexagon slotted nut Tightening torque 250 Nm to 280 Nm M20 x 1 5 hexagon slotted nut Tightening torque 210 Nm to230 Nm 7 Adjust track as specified by the vehicle manufacturer 8 Align clamps 8 and 6 upwards and tighten Tightening torque 80 Nm to 90 Nm 9 Align clamps 3 downwards and tighten Tightening torque 80 Nm to 90 Nm Fig 1...

Page 250: ...10 On variant with stabilizer secure tie rod to bracket Tightening torque 220 Nm Assembly EN 4474 751 104a 2018 06 113 4 113 ...

Page 251: ...6 080 ft 1 853m 1 Knoten 1 n mile h 1 852 km h 11 1 2 Conversion of mass units Unit gr dram oz lb long cwt sh cwt long tn sh tn g Kg t Avoirdupois system in UK and US generally used commercial weight 1gr 1 0 03657 0 00229 1 7 000 0 064799 1 dram 27 344 1 0 0625 0 00391 1 77184 1 oz 437 5 16 1 0 0625 28 3495 1 lb 7 000 256 16 1 0 00893 0 01 0 0005 453 592 0 45359 1 long cwt 112 1 1 12 0 05 50 8023 ...

Page 252: ...0 N 1 lbf pound force 4 44822 N 1 pdl poundal 0 138255 N 1 1 sh sthène 103 N 11 1 4 Conversion of pressure units and units of stress Unit N m μbar mbar bar N mm2 Statutory pressure units and units of stress 1 N m2 1 Pa 1 10 0 01 10 5 10 6 1μbar 0 1 1 0 001 10 6 10 7 1mbar 100 1 000 1 0 001 0 0001 1 bar 105 106 1 000 1 0 1 1 N mm2 106 107 10 000 10 1 Pressure units and units of stress to be convert...

Page 253: ... 2 048 16 1 kp m2 1mmWS 10 6 10 4 1 0 2048 1 Torr 1mmHg mmHg 0 00136 13 5951 1 0 00132 0 01934 2 7845 1 atm 1 03323 10 332 3 760 1 14 695 2 116 1 Anglo American pressure units and units of stress 1 lbf in2 0 07031 703 07 51 715 0 06805 1 144 1 lbf ft2 4 8824 0 35913 1 1 tonf in2 1 57488 157 488 152 42 2 240 1 Tab 8 Pressure units and units of stress lbf in2 pound force per square inch psi tonf in2...

Page 254: ...oving hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 52 refer to section Dismantling hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 54 refer to section Dismantling hub RL 85 adjustable bearing page 58 refer to section Assembling the hub RL 75 RL 80 RL 82 and AVN 75 with compact bearing unit page 80 refer to section Installing hub RL 75 RL 80 RL 82 and AVN 75 with ...

Page 255: ...4 118 ...

Page 256: ...4 119 ...

Page 257: ...EN 4474 751 104a 2018 06 ZF Friedrichshafen AG ZF Aftermarket Donaustraße 71 94034 Passau Deutschland Germany Telefon Phone 49 851 494 0 www zf com contact 4 120 ...

Page 258: ......

Page 259: ...REPAIR MANUAL ZF DROP CENTER AXLE AV 132 II AV 132 II T 5871 214 102 en 5 1 ...

Page 260: ...on request ZF Friedrichshafen AG will advise which edition is the latest one Any maintenance work is to be done in accordance with the Operating Manual ZF order No 5871 214 912 and the ZF List of Lubricants TE ML 12 The ZF list of lubricants is being continuously updated and can be obtained or viewed as follows at all ZF plants at all ZF service organizations Internet www zf com ATTENTION Observe ...

Page 261: ...al tools WS 1 11 WH 1 5 D I S A S S E M B L Y 1 1 3 4 1 Disassembly of mounting parts 1 1 Longitudinal control arms air springs and shock absorbers 1 2 Spring carriers 1 3 Brake cylinder and brake 1 4 Hub 2 Disassembly of portal drive 2 1 Removal of portal drive AV 132 II 2 2 Removal of portal drive AV 132 II T 2 3 Dismantling of portal drive 3 Disassembly of differential and input 3 1 Differentia...

Page 262: ...ttern 4 5 Installation of shaft seal input flange 5 Reassembly of portal drive 5 1 Setting and installation of gears 5 1 1 Input gear 5 1 2 Intermediate gears 5 1 3 Output gear 5 2 Mounting of portal drive AV 132 II 5 3 Mounting of portal drive AV 132 II T 5 4 Revolution counter 6 Reassembly of mounting parts 6 1 Hub 6 2 Brake 6 3 Spring carriers 6 4 Longitudinal control arms air springs and shock...

Page 263: ...g school The Service Stations established by ZF Friedrichshafen AG 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 cont...

Page 264: ... 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 renewed 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 ...

Page 265: ...y 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 i...

Page 266: ...ricants e g TE ML 12 INFORMATION ON SPARE PARTS ORDERING The following information is required when ordering genuine ZF spare parts 1 Unit type 2 Unit serial number 3 ZF parts list number 4 Make and type of vehicle 5 Denomination of spare part 6 Spare part number 7 Shipping mode NOTE Item 1 2 and 3 see identification plate Please indicate all the a m details to avoid any mistakes in the delivery o...

Page 267: ...instructions are valid for all bevel gear sets in AV 132 II axles The setting specification is applicable for lapped spiral bevel gears Ideal contact pattern Drive side Coast side The contact pattern must be tangent to the tooth tip on the pinion This example shows a good contact pattern setting on the crown wheel with regard to the tooth depth Further examples Shot peening edge 5 9 ...

Page 268: ... moves to the crown wheel tooth root Flank glossary convex flank drive side concave flank coast side toe crown wheel inner side heel crown wheel outer side Limit position tooth root Drive side Coast side Contact pattern is shifted somewhat too far to the crown wheel tooth root The contact pattern phases out on the crown wheel convex flank on the toe in the root Correction Increase pinion distance ...

Page 269: ...ooth position Coast side Drive side Contact pattern is too far within the crown wheel tooth root Correction Increase pinion distance towards crown wheel I e install a thinner pinion shim Procedure The illustrated contact pattern is not permitted as it does not cover more than 50 of the flank tooth depth top root 5 11 ...

Page 270: ...eel tooth top acoustically extremely critical At the crown wheel tooth top drive the contact pattern forms a V and on the coast side it is completely located at tooth top Correction Reduce pinion distance towards crown wheel I e install a thicker pinion shim Procedure The illustrated contact pattern is no longer permitted A correction is required Correction as illustrated in the example min 0 1 mm...

Page 271: ...ast side Contact pattern is much too close to the crown wheel tooth top acoustically extremely critical Correction Reduce pinion distance towards crown wheel I e install a thicker pinion shim Procedure The illustrated contact pattern is no longer permitted A correction is required Further examples extreme top position correction min 0 15 mm 5 13 ...

Page 272: ...6 Nm 0 138 kpm 1 kg cm 1 bar 1 02 kp cm2 0 070 bar 0 071 kp cm2 1 liter 4 456 liters 1 liter 3 785 liters 1609 344 m 0 C Celsius 0 C Celsius 1 in inch 2 205 lb pounds 7 233 lbf x ft pound force foot 1 lbf x ft pound force foot 5 560 lb in pound per inch 14 233 psi pound force per square inch lbf in2 1 psi lbf in2 0 264 gallons Imp 1 gallon Imp 0 220 gallons US 1 gallon US 1 mile land mile 32 F Fah...

Page 273: ...melzeichen Formula Sign Symbole Neu Alt New Old Nouveau Vieux Umrechnung Conversion Conversion Bemerkungen Note Nota Masse Density Densité m kg kilogram kg Kraft Force Force F N Newton kp 1 kp 9 81 N Arbeit Work Travail A J Joule kpm 0 102 kpm 1J 1Nm Leistung Power Puissance P KW Kilowatt PS DIN 1 PS 0 7355 KW 1 KW 1 36 PS Drehmoment Torque Couple T Nm Newton meter kpm 1 kpm 9 81 Nm T Nm F N r m K...

Page 274: ...0 M18 280 390 460 M20 390 560 650 M22 530 750 880 M24 670 960 1100 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100 Metric ISO fine thread DIN 13 page 13 Dimension 8 8 10 9 12 9 M 8 x 1 24 36 43 M 9 x 1 36 53 62 M 10 x 1 52 76 89 M 10 x 1 25 49 72 84 M 12 x 1 25 87 125 150 M 12 x 1 5 83 120 145 M 14 x 1 5 135 200 235 M 16 x 1 5 205 300 360 M 18 x 1 5 3...

Page 275: ...I AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 1 1 Assembly truck cpl with tilting device 5870 350 000 1 1 2 2 9 2 Fixture 5870 350 093 1 1 2 3 Load carrying fixture 5870 281 046 1 1 8 1 9 6 22 4 Eyebolt M16 5870 204 084 1 1 9 6 22 5 Slotted nut wrench 5870 401 146 1 1 11 1 12 6 15 6 16 6 17 5 17 ...

Page 276: ...ND REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 2 6 Load carrying fixture 5870 281 043 1 1 12 6 15 7 Pry bar 5870 345 036 1 1 16 5 17 8 Assembly fixture 5870 100 069 1 1 18 9 Extractor 5870 650 004 1 2 3 3 10 10 Screw driver 5870 400 001 2 2 4 3 13 5 18 ...

Page 277: ...SEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 3 11 Rapid grip 5873 012 013 1 2 6 12 Basic tool 5873 002 001 1 2 6 3 2 3 16 13 Eyebolt M20x1 5 AA00 609 603 2 2 7 2 8 4 39 4 40 5 33 5 36 14 Fixture 5870 350 110 1 2 9 15 Locating pins M14 5870 204 022 1 2 10 5 14 5 19 ...

Page 278: ...REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 4 16 Load carrying fixture 5870 281 056 1 3 1 4 28 5 35 17 Grab sleeve 5873 002 025 1 3 2 18 Gripping device 5873 002 052 1 3 2 19 Pressure piece AA00 328 122 1 3 2 4 23 4 26 20 Extractor 5870 080 067 1 3 5 5 20 ...

Page 279: ...II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 5 21 Slotted nut wrench 5870 401 173 1 3 11 4 14 4 41 4 43 22 Power wrench 5870 203 002 1 3 11 4 14 4 41 4 43 23 Supporting device AA00 640 418 1 3 11 4 14 4 41 4 43 24 Forcing device 5870 080 044 1 3 14 25 Gripping device 5873 002 051 1 3 16 5 21 ...

Page 280: ...REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 6 26 Inner extractor 5870 300 019 1 3 17 27 Counter support 5870 300 020 1 3 17 28 Assembly fixture 5870 345 080 1 4 8 29 Driver tool 5870 056 008 1 4 12 30 Handle 5870 260 002 1 4 12 4 38 5 9 5 20 5 26 5 27 5 22 ...

Page 281: ...ASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 7 31 Locating pins M14x1 5 5870 204 025 1 4 24 32 Driver tool 5870 058 078 1 4 27 33 Handle 5870 260 003 1 4 27 34 Test equipment 5870 200 121 1 4 30 4 35 35 Adapter ring for AV 132 II T only AA00 692 068 1 4 30 5 23 ...

Page 282: ...ASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 8 36 Locating pin AA00 622 210 1 4 23 37 Locking device 5870 240 002 1 4 31 4 34 38 Straightedge L 580 mm 5870 200 022 1 4 35 4 37 5 21 5 25 39 Driver tool 5870 058 056 1 4 38 40 Eye nut 5870 281 054 1 4 39 4 40 5 24 ...

Page 283: ...ASSEMBLY AND REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 9 41 Driver tool 5870 048 216 1 4 42 42 Assembly fixture 5870 345 103 1 5 4 5 5 43 Driver tool 5870 058 061 1 5 9 44 Plug gage 5870 200 094 1 5 11 45 Driver tool 5870 055 020 1 5 20 5 25 ...

Page 284: ... AND REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 10 46 Driver tool AA00 372 127 1 5 26 5 27 47 Pressing device AA00 387 830 1 5 28 5 39 48 Assembly fixture 5870 610 010 1 6 1 49 Insert M22x1 5 5870 610 002 1 6 1 50 Driver tool 5870 050 007 1 6 3 5 26 ...

Page 285: ...CIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV 132 II AV 132 II T 4472 037 020 Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WS 11 51 Handle 5870 260 004 1 6 3 52 Location arbor 5870 345 121 1 6 5 53 Driver tool AA00 607 922 1 6 10 6 11 54 Assembly aid 5870 651 085 1 6 13 5 27 ...

Page 286: ...o Figure Designation Order No Qty Chapter Fig 5871 214 102 WH 1 1 Magnetic stand 5870 200 055 1 Universal 2 Dial indicator 5870 200 057 1 Universal 3 Gage blocks 5870 200 066 70 mm 5870 200 067 100 mm 1 Universal 4 Digital depth gage 5870 200 072 200 mm 5870 200 114 300 mm 1 Universal 5 Digital caliper gage 5870 200 109 150 mm 1 Universal 5 28 ...

Page 287: ...Torque wrench 5870 203 030 0 6 6 0 Nm 5870 203 031 1 0 12 Nm 5870 203 032 3 0 23 Nm 5870 203 033 5 0 45 Nm 5870 203 034 10 90 Nm 5870 203 039 80 400 Nm 5870 203 016 140 750 Nm 5870 203 011 750 2000 Nm 1 Universal 7 Hot air blower 5870 221 500 230 V 5870 221 501 115 V 1 Universal 8 Plastic hammer 5870 280 004 Ø 60 mm Substitute nylon insert 5870 280 006 1 Universal 9 Lifting strap 5870 281 026 1 Un...

Page 288: ...ASSEMBLY Cons No Figure Designation Order No Qty Chapter Fig 5871 214 102 WH 3 10 Lifting chain 5870 281 047 1 Universal 11 Pry bar 5870 345 071 1 Universal 12 Striker 5870 650 004 1 Universal 13 Set of internal pliers I1 I2 I3 I4 5870 900 013 1 Universal 14 Set of internal pliers I11 I21 I31 I41 90 5870 900 014 1 Universal 5 30 ...

Page 289: ... pliers A01 A02 A03 A04 90 5870 900 016 1 Universal 17 Two armed puller 5870 970 001 Jaw width 80 mm Throat depth 100 mm 5870 970 002 Jaw width 120 mm Throat depth 125 mm 5870 970 003 Jaw width 170 mm Throat depth 125 mm 5870 970 004 Jaw width 200 mm Throat depth 175 mm 5870 970 006 Jaw width 350 mm Throat depth 250 mm 5870 970 007 Jaw width 520 mm Throat depth 300 500 mm 5870 970 026 Jaw width 25...

Page 290: ...No Qty Chapter Fig 5871 214 102 WH 5 18 Three armed puller 5870 971 001 Jaw width 85 mm Throat depth 65 mm 5870 971 002 Jaw width 130 mm Throat depth 105 mm 5870 971 003 Jaw width 230 mm Throat depth 150 mm 5870 971 004 Jaw width 295 mm Throat depth 235 mm 5870 971 005 Jaw width 390 mm Throat depth 230 mm 5870 971 006 Jaw width 640 mm Throat depth 290 mm 1 Universal 5 32 ...

Page 291: ...orber arrow 3 and remove the releasing shock absorber and joint rubber Loosen bolted connection on bottom side of air spring bellows arrow 4 and remove the releasing air spring bellows with washer Disassemble air spring bellows and shock absorbers each analogously Figure 1 1 2 Spring carriers Clamp the axle and use suitable supports S Assembly truck 5870 350 000 S Fixture 5870 350 093 Remove all s...

Page 292: ...rake type are indicated on the identification plate of the brake caliper This figure shows the position of the identification plate arrow using the KNORR brake as an example Figure 4 Mount a suitable steel rod or similar to the vent slots of the brake disk see arrow thus supporting the hub on the brake caliper and blocking it against rotation Loosen bolted connection on the flange shaft Figure 5 M...

Page 293: ...rake caliper S Load carrying fixture 5870 281 046 Figure 8 Loosen bolted connection of brake caliper and remove brake caliper by using eyebolt S and load carrying fixture S S Eyebolt 5870 204 084 S Load carrying fixture 5870 281 046 Figure 9 1 4 Hub Remove hexagon screws and separate flange shaft from the axle Figure 10 Unlock outer slotted nut and loosen it Remove locking plate S Slotted nut wren...

Page 294: ... mounting face Figure 13 2 5 3 7 6 1 4 Disassembly of hub bearing compact bearing figures 14 20 Inspection of the compact bearing inside followed by a grease change is also required within the maintenance interval see List of Lubricants TE ML 12 in case of grease leakage on the shaft seal at brake disk side or when replacing the shaft seals in case of overheated brake parts e g burnt bellows on pr...

Page 295: ...t of the hub hole and remove it S Pry bar 5870 345 036 Figure 16 Disengage retaining ring Remove tapered roller bearing at brake disk side from the hub Figure 17 Press off the inner part of the shaft seal at brake disk side from the tapered roller bearing S Assembly fixture 5870 100 069 Support the tapered roller bearing from below using a suitable tube Figure 18 5 37 ...

Page 296: ... counter towards the portal drive Figure 1 Secure hub carrier by means of lifting device Loosen bolted connection and separate hub carrier from portal housing Figure 2 Dismantle bearing outer shell by means of extractor S and remove the shim behind S Extractor 5870 650 004 Figure 3 Pull oil reservoir and bushing out of the hole on hub carrier S Screw driver 5870 400 001 If necessary dismantle scre...

Page 297: ...nd separate portal drive from the axle housing S Eyebolt AA00 609 603 Pay attention that the differential and stub shaft do not drop Figure 7 1 3 2 2 2 Removal of portal drive AV 132 II T Fix portal housing by means of lifting device see previous figure Loosen bolted connection arrow 1 and separate portal drive from the axle housing S Eyebolt AA00 609 603 Pay attention that the stub shaft does not...

Page 298: ...Figure 9 Bring portal housing into the shown position Install locating pins S instead of hexagon screws see previous figure Carefully force out bearing pins upwards one after the other and remove them S Locating pins 5870 204 022 Figure 10 Push input gear between intermediate gears diagonally backwards Remove intermediate gears together with bearing inner rings one after the other Figure 11 Force ...

Page 299: ...t gear Figure 14 Dismantle bearing outer ring from portal housing and remove the shim behind Force out bearing outer ring see arrow 1 If necessary remove stud bolts see arrows 2 Figure 15 If necessary loosen cylindrical screws on the bracket and remove the releasing bracket This operation is not required for version with cast on longitudinal control arm bracket Disassemble the second portal drive ...

Page 300: ...Driveline Technology and Axle Systems 5871 214 102 1 6 Carefully force hub sided tapered roller bearing and shaft seal out of the hub using a suitable plate Figure 19 If necessary force out both bearing outer shells and remove wheel studs Figure 20 5 42 ...

Page 301: ...e 5870 281 056 Figure 1 Pull off both bearing inner rings S Grab sleeve diff carrier side 5873 002 025 S Gripping device crown wheel side 5873 002 052 S Basic tool 5873 002 001 S Pressure piece AA00 328 122 Support lower bearing inner ring on pressure piece S Figure 2 Block differential against rotation by means of a press and loosen bolted connection Figure 3 Support crown wheel and force out dif...

Page 302: ...r using the extractor S S Extractor 5870 080 067 Figure 5 Take axle bevel gear and thrust washer crown wheel side out of the differential carrier Figure 6 Force slotted pins out of cross joint differential pin Figure 7 Force differential pin out of differential carrier cross joint as far as possible and pull it out of the differential carrier Figure 8 5 44 ...

Page 303: ...e Systems 5871 214 102 3 3 Force out opposite differential pin Then remove all single parts Figure 9 Use striker S to force bearing outer ring out of the housing hole and remove the shim behind S Striker 5870 650 004 Mark installation position of shim reassembly aid Figure 10 5 45 ...

Page 304: ...red with Loctite type No 262 Heat it if required assembly aid You may also use commercial tools to loosen slotted nut Figure 11 Pull input flange off the drive pinion and remove it If necessary disassemble screen sheet from the input flange Figure 12 Lever shaft seal out of the hole S Screw driver 5870 400 001 Figure 13 Tilt axle housing slightly upwards see arrow Then force drive pinion out of th...

Page 305: ...im ring reassembly aid Figure 15 Disassemble bearing inner ring from drive pinion S Grab sleeve 5873 002 051 S Basic tool 5873 002 001 Figure 16 Pull external bearing outer ring out of the hole S Inner extractor 5870 300 019 S Counter support 5870 300 020 Figure 17 Force internal bearing outer ring out of the hole and remove the shim behind Figure 18 5 47 ...

Page 306: ...R e p a i r M a n u a l Corporate Division Off Road Driveline Technology and Axle Systems 5871 214 102 3 6 If necessary force out breather neck outwards Figure 19 5 48 ...

Page 307: ...earing chapter 4 2 C Rolling torque of differential bearing chapter 4 4 D Bevel gear set backlash chapter 4 4 D1 B1 C1 3 A D 2 B A1 1 C Figure 1 Legend 1 Axle housing 2 Crown wheel 3 Drive pinion A1 Shim contact pattern B1 Ring rolling torque of drive pinion bearing C1 Shim rolling torque of differential bearing D1 Shim backlash If either crown wheel or drive pinion is damaged both parts bevel gea...

Page 308: ...ion or marked by hand on pinion head Pinion distance deviation is indicated in 1 100 mm Determine dimension II pinion dimension Pinion basic dimension e g 150 00 mm Pinion distance deviation e g 0 05 mm Dim II 150 05 mm If no pinion distance deviation is indicated the pinion basic dimension corresponds with the pinion dimension dim II Figure 3 Figure 4 Determine dimension III bearing height Dimens...

Page 309: ...ter ring and insert it until contact is obtained Figure 6 Insert the determined shim e g thickness 1 16 mm figure 5 into the bearing hole Undercool the bearing outer ring and bring it into contact position in the bearing hole by using the assembly fixture S Also see the following figure Figure 7 S Assembly fixture 5870 345 080 Figure 8 5 51 ...

Page 310: ...e is obtained when reusing the ring removed during disassembly A check however is absolutely necessary Figure 10 Position drive pinion and mount the heated bearing inner ring until contact is obtained Before mounting the input flange and tightening the slotted nut figures 11 and 12 let bearing inner ring cool down to ambient temperature Figure 11 If disassembled mount screws to the input flange Su...

Page 311: ...ollowing figure If required increase tightening torque step by step up to max 1700 Nm until the required rolling torque 4 10 Nm is achieved While tightening rotate the drive pinion in both directions several times If the required rolling torque cannot be obtained within the specified tightening torque range use a suitable ring figure 10 for correction as indicated below Insufficient rolling torque...

Page 312: ...ressure piece S Figure 16 Place differential bevel gears together with thrust washers and cross joint into the differential carrier 1 Thrust washer 2 Differential bevel gear 3 Cross joint Ensure radial installation position of thrust washers Figure 17 Mount differential pins 4x Ensure radial installation position The holes in the cross joint must be aligned with the holes in the planetary pins Fig...

Page 313: ...r into the differential carrier Figure 21 Fix thrust washer in differential carrier cover using some grease Figure 22 Radially align differential cover by means of locating pins S 2x see arrows and then press it into the differential carrier until contact is obtained S Locating pin AA00 622 210 S Pressure piece AA00 328 122 Figure 23 5 55 ...

Page 314: ...tion by using a press Then connect crown wheel and differential carrier with screws Tightening torque M14x1 5 12 9 MA 250 Nm Permissible crown wheel differential carrier temperature while bolting max 30 C Use of new locking screws is imperative Figure 25 Press on both bearing inner rings until contact is obtained S Pressure piece AA00 328 122 When mounting the second bearing support the lower bear...

Page 315: ... shim removed during disassembly The following check of values however is absolutely necessary Cover several drive and coast flanks of the crown wheel with marking ink Insert preassembled differential into the axle housing S Load carrying fixture 5870 281 056 Figure 27 Figure 28 Position bearing outer ring and washer thickness approx 1 75 mm on the differential Washer 0730 107 963 Figure 29 Mount ...

Page 316: ...djacent figure Read the required backlash on the crown wheel see figure 26 Permitted deviation 0 03 mm When taking the backlash ensure that the screw head side face is located as parallel as possible towards the center axis of the differential If corrections of the backlash are required observe the following specifications 1 Insufficient backlash mount thicker shim figure 27 2 Excessive backlash m...

Page 317: ...l times Then remove differential and compare the obtained contact pattern with the examples on page 0 5 0 9 S Locking device 5870 240 002 In case of any contact pattern deviation a measuring error was made when determining the shim figure 5 which must be corrected by all means If the shim is changed set and check the rolling torque of the pinion bearing and the backlash of the bevel gear set once ...

Page 318: ... into the bearing hole on the portal housing and place the bearing outer shell until contact is obtained S Driver tool 5870 058 056 S Handle 5870 260 002 Figure 37 Figure 38 Mount portal housing to the axle housing and fix it with some screws and hexagon nuts Tightening torque Torx screw M14x1 5 MA 185 Nm Tightening torque hexagon nut M14x1 5 MA 200 Nm S Eyebolt AA00 609 603 S Eye nut hub carrier ...

Page 319: ... total rolling torque is not found correct the shim figure 38 as follows Insufficient rolling torque mount thicker shim Excessive rolling torque mount thinner shim Bring axle housing in upright position and remove portal housing S Eyebolt AA00 609 603 S Eye nut hub carrier 5870 281 054 Figure 40 4 5 Installation of shaft seal input flange Loosen slotted nut and pull off input flange S Slotted nut ...

Page 320: ...102 4 14 Heat input flange and fit it to the pinion Let parts cool down Bolt on and tighten the slotted nut Tightening torque see figure 14 S Slotted nut wrench 5870 401 173 S Power wrench 5870 203 002 S Supporting device AA00 640 418 The slotted nut is secured with Loctite type No 262 Figure 43 5 62 ...

Page 321: ...ylindrical screws with washers arrow 2 and finally tighten them tightening torque M18x1 5 10 9 MA 440 Nm 3 Finally tighten cylindrical screws arrow 1 tightening torque M18x1 5 10 9 MA 440 Nm All cylindrical screws are secured with Loctite type No 243 This operation is not required for version with cast on longitudinal control arm bracket Figure 1 If disassembled fit stud bolts Tightening torque MA...

Page 322: ...x 5 4 Axial bearing 68 x 40 x 9 5 Shaft washer 68 x 30 x 5 6 Retaining ring 7 Input gear 8 Shaft washer 42 x 65 x 4 9 Axial bearing 65 x 45 x 6 10 Housing disk 47 x 65 x 4 11 Cup spring 63 8 x 50 5 x 0 7 Observe installation position of cup springs item 2 and item 11 see sketch Install shaft washers item 5 and item 8 with the larger chamfer radius facing the input gear Install housing disks item 3...

Page 323: ...the cup springs figure 5 until it is possible to mount the input gear figure 7 Observe installation position of single parts see figure 3 Figure 4 Preload cup springs by using the assembly fixture S S Assembly fixture 5870 345 103 Figure 5 Engage retaining ring into the annular groove on the input gear Figure 6 Position input gear in the housing arrow and remove the assembly fixture S Observe inst...

Page 324: ...es of the intermediate gears until contact is obtained S Driver tool 5870 058 061 S Handle 5870 260 002 Figure 9 Fit intermediate gear onto bearing pin Fit tapered roller bearing and shim e g thickness 2 75 mm onto bearing pin According to our experience the correct rolling torque axial play is obtained when reusing the shim removed during disassembly However a check is absolutely necessary Figure...

Page 325: ...position of the single parts Figure 12 Position both intermediate gears in the portal housing Then rotate intermediate gears thereby aligning the input gear centrically towards the bearing holes Figure 13 Grease O rings arrows 1 and insert them into both annular grooves of the bearing pin Mount determined shim see figure 11 and fix it with grease arrow 2 Turn in locating pin on bearing bolt S Loca...

Page 326: ...ough the housing recess see arrows in the following figure If the axial play is not correct mainly in case of used portal housings it is necessary to correct the shim figure 14 as follows Insufficient axial play no play install thicker shim Excessive axial play install thinner shim Centrically align input gear and axial bearing Figure 17 Figure 18 Mount stub shaft on input gear until contact is ob...

Page 327: ...5870 260 002 Figure 20 Y S S Determine total height of output gear bearing figure 21 23 Ring 0730 161 832 S Straightedge 5870 200 022 Figure 21 Determine dimension I total bearing height including rings Dim I e g 165 05 mm Rotate output gear bearing in both directions several times roller setting Figure 22 Determine dimension II total height of rings Dim II e g 30 00 mm Calculation example A Dim I...

Page 328: ...22 This dimension may be positive or negative Calculation example B Dim III 136 50 mm Dim IV 0 02 mm Total 136 52 mm Dim Y 135 05 mm Axial play e g 0 01 mm Shim thickness 1 46 mm Insert determined shim e g thickness 1 46 mm into the bearing hole on the hub carrier and insert bearing outer shell until contact S Driver tool AA00 372 127 S Handle 5870 260 002 Figure 25 Figure 26 Insert bearing outer ...

Page 329: ...e hub carrier until contact is obtained Then mount oil reservoir into the bushing Observe installation position of oil reservoir See figure Also observe installation depth See following figure Grease O ring see arrow and insert it into the annular groove of the hub carrier Figure 29 2 3 4 X 1 Legend 1 Hub carrier 2 Bushing 3 Oil reservoir 4 Bearing outer shell with shim behind X Installation depth...

Page 330: ... beware of squeezing in the area between differential and portal drive Bring portal drive into contact position with axle housing S Eyebolt AA00 609 603 Figure 33 Fix portal drive by means of hexagon nuts and washers and Torx screws Tightening torque Torx screws MA 185 Nm Tightening torque hexagon nuts MA 200 Nm Figure 34 5 3 Mounting of portal drive AV 132 II T Grease O ring arrow 1 and mount it ...

Page 331: ...ution counter Mount bushing to the hub carrier until contact position Figure 37 Wet outside surface of revolution counter with silicone grease Then mount revolution counter to the bushing until it protrudes approx 1 3 mm on the contact face of the compact bearing see black line Then install clamp see arrow and mount cable Figure 38 Mount the pressing device S to the hub carrier with the recess fac...

Page 332: ...e maintenance interval make sure that hub and compact bearing are cleaned thoroughly Figure 2 Press both bearing outer rings into the hub until contact is obtained S Driver tool 5870 050 007 S Handle 5870 260 004 Figure 3 Grease compact bearing within the marked area Total grease quantity on each output side 125 grams max 150 grams Richly grease the bearing rollers inside and outside as well as on...

Page 333: ...ee arrow Exact engagement of the retaining ring later is only ensured when using the location arbor Also use the location arbor S when the brake disk is mounted Mount hub to the bearing inner ring and place external bearing inner ring into the hub Figure 5 Figure 6 Use a suitable plate to press against the external bearing inner ring until engagement of the retaining ring is audible Rotate hub in ...

Page 334: ... 607 922 Use of the specified special tool S ensures the exact installation position Observe installation position marking OILSIDE to show upwards outwards Figure 10 Mount the shaft seal at brake disk side S Driver tool AA00 607 922 Use of the specified special tool S ensures the exact installation position Observe installation position sensor ring to show upwards outwards and marking INSIDE towar...

Page 335: ...mbled hub to the hub carrier by means of the lifting device until contact is obtained Then remove the assembly aid S S Load carrying fixture 5870 281 043 Bolt on inner slotted nut with the chamfer facing outwards also see fig 18 S Slotted nut wrench 5870 401 146 Pretighten slotted nut with MA 100 Nm 74 lbf ft Rotate hub several times Finally tighten inner slotted nut Tightening torque inner slotte...

Page 336: ... 8 9 from the compact bearing Correct assembly fault if required Mount locking plate with the tab facing inwards Then bolt the outer slotted nut onto the hub carrier with the chamfer showing inwards and tighten it Tightening torque outer slotted nut MA 1200 Nm S Slotted nut wrench 5870 401 146 Installation position also see figure 18 Figure 17 5 2 3 4 1 Legend 1 Inner slotted nut 2 Locking plate 3...

Page 337: ... the screws tighten the screws during the process shown in figure 25 Figure 21 6 2 Brake The brake manufacturer s instructions and specifications are mandatory for any operations done on the brake system The relating information is included in the repair maintenance and service manuals of the component manufacturer The applicable instructions are to be requested from the brake manufacturer or can ...

Page 338: ... means of spring cotter Figure 24 Mount suitable steel rod or similar to the vent slots on the brake disk see arrow thus supporting the hub on the brake caliper and blocking it against rotation Tighten hexagon screws on the flange shaft if not yet tightened Tightening torque M18x1 5 10 9 MA 440 Nm Figure 25 Position brake cylinder on the brake caliper and fix it by means of locknuts Tightening tor...

Page 339: ...r longitudinal control arms arrow 2 and fix them by means of screws Tightening torque M18x1 5 10 9 MA 440 Nm Tightening torque M18x2 10 9 MA 420 Nm Tightening torque M18 10 9 MA 390 Nm Tightening torque M16 10 9 MA 280 Nm Place joint rubber onto spring carrier arrow 3 and mount shock absorber Fix shock absorber by means of screws Tightening torque shock absorber MA 60 10 Nm Place washer onto sprin...

Page 340: ......

Page 341: ...eveling system 4 Rear anti roll bar system and leveling system Air suspension systemꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ SU 6 1 Introduction of ECAS system 2 Composition of ECAS system 3 Installation requirements and test of all ECAS system components 4 Parameters setting of ECAS system 5 Calibration of ECAS system 6 Diagnosis of ECAS system 7 How to judge...

Page 342: ...e the valve which decides the air supply or exhaust for maintaining the height between the axle and the frame at the set value For specific auto models the space between the axle and the frame or body so called suspension height is set by the length of the control rod If the suspension height is found to be different from the calibrated value it can be adjusted by changing the length of the telesc...

Page 343: ...alve 6 7 6125G02 2908501 Overflow valve to pipe filter 1 8 PaG12 1 5 Pa11 tube black 12 1 5 25 9 6125G02 2908502 Pipe filter to solenoid valve 1 10 GB3737 1 G12 Straight connector bite type 2 11 GB3752 1 G12 Combined elbow bite type 4 12 S6122J01 2908701 Intake connector air bellow 6 13 JB982 10 Sealing washer 6 14 6125G02 2908611 Intake pipe right front air bellow 1 15 6125G02 2908612 Intake pipe...

Page 344: ...SU 4 Suspension System ECAS Electric control system WABCO Bus ECAS operation manual 6 4 ...

Page 345: ...Connection of cables 8 3 5 Installation of ECU 9 3 6 Installation of lights and switches 9 3 7 Test after installation 9 4 PARAMETERS SETTING OF ECAS SYSTEM 9 4 1 Parameters setting equipment 9 4 2 Connection methods 9 4 3 Parameters setting description 10 5 CALIBRATION OF ECAS SYSTEM 10 6 DIAGNOSIS OF ECAS SYSTEM 11 6 1 Diagnosis by diagnostic unit 11 6 2 Flashing code diagnosis a simple and prac...

Page 346: ...the target height preset in the ECU ECAS senses the current height of vehicle all the time When the height difference exceeds the stated tolerance range ECAS shall activate the solenoid which then regulates the actual height to stated value by increasing and decreasing the pressure of air bellow Different from the conventional air suspension systems ECAS can control other preset heights besides th...

Page 347: ...CAS also takes the door position into consideration and it monitors the contact spring under the door to guarantee the descending safety If the contact spring has any response in the descending process the bus will resume the normal height The descending height for Kneeling is set by ECU parameters Kneeling occurs at speed below 5km h and with ride height not above the normal value otherwise the v...

Page 348: ...during installation Verify if the vehicle is rising or descending when the swinging rod is moving upward before fixing For the normal operation of height sensor it is critical that the inductance converted by ECU is increased along the ride height Please refer to the WABCO drawing 4410500110 605 for detailed instruction Avoid bending the swinging rod forcibly to prevent applying torque to the sens...

Page 349: ...whether the vehicle is at the required height Special height II indicator Kneeling indicator normal height I II changeover switch switch of manual automatic raising descending chassis Kneeling switch and Kneeling halt switch There is no need to install all the switches and indicators on one chassis The specific positions and labels of switches and lights are determined by the main unit manufacture...

Page 350: ... the vehicle parameters of ECU shall be set after the system startup or repair for example the height sensor value shall be corresponding to normal height of vehicle This value will be read in ECU lasting memory of with code of normal height For this reason when a system is replaced the calibration of the new system shall be set During rated values setting it needs calibrating three height values ...

Page 351: ... behalf of ECAS for vehicle allows displaying troubles by flashing code with the help of alarm light trouble codes can be flashed When turning on the ignition switch ground the wire L ECU PIN2 for 2 seconds at least once the grounding is disconnected the first flashing code of trouble will be displayed in about 3 seconds Flashing codes will be flashed one by one in uprising order which indicates t...

Page 352: ...nsor Short open circuit to UB 1 2 1HSA ECU PIN26 of height sensor 1HSA Short open circuit to UB 1 5 ECU Pin6 of pressure sensor Short circuit to UB 1 7 ECU pin24 for road condition detection Short open circuit to UB 2 0 ECU PIN8 of 2HSA right height sensor Grounding in short circuit 2 1 ECU PIN25 of 2HSA left height sensor Grounding in short circuit 2 2 ECU PIN26 of 1HSA height sensor Grounding in...

Page 353: ...t open circuit to UB 3 6 Door valve ECU PIN11 Short open circuit to UB 3 9 Main throttle ECU PIN35 of valve Short open circuit to UB 4 0 ECU pin15 of 3 2 solenoid valve Grounding in short circuit 4 1 Left ECU pin13 of 2 2 solenoid valve Grounding in short circuit 4 2 2HSA right ECU pin31 of 2 2 solenoid valve Grounding in short circuit 4 3 2HSA left ECU pin12 of 2 2 solenoid valve Grounding in sho...

Page 354: ...e ECU pin18 controlling transverse throttle and resistance Grounding in short circuit 8 0 ECU WABCO data Check all troubles 8 1 ECU Odometer signal Deleting all the troubles saved All the saved troubles can be deleted by grounding wire L when the ignition switch is turned off and then turn on the ignition switch For this be sure that the ignition switch shall be turned off for at least 6 4 seconds...

Page 355: ...seriousness to alarm the driver of the trouble Reasons causing to indicator illumination Permanent flashing Yellow indicator Red trouble indicator Illuminated for 2 seconds after the ignition switch is turned on Diver shall check the bulbs Indicated height unequal to normal height It needs raising descending One defect not so serious Might be that there is no speed signal or the height can not be ...

Page 356: ...r sales service Caution The vehicle user and service staff shall not adjust the longitudinal rod length of height sensor at will otherwise the ECAS parameters might be in fault After sales service departments see the table attached Details of WABCO service station Annex 1 ECAS BUS A components details No Product name S N Remarks 1 ECU 446 055 506 0 8 pulses 2 Solenoid valve 472 900 056 0 W kneelin...

Page 357: ......

Page 358: ... ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ SR 8 1 Heavy steering wheel 2 Steering wheel off tracking 3 Steering wheel vibration 4 Steering wheel s failure to return 5 Early wear of tyre 6 Steering run out 7 Abnormal noise with the steering gear 8 Analysis on common malfunction of the hydraulic components Assembly disassembly and adjustment of steering system ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ...

Page 359: ...is underway through the rotary valve s controlling of the hydraulic system the hydraulic booster cylinder timely joins together to turn the lower pitman arm for steering then directly push the steering link rod and after magnification boosting the steering force is transmitted to the steering knuckle arm of the front axle assembly which in turn pushes the turning wheels to deflect and therefore re...

Page 360: ...nal slotted nut 1 1 Integrated power steering booster steering gear 1 Steering gear input shaft 2 Steering valve shaft 3 Gear shaft 4 Oil cylinder piston rack The input shaft 1 of the steering gear is connected to the steering column and fastened in the rotary valve by the torsion bar The rotary valve shaft is rotated into the piston with roller threads 2 and moves in the piston in contact with st...

Page 361: ...s pass the oil outlet of the boosting pump and high pressure oil pipes to enter the steering gear The hydraulic oils discharged from the steering gear return to the boosting oil pan via oil pipes 1 Bolt 2 Nut 3 Plane washer 4 Spring washer 5 Bracket steering oil can 6 Power steering reservoir assy 7 Straight thread elbow connector 8 Fine filter element 9 Sight glass 10 Thread 11 Nut G14 12 Connect...

Page 362: ...mp 17 Transition connector steering gear 18 Sealing pad 19 Hose clip 30 20 Hose clip 40 21 Straight thread connector 22 Oil inlet pipe assembly power steering 23 Elbow connector 24 Low pressure oil pipeline assy power steering 25 Sealing washer 7 5 ...

Page 363: ...ole depth 24 mm 520 M45X1 5 10 9 Steering drop arm mounting nut 700 Steering limiter 12 M24X1 5 Link rod ball head slotted nut 240 260 M14X1 5 Link rod hoop bolt 90 105 Installation and adjustment requirements of ZF 8098 steering gear Ambient requirements for steering gear installation Contamination in the steering oil pipeline may lead to steering gear failure therefore it s necessary to maintain...

Page 364: ...ed limit bolt on the axle must be adjusted to the right place according to the stipulated angle 2 turn the steering wheel to the left and right respectively at the speed of no more than 3 turns sec until it reach the axle s mechanical limit At this time the limit set of steering is completed principle of steering limiting stopper Put the stopper valve push rod against sliding sleeve of adjusting s...

Page 365: ...mally because of uneven road conditions Under such circumstance it is imperative to make turning test by driving under various road conditions The steering wheel off tracking is possibly caused by improper positioning angle of the front wheel unbalanced tyres and excessive clearances of the steering mechanism or loosened steering mechanism As to the hydraulic system besides the malfunctions of the...

Page 366: ...l head linkage Check lubricate the ball pin Too low tyre pressure Inflate the tyre to its specified pressure Excessive tyre wearing Replace the tyre 5 Steering wheel vibration Malfunction Causes Troubleshooting Steering wheel vibration Steering system Loosened steering gear housing or steering column bracket Tighten it with specified torque Loosened steering linkage points Refit the linkage points...

Page 367: ... tyre or wheel Other Failures caused by abrupt acceleration or braking Improve your driving style Overload Loading according to rated load 8 Steering run out Malfunction Causes Troubleshooting Steering run out Loosened or worn steering system parts Loosened steering gear assembly screws Improperly adjusted steering gear Too high pressured tyre or unequal pressure with left right tyres Adjust or re...

Page 368: ...oil loosened connection High oil temperature High leakage level or oil viscosity not matching Oil cannot be drained Damaged mechanical steering system parts Hydraulic cylinder Frustrated crawling working status not smooth Air ingress or poor concentricity between the piston the piston rod Abnormal impact with working stroke Excessive clearance between the piston the cylinder which causes failure o...

Page 369: ...ve the wire clamping board steering column s sealing jacket and steering column s protective cover Removal of the steering column and steering transmission shaft assembly 1 Remove the screws of steering column 2 Use a copper hammer to strike the head of the steering shaft to separate the steering shaft and the steering column pipe 3 Remove the steering shaft and steering slide fork assembly 4 Make...

Page 370: ...aring are detached from the bearing hole 3 Remove the bearing from the steering shaft Note If the parts are found to be undamaged and rotate flexibly there is no need to disassemble the bearing Inspection 1 Clearance between cross shaft needle bearing and shaft journal 2 Clearance between steering shaft bushing hole and shaft journal 3 Clearance between slide fork key and key groove Installation o...

Page 371: ...ft and sealing jacket 2 Install the steering column onto the pedal bracket 3 Install the wire clipping board 1 Screw 2 Wire clipping board Install the combined switch 1 Install the starting switch assembly and the wire connectors 2 Install the combined switch assembly and the wire connectors 1 Combined switch 2 Screw 7 14 ...

Page 372: ...ive cover Caution ensure that the switch cover does not interfere with the adjusting nuts key switches and combined switches Install the steering wheel 1 Turn the steering gear to the middle position maintain straight travel put on the steering wheel as shown in the figureand insert it into the spline 7 15 ...

Page 373: ... that the steering wheel operates normally without swinging steering difficulty or deviation Caution 1 ꞏApply a coat of lubricating greases on the inner surface of the bearing during installation of needle bearing 2 ꞏInstall the elastic retainer ring inside the snap groove and the components should rotate flexibly after assembly 3 The grease nozzle of the cross shaft should be assembled in the sam...

Page 374: ...f Note The drag link assembly is non detachable and if the ball head is loose the drag link assembly has to be changed 2 Remove the split pins of the left and right joints of the tie rod loosen the slotted nut and now the tie rod assembly can be taken off Inspection Abrasion of ball headed pins of tie rod and drag link Reinstallation of tie rod and drag link Reinstall them in the reversed sequence...

Page 375: ...f polluted 6 For the sake of installation please check the marks made during removal 7 Do not damage the contact surfaces of oil seals 8 Take care to fasten various elements with the required torque Adjustment of hydraulic pipelines 1 Inject new working oils after assembly of the hydraulic system 2 Discharge the air inside Support the front wheels above the ground run the engine at idle speed turn...

Page 376: ...cked twisted or bent too much leading to unsmooth oil flow or insufficient flowrate Oil pipes not conforming to requirements should be replaced Now check the power steering oil tank Make sure the oil reaches the specified level If the pump adopts a belt transmission check if the belt is slipping The belt may be tight but may also be slipping due to wear A slipping belt does not always screech Plea...

Page 377: ...se transmission belt of oil pump or transmission gear fault Tension the transmission belt or repair the transmission gear Insufficient oil in oil tank or air absorption of oil pump Locate the cause remove the fault add sufficient oil and discharge air Blocked filter of oil tank Clean replace the filter and change the oil Blocked or seriously deformed oil pipe Eliminate the blockage and then repair...

Page 378: ...allation by adding shims to allow the piston move freely Instable steering input Worn universal joint of steering column Check and replace the universal joint Incorrect positioning of universal joint Readjust the positioning of steering column Low oil flowrate Tension the belt of the oil pump till it does not slip at a low or idle speed operation or repair the oil pump Insufficient oil or air abso...

Page 379: ...pplement the oil c Turn the steering wheel from the left to the right till the limit position several times Now recheck the oil level of the tank and add oil if necessary d Let the engine work at high speed for ten minutes and then check if the oil pump works normally and the whole steering hydraulic system has neither oil leakage nor seepage Repeat high speed engine operation several times and ma...

Page 380: ...1 HERG AP vehicles chassis instruction manual centralized lubrication system AP 型车辆底盘润滑系统 AP Lubrication System for Automotive Chassis 国家认可注册号 National Accreditated Registration No 通过 ISO9001 2000 认证 With ISO9001 2000 authentication 使用说明书 Operating Instruction Manual 中日合资 Sino Japan joint venture 7 23 ...

Page 381: ...24 Steering System 追求卓越创造精品 Strive for excellence and create finest products 目录 Contents 页数 Page number 一用途与特性 I Usages and Features 二产品规格及技术参数 II Specification and Technical Parameters of Products 7 24 ...

Page 382: ...滑泵内藏程控齿轮润滑泵与之配套的分配器是引进日本国日本油机株式会社的先进技术设备及检测设备生产的在使用前请您详细阅读本说明书正确地掌握润滑泵的使用方法以充分利用它的优异性能多谢合作 Thank you sincerely for choosing HERG AP type vehicle chassis grease pump The HERG series centralized lubrication systems of Japanese brand produced by our company include manual electric thin oil grease lubrication pump built in program control gear lubrication pump and the matched distributor whic...

Page 383: ... resistance type distributor to achieve proportionally grease injection for the lubricating points AP 型系列电动润滑油脂泵适用于城市大客车豪华巴士重型卡车特种汽车轨道车辆工程机械等 AP series electric grease lubrication pump is applicable for urban bus luxury bus heavy duty truck special vehicle rail vehicle construction machinery etc 特性 Features 1 采用直流 12V 或 24V 电机可直接用汽车发电机电源 1 With DC 12V or 24V motor and power supply of automob...

Page 384: ...境温度应高于 10 C Note Ambient temperature shall be higher than 10 C if 0 lubricating oil is used AP 型电动润滑油脂泵型号标志及其说明 Models and explanations for AP type electric grease pump X 表示内藏卸压机构配合定量容积式分配器使用 X indicates a built in pressure relief mechanism which is used together with quantitative volume distributor T 表示无卸压机构配合抵抗式分配器使用 T indicates no pressure relief mechanism which is used with resistance type d...

Page 385: ...c 4 300 400cc 电动润滑油脂泵编号 Serial number for electric grease pump 例 AP 32 300X 代表吐出油量为 200 300cc min DC24V 不带压力开关内藏卸压机构 3 升油箱的 AP 型电动润滑油脂泵 Eg AP 32 300X suggests that the discharge capacity is 200 300cc min DC24V suggests AP type electric grease pump without pressure switch built in pressure relief mechanism and 3 L tank 三外形和安装尺寸 III Outline and Mounting Dimensions 7 28 ...

Page 386: ...for your choice 4 接通电源点动电机确认电机转向是否与电机尾部标注箭头方向相同如相反则须调换两线在未接润滑系统主管之前点动须注油进行对泵内空气清除之后接上主管打开润滑系统尾部油塞点动油泵注油以便将主管内空气排尽检查主管必须保证无渗漏现象注油直至每个润滑点都出油为止 4 After switch the power on press the button of motor and immediately release and check whether motor rotates in the direction as indicated by the arrow marked at the end part of motor if not the two wires shall be swapped Before connecting mai...

Page 387: ...时间不允许情况之时支管可事先用油脂加油泵进行分别注满后在与分配器连接 Advice If time does not permit branch pipes can be connected to distributor after they are fully filled by grease pump in advance 五车载程控器的说明 V Description of In vehicle Program Controller 7 30 ...

Page 388: ...d or decreased for interval time one value is 0 5 hour the corresponding indicator is on all other indicators are off and the set motor rotation time is supported by power off memory function Because the working time and shutoff time has been set by manufacturer it is recommended not to change it at will and default settings are the best If time adjustment is deadly needed make sure to adjust unde...

Page 389: ... power down and can be used directly when power is energized For example if the rotation interval of motor is set to be 8 hours and the timer has counted six hours lash time when power is cut off and motor begins to rotate when the timer counts for another two hours next time after power is switched on 7 先按住消除报警再按住手动润滑键 3 秒听到嘟一声锁键盘再按此顺序操作一次开键盘 7 First push and hold the DISALARM key then ...

Page 390: ...密封是否可靠以免行车中混入沙泥与油脂里造成油泵工作故障吐出量减少和压力不足 2 Tightness of tank shall be checked every half year for reliability to avoid mud and sand mixed in grease which may cause pump failure decreased discharge and insufficient pressure 七常见故障及排除方法 VII Common Faults and Troubleshooting Method AP 型电动润滑油脂泵常见故障及排除方法 Common Faults and Troubleshooting Method for AP type Electric Grease Pump 序号 No 现象 Phenomenon 原因 C...

Page 391: ...ls 2 压力不足 Insufficient pressure 主油管泄漏 Leakage of main oil pipe 检查主油管排除泄漏现象 Check main oil pipe and eliminate leakage 油泵溢流阀密封不好 Seal of relief valve is poor 拆下清洗调整溢流阀 Remove and wash adjust relief valve 吸油口处堵塞 Oil suction is blocked 清洗油箱吸油口处滤网 Clean and wash tank filter screen of oil suction 3 不出油 Oil does not come out 泵内空气未排清 Air in the pump is not completely exhausted 多几次泵油必要时松开出油口再泵油 Pump o...

Page 392: ...eline 必须大于 30kgf cm2 It shall be greater than 30kgf cm2 接线错误 Wiring error 按电气接线图正确接线 Wiring according to correct wiring diagram 6 电机不停 Motor does not stop 程控器故障 Fault of program controller 交回车辆生产厂家检测维修 Return it to vehicle manufacturers for inspection and maintenance 八附装箱单 VIII Packing List 名称 Name 规格 Specification 数量 Quantity 备注 Notes 润滑油脂泵 Grease Pump 1 台 One 螺栓 Bolt M8 25 4 个 Four 垫圈 Washer 8 ...

Page 393: ...l Tube Connector 代号 Code 管外径 Outer Diameter L D S PA 4 Ø4 12 M8 1 8 PA 10 Ø10 30 M16 1 5 17 密封圈 Gasket Ring 代号 Code 管外径 Outer Diameter d D L PB 4 Ø4 Ø4 1 Ø6 5 PB 10 Ø10 Ø10 2 Ø12 8 固定双通接头 Fixed Double Passage Joint 代号 Code D d L S 2TD 8 8L M8 1 M8 1 30 Ø14 7 36 ...

Page 394: ... M8 1 12 PD 410 Ø4 20 M8 1 M10 1 14 PD 1 8 Ø4 18 M8 1 R1 8 10 PD 1038 Ø10 32 M16 1 5 R3 8 19 PD 416 Ø4 30 M8 1 M16 1 5 17 PD 616 Ø6 30 M10 1 M16 1 5 17 双通接头 Duplex Fitting 代号 Code 管外径 Outer Diameter d1 d2 2T 16 16 Ø10 M16 1 5 M16 1 5 双通接头 Duplex Fitting 代号 Code d1 d2 h1 h2 L1 L2 h 3T 16 16 M16 1 5 Ø7 15 30 25 52 40 7 37 ...

Page 395: ...R1 8 18 18 PL 1 8F M8 1 R1 8 22 20 PL 406 M8 1 M6 1 18 18 PL 406F M8 1 M6 0 75 18 18 PL 408 M8 1 M8 1 18 18 PL 410 M8 1 M10 1 18 18 PL 412 M8 1 M12 1 22 20 PL 418 M8 1 R1 8 18 18 油管衬套 Oil Tube Sleeve 代号 Code D d L PT 4 2 Ø3 8 Ø2 9 PT 4 2 5 Ø3 8 Ø2 5 9 PT 10 7 Ø9 5 Ø7 18 7 38 ...

Page 396: ...opper GU 4L Ø4 Ø2 铝 Aluminum GU 10L Ø10 Ø7 铝 Aluminum GU 4 2NA Ø4 Ø2 尼龙带色 Nylon color GU 10 7 5NA Ø10 Ø7 5 尼龙带色 Nylon color GU 4 2Ny Ø4 Ø2 尼龙带色 Nylon color GU 4 2 5Ny Ø4 Ø2 5 尼龙带色 Nylon color GU 10 7Ny Ø10 Ø7 尼龙带色 Nylon color 单边固定管夹 One side Fixed Pipe Clip 代号 Code B L 管数 Number of Pipes 7 39 ...

Page 397: ...0 1Ø4 PC 1204 10 25 2Ø4 PC 1304 10 28 5 3Ø4 PC 1110 12 27 1Ø10 油塞 Oil Plug 代号 Code D L S PS 08Z M8 1 16 5 8 PS 16 M16 1 5 17 20 单边固定管夹 One side fixed Tube Clip 代号 Code d D L P0 16 Ø16 2 Ø19 1 8 内接双通接头 Inner Two Way 代号 Code D d L S 7 40 ...

Page 398: ...Code 管径 Outer Diameter d1 d2 AL 16 16 Ø10 M16 1 5 M16 1 5 AT 接头 AT Joint 代号 Code 管径 Outer Diameter d1 d2 d3 AT 16 16 10 Ø10 M16 1 5 M16 1 5 M10 1 波纹管 Corrugated Tube 代号 Code d1 da L PH 7 5 Ø7 5 Ø11 5 定做 Customized PH 9 5 Ø9 5 Ø14 5 定做 Customized PH 12 Ø12 Ø17 定做 Customized 7 41 ...

Page 399: ...ubber hose it can be used in places of harsh working conditions and the applicable temperature range is 20 80 C 规格型号及技术参数 Model and Technical Parameters 代号 Code 配管外径 d1 Mm Outer Diameter of Pipe 使用压力 Mpa Working Pressure 最小变曲半径 Minimum Bending Radius d2 L mm SOP 4 Ø4 4 5 R20 Ø11 5 可按用户要求定制 Can be customized in accordance with user requirement 7 42 ...

Page 400: ...r Diameter of Pipe 使用压力 Mpa Working Pressure 最小变曲半径 Minimum Bending Radius d2 L mm HXJ 4 Ø4 20 R40 Ø8 5 可按用户要求定制 Can be customized in accordance with user requirement 外钢丝耐压软管使用复合橡胶材料软管可在工作环境恶劣的场所下使用适用温度范围 20 80 C The outer steel wire pressure hose uses hose of compounded rubber can be used in places where the working conditions are poor and applicable temperature range is 20 80 C 规格型号及技术参数 Model...

Page 401: ...dance with user requirement 压力开关 Pressure Switch 型号标记方法 Model Marking Method 型号 Model 接通压力 kgf cm2 Switching on Pressure kgf cm2 断开压力 kgf cm2 Switching off Pressure kgf cm2 接头规格 Joint Specification PS 2008 20 14 M8 1 PS 连接细牙螺纹 08 M8 1 10 M10 1 Connect fine thread 08 M8 1 10 M10 1 压力单位 kgf cm2 Pressure unit kgf cm2 型号前缀 Prefix 7 44 ...

Page 402: ...GH 60 型手动加油枪专门为补充油量设计方便快捷轻巧实用建议您随车配置 In order to ensure the normal work of lubrication pump please complement oil in pump timely GH 60 manual oil gun of our company is specially designed for complementing oil which is convenient fast indicator weight and handy and practical It is recommended to equip it in your vehicle 7 45 ...

Page 403: ...ng 8 4 PB 10 Sealing ring 8 5 PA 10 Oil pipe connector 8 6 AD 2 AD type distributor 1 7 PB 4 Sealing ring 26 8 PA 4 Oil pipe connector 26 9 PL 4 Square connector 4 10 PD 4 Square connector 11 11 AD 4 AD type distributor 1 12 AD 3 AD type distributor 1 13 AD 6P AD type distributor 1 14 PS 2008 Pressure switch 1 15 NK 5 The NK 5program controller 1 16 AP 32 XML Centralized lubrication device 1 7 46 ...

Page 404: ......

Page 405: ...hooting BR 14 1 Insufficient brake force 2 Brake deviation or instability 3 Brake drags or can t be released 4 Brake screeches z Use and maintenance of the parts of brake system BR 16 1 Air dryer 2 Four way protective valve 3 Master valve of air brake 4 Hand brake valve 5 Quick release valve 6 Relay valve 7 Air brake chamber for front wheel 8 Spring brake chamber for rear wheels 9 Automatic cleara...

Page 406: ...he compressed air will be transmitted via pipeline to the rear relay valve and front quick release valve when the brake pedal is stepped down The rear relay valve will open the control air circuit to enable the rear wheels to brake while the front quick release valve will directly enable the front wheels to brake After the brake pedal is released the passage of rear air reservoir and rear relay va...

Page 407: ...e system adopts a dual line system with the front wheels and rear wheels separately controlled The master brake valve controls the airflow If one circuit is damaged the other one will still works avoiding a failure of the whole brake function Each circuit is composed of various valves and brake chambers one for each wheel and has a separate light and gauge display In service braking when the maste...

Page 408: ...gh the air compressor still runs the air is not compressed The air compressor is in idle motion When the air pressure is reduced to below the rated pressure the pressure regulator will work again The compressed air in the upper part of the unloading valve will be exhausted to let the valve reset The air compressor now will be able to produce compressed air again 出气阀门 Exhaust valve 卸荷柱塞 Unloading p...

Page 409: ...m to top via the filter tube b the compressed air will absorb the moisture in the surface of the drier a and be discharged from the exhaust port 3 via the passage C and exhaust valve e When the air pressure reaches the value for switching on of the pressure regulator the exhaust valve e will be closed and the whole drying process will start again The optional heater can prevent the structural comp...

Page 410: ...stant input pressure it makes the output pressure and the input of the control signal the pedal stroke and pedal effort to form an increasing function relation The change of its output pressure should be progressive in certain scope The output pressure of brake valve can be directly fed to the air brake chamber of the transmission device as actuating line pressure or as control signal to another d...

Page 411: ... close the air line of rear brake and the compressed air in the rear brake air cavity and rear brake air line will be rapidly discharged from the relay valve to release the rear braking Meanwhile the middle piston f will continue to move upward under the function of the compressed air in the cavity C the lower valve g will do the same to close the passage between the right rear air reservoir and t...

Page 412: ...mber near to the chamber As it is near to the air chamber the air release circuit is short leading to a rapid air release In the figure below the intake valve of the quick release port is closed while the exhaust port is open 1 上阀体 1 Upper valve body 进气口 Intake port 出气口 Outlet port 芯管 Core Tube 快放阀 Quick release valve 阀体 Valve body 3 膜片 3 Diaphragm 弹簧 Spring 阀门 Valve 4 下阀体 4 Lower valve body 2 O 型...

Page 413: ... closed simultaneously When the brake pedal is released the air pressure at the port B will be reduced and will move the piston 1 upwards under the function of the air pressure in the cavity C At this time under the spring function the exhaust valve 2 will close the intake valve or separate the cavity A and cavity C while the compressed air from the air brake chamber will be rapidly discharged fro...

Page 414: ...e arm Screwing out the bolt g will release the parking brake mechanical devices which is used to release the brake manually in case of no compressed air 5 Device for braking force adjustment ABS Considering from improving the safety of car braking the adhesion conditions should be fully utilized to produce a possibly largest braking force and it is better to realize a simultaneous lock and slip of...

Page 415: ...on coefficient but also the lateral adhesion coefficient between wheels and the ground are large ensuring the directional stability 6 Air pressure brake lines There are three lines connecting various components in the air pressure brake system 1 Energy supply line connecting the components of energy supply devices such as air compressor and air reservoir and connecting the energy supply devices wi...

Page 416: ...nt of worm shaft will release the cone ratchet wheel at its left end When the brake is released The spring will counteracts on the worm wheel shaft to make the it mesh with the cone ratchet wheel The rack will be pushed back to the initial place in the clearance groove The wear of brake shoe will cause the ratchet wheel lock up by rack rotation and meanwhile the locked ratchet wheel will turn the ...

Page 417: ...System BR 6125J93C 01 BR 13 Structural outline No Name No Name No Name 1 Housing 2 Worm wheel shaft 3 Front guard ring 4 Yellow lubrication fitting 5 Worm wheel 6 Bracket 7 Control arm 8 Rear guard ring 8 13 ...

Page 418: ...n Grease or oil on the brake shoe liner Replace the liner Defected liner material bad mixing Replace the liner Non uniform liner contact area Calibration Improper adjusted brake shoe Adjust Non uniform clearance of brake shoe Clearance adjustment Deformation of brake drum Adjustment or replacement Seriously worn brake drum Adjustment or replacement Loose wheel hub bearing Adjust or repair the bear...

Page 419: ...oosened liner rivet Replace the rivet or further tighten it Contact of the liner rivet with the brake drum Replace the liner and rivet Deformed or worn brake drum Repair or replace Foreign material between the brake drum and the liner Clean the liner surface or replace the liner Loose wheel hub bearing Adjust or repair the bearing 8 15 ...

Page 420: ...ormal case dissemble the dryer and inspect the drier If the drier is seriously polluted replace the drying cylinder Key points of assembly 1 In installing the drier cartridge use new O rings gaskets and seal rings 2 Apply lubrication oil lithium based on the sliding surfaces and O ring grooves of all parts 3 A O rings 4 B Sliding surface Key points of installation inspection 1 Run the engine to ra...

Page 421: ...ard 2 Apply a layer of grease of suitable amount on all working surfaces and the valve assembly 8 upper spring 11 and adjusting screw 13 3 Carry out the assembling in a procedure contrary to that of dismantling The tightening torque for cross recessed head screw 16 is 6N m 4 Coat an adhesive of proper medium strength on the upper part of the adjusting screw assembly when the assembling is complete...

Page 422: ...echnician of repair shop The O seal rings should be replaced the upper and lower valves should be replaced if they have evident wear and the upper and lower pistons and the relay piston should also be adjusted if they are roughened 5 The air bleeding in the upper and lower valves are mostly because there are sands or rust on the valve rubber surface They should be dismantled and cleaned with alcoh...

Page 423: ...rocedure 1 Test device diagram 气源 Air supply 2 Tightness test a With the brake released viz F 0 charge air into the ports 11 12 till 800kPa Close the switches 6 7 and five minutes later the pressure in the gauges 4 8 should be less than or equal to 10kPa b At a full braked state or F 2000N charge air into the ports 11 12 to a pressure of 800kPa Close the switches 6 7 and five minutes later the pre...

Page 424: ...intenance 1 When any air leakage is found check if the diaphragm is damaged 2 In making a second class maintenance the quick release valve should be dismantled cleaned and inspected 6 Relay valve Precautions for use and maintenance 1 When the relay valve is found with air leakage remove and check all seal rings for wear check intake and exhaust valves for damage or dirt on surface and check the va...

Page 425: ...ir chamber clamp and the air chamber cover 3 Insert the bolt from the side opposite to the exhaust port and use a nut to uniformly tighten the bolt to required torque 排气口 Exhaust port Air leakage test As shown in the Figure apply soap water on the brake chamber and charge air at a pressure of 785 kPa 肥皂水 Soap water 空气 Air 8 Spring brake chamber for rear wheels Important instructions on use and mai...

Page 426: ... Dismantling the spring brake chamber 1 Remove the piston driven disc and then dustcover spring pin and release bolt 2 Use a press or special tool to compress tightly the spring and then remove the bolt of the air chamber cover Dedicated tools the piston release bolt of spring brake 1 Dust shield 2 Cotter pin 3 Slotted nut 4 Filter 5 Spring brake air chamber 6 Spring 7 Piston ring 8 Piston 9 O rin...

Page 427: ...r and the spacer 2 Use a press or special tool to compress tightly the spring and then tighten the air chamber cover with bolts Special tool the piston release bolt of spring brake 3 Screw in the release bolt till its head contacts the piston flange and then screw back the release bolt one ore two turns 开口 Opening 4 Install the piston driven disc on the piston Caution Caution Apply thread locking ...

Page 428: ...n the bolt with required torque 排气孔 Exhaust vent 4 Turn the release bolt clockwise to release the spring of spring brake chamber Air leakage test Charge the compressed air at a pressure of 834 kPa via the intake ports marked with E and S Make sure there is no air leakage in all joints of the assembly 标记 S Mark S 标记 E Mark E Check the piston movement Gradually charge the compressed air at a pressur...

Page 429: ...ard ring 2 Spring 3 Thrust washer 4 Housing 5 Shaft sleeve 6 Worm wheel shaft 7 O ring 8 Bearing 9 Transmission gear 10 Spring 11 Inner cover 12 Thrust bearing 13 Front guard ring 14 Spring 15 Spring 16 Plug 17 Rack 18 O ring 19 Worm wheel 20 O shape figure 21 Washer 22 Bracket 23 Rivet 24 Plug 25 TORX screw 26 Yellow lubrication fitting 8 25 ...

Page 430: ...move the rack 4 Use a screwdriver to push and press the spring and contact the plug with a steel chisel 5 Use the steel chisel and hammer to remove the plug 6 Remove the spring Dismantling of worm wheel shaft and worm wheel 1 Use a hexagon spanner to release the rear guard ring counterclockwise and remove it 2 Remove the spring and thrust washer 3 Use a dedicated tool to turn the front guard ring ...

Page 431: ...tools Mandrel and positioning ring 心轴 Mandrel 定位环 Locating ring 6 Use a bench clamp to make slow turning till the bearing and worm wheel shaft are removed 7 Remove the bearing and worm wheel shaft 8 Remove the worm wheel 9 Remove the external O ring of worm wheel Removal of grease nozzle Clean the parts as shown in the figure 8 27 ...

Page 432: ...ing 3 Apply lubricating grease to the worm wheel shaft and bearing 4 Align the hexagon adjusting component with the front direction of front guard ring and fully insert it for installation 5 Insert dedicated tool until it contacts with the bearing 6 Use a bench clamp to install the worm wheel shaft and bearing and match them well 7 Use a spanner to rotate the worm wheel shaft for about 22 times an...

Page 433: ...d torque spanner to fasten the front guard ring Caution Do not use a machine operated spanner 11 Use the spanner to turn the worm wheel shaft and the worm wheel and make sure they rotate smoothly 12 Insert the dial gauge a dedicated tool into the rear guard ring and then insert the universal spline of dedicated tool into the spline of worm wheel 13 Turn left and right the universal spline and reco...

Page 434: ...n the figure 3 Use a steel chisel and hammer to insert a new plug to block the opening Caution Be careful about the plug direction 使突出面与钢杆接触 Align the projecting face to the steel rod 4 Apply lubricating grease to the thrust washer spring and rear guard ring and then install them Caution Be careful about the thrust washer direction 留心方向 Pay attention to the direction 5 Use a hexagon spanner to fas...

Page 435: ...at the rear guard ring and fasten it on the load tester at the end of the dedicated tool 3 Fix tightly the housing check whether the pointer of the dial gauge at that time has the same status as showed in the figure 六角扳手 Hexagon spanner 215 毫米 8 465 英寸或以上 215 mm 8 465 inches or above 4 Confirm that the control arm part of the bracket can be moved manually 5 Use your thumb facing the rear guard ri...

Page 436: ...ter assembly so as to confirm whether it is proper or not Ending 1 Use a punch or hammer to knock the rivet into the guard ring 2 Confirm the inner diameter of the bearing and use a bench clamp to press it into the housing Caution confirm the inner diameter of the bearing as repairing such set including various kinds of bearings 3 Remove the old bolt plug and use dedicated tool to install new plug...

Page 437: ...e of wheel bearing is necessary which can ensure a mutual alignment between the brake shoe and the brake drum Operation inspection 1 Measure the pushrod length when the brake air chamber is in full release which is the distance from the air chamber surface to the center line of U clamp pin of pushrod and record it as Distance A 2 Ask your assistant to execute an 800kPa braking operation and measur...

Page 438: ...justing arm 11 Plain washer 20 Dust boot 29 Spring washer 38 Oil seal 3 Cotter pin 12 Spring washer 21 Brake backing plate 30 Bolt 39 Camshaft 4 Plain washer 13 Bolt 22 Positioning screw 31 Roller pin shaft 40 Brake friction plate 5 Washer 14 Camshaft spacer 23 Steel lock wire 32 Roller 6 U fork 15 Gasket 24 Bearing pin 33 Retainer ring 7 Flat headed pin 16 Front brake air chamber 25 Rivet 34 Retu...

Page 439: ... to avoid damages to the steering knuckle during wheel hub removal After removal of the wheel hub use a piece of clean cloth to wrap the bearing Please refer to Front Axle for above work 8 Use a dedicated tool for return spring to remove the return spring 回位弹簧专用工具 Dedicated tool for return spring Caution Before taking out the return spring use a ring or iron wire to bind the brake shoe to prevent ...

Page 440: ...ner ring 弹簧卡环 Spring retainer ring 13 Remove the adjusting arm 14 Remove the camshaft sleeve oil seal and brake camshaft 制动凸轮轴 Brake camshaft 凸轮轴衬表油封 Oil seal of camshaft bushing 15 Remove the brake backing plate and dust boot Caution The two bolts fasten the tie rod arm together 16 Remove the brake air chamber chamber support and support gasket 衬垫 Gasket 制动气室支架 Air brake chamber bracket 8 36 ...

Page 441: ...on plate 3 Rubber plug 12 Retainer ring 21 Retainer ring 4 Flat headed pin 13 Camshaft bushing 22 Return spring 5 Air chamber bracket 14 Grease nozzle 23 Brake shoe 6 Brake air chamber 15 Brake backing plate 24 Brake shoe shaft 7 Camshaft 16 Oil seal 25 Bushing brake shoe 8 Washer 17 Roller shaft 26 Lock screw 9 Dust ring 18 Roller 8 37 ...

Page 442: ... with a dedicated tool 8 Use a hub puller to remove the outer hub bearing and brake drum Caution Special care should be taken in removing the wheel hub to avoid damaging the threads of the axle shaft sleeve 9 Use a dedicated tool for return spring to remove the return spring Caution Before taking out the return spring use a ring or iron wire to bind the brake shoe 回位弹簧专用工具 Dedicated tool for retur...

Page 443: ...ve the nut and air pipe and remove the air brake chamber from the air chamber support 14 Remove the brake adjusting arm Remove the elastic retainer ring and adjusting arm 弹性挡圈 Elastic retainer ring 15 Remove the camshaft 凸轮轴 Camshaft 16 Remove the support for the brake air chamber 17 Remove the brake backing plate and dust boot 8 39 ...

Page 444: ... nut off and remove the friction plate and nut from the brake shoe 2 Clean away the filths and rusts on the contact face of the brake shoe and friction plate 3 Place the new friction plate on the brake shoe and align the rivet holes 4 Install the bolt spring washer and nut and rivet them Bushing brake shoe Front brake and rear brake 1 Use a dedicated tool to press out the brake bushing 2 Clear off...

Page 445: ...n return spring 24 Bushing brake shoe 4 Brake bottom plate 11 Dust boot 18 Brake friction plate 25 Bearing pin brake shoe 5 Oil seal 12 Roller 19 Rivet 26 Camshaft bushing 6 Camshaft 13 Pin shaft roller 20 Dust boot 27 Dust ring 7 Rubber plug 14 Spring retainer ring 21 Positioning screw 28 Spacer camshaft 1 Install the air brake chamber support and gasket on the steering knuckle 衬垫 Gasket 制动气室支架 A...

Page 446: ...g plate 防尘罩 Dust boot 制动底板 Brake bottom plate 5 Install the brake backing plate on the steering knuckle Fasten the two queen bolts and two short bolts on the backing plate Brake bottom plate fastening bolt Tie rod arm fastening bolt 6 Install the oil seal and dust ring and apply grease on the inner surface of camshaft Then install the camshaft 凸轮轴 Camshaft 油封 Oil seal 8 42 ...

Page 447: ...ter pin 平垫圈 Plain washer 垫片 Washer U 形叉 U fork 9 Assemble the roller and roller pin shaft of brake shoe and fix them with retainer ring to ensure a free rotation of the roller Caution Don t apply lubricating grease between the roller and the pin shaft 销圈 Pin washer 滚轮 Roller 滚轮销 Roller pin 10 Install the brake shoe Caution Apply lubricating grease in the oil storage groove on the inner surface of ...

Page 448: ...Install the gasket and fasten the slotted nut Caution Make sure the wheel can smoothly rotate without clearance and measure the bearing pre tightening force Refer to the front axle service method for the measurement and adjusting 15 Use the cotter pin to lock the slotted nut 16 Fill the hub bearing cover with grease and install the gasket and bearing cover 17 Turn the adjusting screw of adjusting ...

Page 449: ...ositioning screw 27 Flat headed pin 3 Grease nozzle 11 Pin shaft roller 19 Steel lock wire 28 Cotter pin 4 Camshaft bushing 12 Brake friction plate 20 Dust boot 29 Plain washer 5 Brake backing plate 13 Return spring 21 Bushing bearing pin 30 U fork 6 Oil seal 14 Bolt 22 Bearing pin 31 Lock nut 7 Camshaft 15 Return spring 24 Spacer 8 Rubber plug 16 Brake shoe 25 Retainer ring 8 45 ...

Page 450: ...haft bushing and then install the camshaft 凸轮轴 Camshaft 4 Adjust the position of the support of air brake chamber to ensure a free rotation of camshaft and then fix the support 5 Fix the spacer of camshaft install the adjusting arm and set the retainer ring in place 弹性挡圈 Elastic retainer ring 6 Install the roller and pin shaft on the brake shoe and fix them with retainer ring to ensure a free rota...

Page 451: ...ne with less turns on the side of anchor pin 回位弹簧专用工具 Dedicated tool for return spring 9 Align the alignment hole of anchor pin to the positioning screw hole in the brake bottom plate install the positioning screw and lock the screw with steel lock wire 蹄片支销 Brake shoe pin 钢丝锁线 Steel lock wire 安全定位螺钉 Positioning screw 10 Install the oil seal seat 油封安装工具 Oil seal installing tool 11 Install the inne...

Page 452: ...ole If necessary use washers on both sides of the arm and U fork to eliminate the lateral force of pushrod 21 Turn the adjusting bolt of adjusting arm to eliminate the clearance between the brake drum and the brake friction plate U 形叉 U fork 开口销 Cotter pin 平垫圈 Plain washer Caution Please refer to the front brake for the adjustment method 22 Turn the adjusting screw left till the pushrod stroke is ...

Page 453: ...Break System BR 6125J93C 01 BR 49 z Annex 1 Schematic diagram of braking pipelines 1 Schematic diagram of the air pipeline in the braking system 8 49 ...

Page 454: ...BR 50 Brake System BR 6125J93C 01 2 General schematic diagram of brake system 8 50 ...

Page 455: ...2 1 5 8 Straight connector wall through bite type 27 Two way check valve 9 Quick release valve assembly 28 Switch valve assembly 10 Elbow pipe connector cone thread end 29 Straight connector taper thread end 11 Transition connector 30 Pa11 tube yellow 12 1 5 12 T joint 31 Pa11 tube black 12 1 5 13 Elbow pipe connector cone thread end 32 Pa11 tube red 12 1 5 14 Pa11 tube brown 12 1 5 33 Pa11 tube b...

Page 456: ...nt to standby cylinder 9 Combined T joint bite type 29 Four way protective valve 10 Bushing 6 30 Combined elbow bite type 11 Clip 8 31 Air intake pipe 4 way protective valve 12 Connector door cylinder air reservoir 32 4 way protective valve intake pipe of air bellow cylinder 13 Nut for thread connector 33 Auxiliary cylinder to retarder I 14 Air reservoir assembly 14L 34 T joint bite type 15 Automa...

Page 457: ... compressor 26 Clip 6 9 Nut for thread connector 27 Sealing washer 10 Clip 28 Sealing washer 11 Sealing washer 29 Pall tube 12 Corrugated hose Stainless steel wiring woven 30 Bite type rubber connector assembly 13 Copper pipe I air supply 31 Bite type rubber connector assembly 14 Copper pipe II air supply 32 Air reservoir assembly 20L 15 Air intake pipe 4 way protective valve 33 Connecting pipe re...

Page 458: ...ht connector bite type 3 Pipeline filter 11 Combined elbow bite type 4 Connector body 4 way protective valve 12 Intake connector air bellow 5 Sealing washer 13 Sealing washer 6 Air intake connector PVC valve 14 Intake pipe right front air bellow 7 Overflow valve to pipe filter 15 Intake pipe left front air bellow 8 Pa11 tube black 12 1 5 16 Combined T joint bite type 8 54 ...

Page 459: ...Break System BR 6125J93C 01 BR 55 z Annex 2 Instructions of WABCO ABS for Commercial Vehicles Instructions of ABS ASR D and E for Commercial Vehicles WABCO Ltd China 8 55 ...

Page 460: ... control unit ECU gear ring sensor electromagnetic valve sensor and electromagnetic valve leads ABS warning light switch optional for the main unit manufacturer relay for retarder control for vehicles furnished with retarder power cord with fuse and grounding wire Additional functions can be obtained by the following components one ASR indicator one switch or key for ASR one differential brake val...

Page 461: ...ictly prohibited to use a hard object to knock on the gear ring lest the gear surface and shape should be damaged The axial deviation after the installation should be smaller than 0 2mm and the height deviation between adjacent teeth should be smaller than 0 04mm 3 2 Sensors 3 2 1 Installation of sensors Generally the installation holes for the clamp sleeve of the front axle sensor are located on ...

Page 462: ...BR 58 Brake System BR 6125J93C 01 8 58 ...

Page 463: ...ard with a deviation of 30 3 3 2 Testing of electromagnetic valve a Turn on the ignition switch and listen for the cycle sound of the solenoid If no sound cycle is heard inspect the electric circuit connection b Use the diagnosis software to excite the electromagnetic valve and judge if the valve works normally The resistance between each of the pole leg of electromagnetic valve and the grounding ...

Page 464: ...enoid vale and the other is from the ignition switch which is ECU power source The maximum and minimum voltages of the two power supplies are 30V and 18V respectively ECU installation ECU should be installed in a sealed bin which should be water proof and far from heat source and should be kept from impact with any objects 3 9 Switch and indicator 3 9 1 ABS ASR lights ABS ASR lights are yellow and...

Page 465: ...is on instantly for about 3s and goes off Indicating the ABS system is normal Turn on the ignition switch ABS indicator is always on If the indicator goes off when the wheel speed is higher than 7km h the ABS system is normal If the indicator will not go off when the car speed is higher than 7km h the ABS system has trouble Explanation when the vehicle is started for the first time or after a syst...

Page 466: ...t wheel 4 Right rear wheel 5 Diagnosis methods of ABS system WABCO has provided several possible diagnosis methods for the diagnosis of ABS system troubles such as diagnostic apparatus PC diagnosis portable diagnostic unit and flashing code diagnosis Diagnostic apparatus and PC diagnosis are better suitable for the off line testing of the vehicle manufacturers and for the trouble diagnosis of the ...

Page 467: ... software 446 301 620 0 can t be used for Model E z WABCO Model E PC software 446 301 637 0 can also be used for Model D z Diagnosis line 894 604 303 2 z Adapter 446 301 021 0 5 3 Portable diagnosis unit Portable diagnosis unit Version D 446 300 410 0 can t be used for Version E Portable diagnosis unit Version E 446 300 430 0 can also be used for Version D Diagnosis line 894 604 303 2 5 3 1 Connec...

Page 468: ...l be first displayed and then old will appear Now press and release ERROR key and the stored troubles will be displayed d When all troubles are displayed ABS will appear on the screen 5 3 3 Deletion of troubles The prerequisite is that no trouble exists currently a Press for more than 0 5s and release CLEAR key b Clear will appear on the screen c Then ABS will appear d Turn off the ignition switch...

Page 469: ...Break System BR 6125J93C 01 BR 65 8 65 ...

Page 470: ...BR 66 Brake System BR 6125J93C 01 8 66 ...

Page 471: ...Break System BR 6125J93C 01 BR 67 8 67 ...

Page 472: ...e light will display the code of each stored trouble and then off The trouble will be displayed only once Step 3 determine the flash code according to the number of flashings The first group of figures Which will be flashed for 1 8 times with an intermission of 1 5 seconds The second group of figures Which will be flashed for 1 6 times with an intermission of 4 second Turn off the ignition switch ...

Page 473: ...rge sensor clearance 2 Left front wheel 4 Open circuit or short circuit of sensor 3 Right rear wheel 5 Instable sensor signal 4 Left rear wheel 5 Third axle of right wheel 6 Gear ring damage 6 Third axle of left wheel 7 System function 1 Data interface 2 ASR differential valve 3 Third brake relay 4 ABS light 5 ASR configuration 6 ASR proportional valve 1 Low voltage 2 High voltage 3 Internal troub...

Page 474: ...g wiring Interrupted speed Abnormal speed tremble Too high frequency 3 2 ABS wheel ABS is failed ASR is failed 1 2 3 4 5 6 7 8 9 10 11 12 Right front wheel sensor Sensor clearance Improper tire Short circuit of storage battery power supply Short circuit of grounding Open circuit Short circuit Incorrect gear ring Looseness Wrong wiring Interrupted speed Abnormal speed tremble Too high frequency 3 1...

Page 475: ... 3 4 5 6 7 8 9 10 11 12 Right rear wheel sensor Sensor clearance Improper tire Short circuit of storage battery power supply Short circuit of grounding Open circuit Short circuit Incorrect gear ring Looseness Wrong wiring Interrupted speed Abnormal speed tremble Too high frequency 3 3 ABS wheel ABS is failed ASR is failed 1 2 3 4 5 6 7 8 9 10 11 12 Electromagnetic valve of left front wheel Open ci...

Page 476: ...ort circuit of storage battery power supply 2 4 Right front left rear and differential braking are failed 14 Sensor of right rear wheel Open circuit of intake and exhaust valves Open circuit Short circuit of grounding 2 3 ABS is failed The differential braking is failed 13 15 16 Short circuit of storage battery power supply 2 3 Left front right rear and differential braking are failed 14 Retarder ...

Page 477: ...ing is failed ASR is failed 17 18 19 Proportional valve short circuit of storage battery power supply Open circuit of proportional valve Proportional valve short circuit of grounding 7 6 17 18 19 No C3 signal C3 signal is short circuited C3 signal is open circuited The gear switch is incorrect C3 signal is incorrect C3 pulse quantity is incorrect 7 1 7 1 7 1 7 1 7 1 7 1 C3 signal is omitted ASR in...

Page 478: ... there is intermittent contact Read out the voltage and compare it with the required value The wheel speed disappears temporarily 11 Check the sensor wire harness and plug to see if there is intermittent contact Check the gear ring for damage Read out the voltage and compare it with the required value 12 Check the sensor wire harness and plug to see if there is intermittent contact If the trouble ...

Page 479: ... is neutral or not processed It is used together with the proportional valve for vehicles with non synchronous gear box 38 Check the wire harness and the speedometer signal 39 Check C3 B7 signal measurement and the tire size 40 Check the wire and light to see if the flash code switch s working time is more than 16 seconds and if there is no load at the positive pole of output measurement 49 Check ...

Page 480: ... in no way be compared with ABS which can realize 3 5 changes in one second When the vehicle is furnished with an ABS system the driver should in making an emergency braking first quickly presses the clutch and then strongly presses the brake pedal and meanwhile uses the steering wheel to control the vehicle to avoid any obstacle If the ABS light is on during driving the ABS system has trouble But...

Page 481: ...Electromagnetic valve 472 195 018 0 5 ASR differential braking valve 472 170 606 0 6 Extension wire of electromagnetic valve 449 513 xxx 0 7 Extension wire of sensor 449 711 xxx 0 8 ASR valve lead 449 415 xxx 0 9 Two way single directional valve 434 208 028 0 10 Diagnosis interface 894 101 722 2 11 Sensor 441 032 809 0 12 Sensor bushing 899 759 815 4 13 Lubrication grease 830 503 062 4 8 77 ...

Page 482: ...way single directional valve 434 208 028 0 9 Diagnosis interface 894 101 722 2 10 Sensor 441 032 809 0 11 Sensor bushing 899 759 815 4 12 Lubrication grease 830 503 062 4 Appendix 3 List of added or changed parts for EBL function No Product name Code 1 Electromagnetic valve Changed from 472 195 018 0 to 472 195 055 0 2 Pressure sensor 441 044 001 0 3 Pressure sensor wire 449 732 100 0 Appendix 4 L...

Page 483: ...Break System BR 6125J93C 01 BR 79 8 79 ...

Page 484: ...not exceed 0 28 OHM 传感器导线纽结 Sensor cable twists 对于绝缘导线每 50mm 最少 1 个纽结 For insulated cables there should be at least one twist every 50mm 对于非绝缘导线每 33mm 最少 1 个纽结 For non insulated cables at least one twist every 33mm 截面积 0 5mm2 The cross sectional area is greater than 0 5mm2 无标注的导线规格 The specifications for non marked cables 0 75 到 1 5mm2 虚线表示可选择的 From 0 75 to 1 5mm2 the dotted line means it is op...

Page 485: ...Break System BR 6125J93C 01 BR 81 8 81 ...

Page 486: ...ompanied with two Ф 50 funnel type rubber hole cover 11 接 ECU 的 0 173 号线端子用镀金插头 12 The plugs for ECU s 0 173 wire terminals are gilded 接 ECU Connected to ECU 接缓行器线束 Connect to the wire harness of retarder 康明斯电喷发动机加装 ASR 用此线束 This wire harness is used for installing ASR to the Cummins electronic fuel injection engine 接右后转速传感器 Connect to the right rear wheel speed sensor 接右后电磁阀 Connect to the right ...

Page 487: ......

Page 488: ...ples for selection of tyres 2 Operating precautions of tyres Tyre troubleshooting ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ WT 16 1 Trouble at tyre crown 2 Trouble at tyre shoulder and tyre sidewall 3 Trouble at tyre body 4 Trouble at tyre bead 5 Schedule of common troubles of tyres Removal and assembly of wheels and tyresꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ...

Page 489: ... wheel hub and wheel rim Structurally the wheel hub is a subassembly mounted on the axle The wheel hub and wheel spokes are integrated together as the wheel steel rim Spokes and hub are connected with bolts in two methods i e spherically aligned connection and center hole aligned connection In the former case bolts are rotated in two directions in the latter case bolts are rotated only in the same...

Page 490: ...e designation 2 Wheel rim type X indicates single component wheel rim i e each wheel rim consists of one component indicates multi component wheel rim i e each wheel rim consists of multiple components normally including retainer ring and lock ring 3 Wheel rim depth wheel rim height is normally indicated by wheel rim width followed by one Latin alphabet 2 Structure of tyre Automobiles are normally...

Page 491: ...tyre sidewall tyre bead and other parts structurally and tyre tread buffer layer belt layer ply cord layer etc in layout 胎侧 Tyre sidewall 胎肩 Tyre shoulder 胎冠 Tyre crown 胎圈 Tyre bead A 部放大 Magnification of Part A 胎面 Tyre tread 缓冲层或带束层 Buffer layer belt layer 窗布层 Ply cord layer 1 Tyre crown Tyre crown is the part between two shoulders of the cover tyre and specifically includes tyre tread buffer la...

Page 492: ...ssification 1 Tyres are divided into tube containing tyre and tubeless tyre based on makeup 2 Tyres are divided into diagonal tyre and radial tyre structurally 3 Tyres are divided into high pressure tyre low pressure tyre and ultralow pressure tyre based on the air pressure inside 4 Tyres are divided into cotton ply cord tyre synthetic yarn tyre nylon tyre steel cord tyre polyester tyre etc based ...

Page 493: ...l puncture for a tubeless tyre the air will leak out slowly through the small clearance between tyre rubber and nail so that the tyre pressure will fall slowly Even if the nail is removed air can only leak through the small puncture hole and therefore sharp pressure drop can be avoided Meanwhile the tyre bead is more closely engaged with the wheel rim in the absence of an inner tube so that the ty...

Page 494: ...sure and can be indicated as load index LI Load index and load are matched together based on certain relations Please see the following table for some of the data LI kg LI kg LI kg LI kg LI kg LI kg 50 190 60 250 70 335 80 450 90 600 100 800 52 200 62 265 72 355 82 475 92 630 102 850 54 212 64 280 74 376 84 500 94 670 104 900 56 224 66 300 76 400 86 530 96 710 106 950 58 236 68 315 78 425 88 560 9...

Page 495: ...width of tyre has mm as the unit Nominal height breath ratio of tyre has the fraction of H B as the unit Speed symbol km h Symbol of tyre structure Nominal diameter of wheel rim inch 外直径 Outer diameter 轮辋宽度 Wheel rim breadth 段面高度 Section height 缎面宽度 Section breadth 总宽度 Total breadth 轮辋名义直径 Nominal diameter of wheel rim Tyre dimensions marked Eg 195 60HR14 Nominal diameter of wheel rim 14inch Tyre ...

Page 496: ...码 ECE certification code 中文全钢丝载重子午胎 Chinese full steel cord radial tyre 轮胎骨架材料结构介绍 Tyre frame material structure introduction 层级 Ply rating 单胎最大充气压力 Maximum inflating pressure of single tyre 花纹可重刻标记 Pattern can be re engraved 铭牌 Nameplate 单胎最大充气压力 Maximum inflating pressure of single tyre 轮辋代号 Wheel rim code 全天候越野花纹标志 Weatherproof cross country tread pattern mark 安全警告标志 Safety alarm mark...

Page 497: ... 英文字母 English 所示内容 Chinese 1 ALL STEEL RADIAL 全钢丝子午线轮胎 2 REGROOVABLE 花纹可再刻轮胎可翻新 3 STANDARD RIM 标准轮辋 4 TREAD 5PLIES STEEL CORD 胎面五层钢丝 5 SIDEWALL 1PLY STEEL CORD 胎侧一层钢丝 6 E ECE 证号 7 DOT DOT 证号 8 RR100 RR9 RLB1 花纹代号 9 TUBELESS TYPE 无内胎 10 MAX LOAD SINGLE AT COLD 单胎最大负荷及相应气压 11 MAX LOAD DUAL AT COLD 双胎最大负荷及相应气压 9 10 ...

Page 498: ...RD Tyre tread with five layers of steel coil bed 5 SIDEWALL 1PLY STEEL CORD Tyre sideweel with 1 layer of steel coil bed 6 E ECE certification code 7 DOT DOT certification code 8 RR100 RR9 RLB1 Pattern code 9 TUBELESS TYPE W o inner tyre 10 MAX LOAD SINGLE AT COLD Maximum load and inflating pressure of single tyre 11 MAX LOAD DUAL AT COLD Maximum load and inflating pressure of twin tyres 9 11 ...

Page 499: ...on will increase the friction between tyre bead and wheel rim and thus damage the tyre bead d Excessive deformation will reduce the critical speed of standing waves of tyre cause the tyre to heat up easily and result in early damage e In case of low atmospheric pressure the tyre may suffer irregular wear and tear e g tyre shoulder abrasion and its service life may be reduced f Low internal pressur...

Page 500: ... fasten the cap of the inflating valve j The backup tyre shall be kept readily available Load 1 Influence of excessive load a Load and internal pressure are interrelated In case of normal atmospheric pressure overloading is equivalent to low pressure for a tyre For that reason the troubles that may occur in case of low internal pressure will also take place in case of high load It is necessary to ...

Page 501: ...n 5mm 2 If the outer diameters of the twin tyres are different the one with a lower outer diameter shall be installed on the inner side 3 The differential pressure of twin tyres shall be kept within 20kpa 0 2kg cm2 4 Low internal pressure and high load will easily shorten the distance between twin tyres and even bring them in contact In this case the tyres will rub against each other to generate h...

Page 502: ...yres 1 Avoid direct exposure to the sunshine during storage 2 Avoid excessive rainwater and humidity 3 Avoid proximity to or frequent contact with equipment that generate ozone easily 4 Avoid placing a tyre in a particularly hot place 5 Avoid contact with organic solvents 6 Tyres shall be kept on a shelf or in an independently erected state Tyre installation 1 Tyres must be installed by trained pr...

Page 503: ...overy Crown peeling 1 Phenomena tyre surface becomes coarser and peels off in blocks 2 Cause tyre travels on a sand and stone paved road for a long term so that tyre tread is damaged by sharp stones Bus brake control system is in trouble so that tyres are kept in a rolling and skidding state Skidding and idle running of the bus 3 Precaution keep appropriate tyre pressure preclude overloading reduc...

Page 504: ...deformation and abrasion of tyre patterns 3 Precaution check the bus conditions in a regular manner Keep the tyre in an appropriate pressure replace the tyre in a frequent and timely manner and drive properly without overloading Install the tyre in a correct manner to balance the components Twin tyres must be installed in a matching manner including designation pattern specification ply rating pre...

Page 505: ...amaged by a sharp stone embedded between twin tyres Tyre sidewall is scratched by any machinery of the bus itself 3 Precaution take care to ensure proper driving and prevent the bus from scratching or squeezing any obstacle or projecting object during traveling or parking e g staircase rock wall pit etc Take care of the road conditions during routine driving Check the tyre frequently or regularly ...

Page 506: ... snap Improper assembly of new tyres so that the inflating valve leaks presence of foreign matters in the inner tube so that it is ground to damage due to under pressure 3 Precaution it is necessary to be highly alert during traveling and take reasonable and effective measures upon detection of any anomaly Overspeed is forbidden 4 Trouble at tyre bead Tyre bead is damaged and ground 1 Phenomena ty...

Page 507: ...na toe bursting big scar bursting from inside out normally in a sector shape 2 Cause overload and overspeed upon turning so that the tyres on one side are excessively loaded and burst The toe is worn out for the long term and the wrapping fabrics and ply cords are broken so that the toe bursts 3 Precaution wheel rims that fit in with the tyres must be used Do not use deformed wheel rims Maintain a...

Page 508: ...od driving habit and forbid frequent sharp turning 5 Schedule of common troubles of tyres Crown Shoulder and tyre sidewall Body Bead 1 Crown bursting Tyre sidewall bursting Ply cords are loosened and cracked internally Tyre bead is damaged and ground 2 Crown peeling Shoulder and sidewall are externally damaged Tyre damage due to underpressure and grinding on the road Toe rupture 3 Crown scratch Ty...

Page 509: ...arge or replenish the tyre before checking if the retainer ring is installed in place and if the wheel hub is damaged 5 Check the tyre pressure in a cold state Do not deflate the tyre at a hot state to avoid insufficient charging Insufficiently charged tyres may be easily overheated and suddenly damaged due to excessive deformation and thus there is difficulty in operation 6 Do not use the tyre as...

Page 510: ...tion 1 Check all components and replace excessively worn out and damaged components Clean foreign matters from wheel hub bolts wheel nuts and the side of the wheel facing the brake drum 2 Apply lubricants on the threads of wheel hub bolts and wheel nuts engine oil or lubricating greases 3 Rotate the wheel if necessary and check if the wheel hub bolts are in the middle of the wheel hub bolt holes a...

Page 511: ...2019 12 17 CATL Confidential Introduction of Power Battery System CATL AFS STTG ...

Page 512: ...1 2 3 Composition of Battery System Introduction of Battery System Hardware Introduction of Battery Management System BMS Content ...

Page 513: ...2019 12 17 CATL Confidential Page 3 Composition of Battery System Chapter 1 ...

Page 514: ...tem 2019 12 17 CATL Confidential Page 4 Battery Box PACK High Low voltage wiring harness Thermal management accessories High voltage Box S Box Cold plate heating film optional Several High voltage wiring Low voltage wiring Several One BMS ...

Page 515: ...1 2 The Location of Battery Box in the Vehicle Example 2019 12 17 CATL Confidential Page 5 Including 4 locations Chassis Classic Rear Classic Side of rear Common Roof Uncommon ...

Page 516: ...2019 12 17 CATL Confidential Page 6 Introduction of Battery System Hardware Chapter 2 ...

Page 517: ...e 7 1 HV positive pole 2 HV negative pole 3 heat input 4 heat output 5 LV input 6 LV output 7 Manual Service Disconnect Socket 8 Pressure Valve Upper lid 9 hook 10 Warning label No tread on or touch HV With fuse Without fuse 8 9 10 1 2 Two types of MSD 3 5 4 6 7 ...

Page 518: ...Appendix 1 MSD 2019 12 17 CATL Confidential Page 8 MSD A With Fuse MSD B Without Fuse ...

Page 519: ...Appendix 2 Pressure Valve Upper Lid 2019 12 17 CATL Confidential Page 9 Outer side Inner side ...

Page 520: ...2 2 Explosive View of Battery Box 2019 12 17 CATL Confidential Page 10 1 Lid 2 Sealer 3 Cell supervision circuit CSC 4 Copper bar 5 Module 6 Box 7 Pressure valve 1 2 3 4 5 6 7 Pressure valve ...

Page 521: ...rotection Level of Shell IP code 7 Prevent flooding effect in a short time Highest 8 Static depth of water 1m Flooding time 30min 6 Keep metal piece off the dangerous part Highest 6 Prevent metal piece with a diameter larger than 1 0mm into shell Effect No entrance of dust Dust proof Level Water proof Level ...

Page 522: ...2 4 Module 2019 12 17 CATL Confidential Page 12 1 2 3 1 Aluminum bar 2 Temperature sampling line 3 Voltage sampling line 4 module s general positive pole 5 module s general negative pole 4 5 ...

Page 523: ...2 5 Explosive View of Module 2019 12 17 CATL Confidential Page 13 1 Dielectric plate 2 Wiring harness plate 3 cell 4 side plate 5 end plate 6 baseplate 1 2 3 5 4 6 ...

Page 524: ...2 6 Connection Type of Cells Example 2019 12 17 CATL Confidential Page 14 P Parallel connection S Series connection Parallel connection Parallel connection ...

Page 525: ...2 7 Cell 2019 12 17 CATL Confidential Page 15 1 5 4 1 Positive column 2 Negative column 3 Vent 4 Shell Al 5 Dielectric plate 2 3 ...

Page 526: ...2 8 Anatomical Drawing of Cell 2019 12 17 CATL Confidential Page 16 1 Positive pole Al 2 Negative pole Cu 3 Shell Steel Aluminum 4 Separate membrane 5 Electrolyte 1 4 5 2 3 DANGER No Disassembly ...

Page 527: ...itive pole 7 DC charge positive pole 8 LV connector socket 9 8 LV connector plug 10 DC DC positive negative 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 10 18 19 20 21 11 LV input 12 LV output 13 Battery positive pole 1 14 Battery positive pole 2 15 Battery negative pole1 16 Battery negative pole2 17 heat input 1 18 heat input 2 19 heat output1 20 heat output 2 21 MSD ...

Page 528: ...TL Confidential Page 18 1 Upper lid 2 Copper bar 3 Heater relay 4 Insulation column 5 Current sensor 6 MSD base 7 PDM 8 BMU 9 HVB HV sampling plate check if there is adhesion of EVC500 temperature of charging base 10 HV relay 1 2 3 4 5 9 6 7 8 10 ...

Page 529: ...Upper lid 2 Backup power BPM 3 BPM installation component 4 Copper bar 5 Current sensor Insulation column 6 Power distribution module PDM 7 Battery disconnect unit BDU 8 Battery management unit BMU 9 Box and connector 10 Manual Service Disconnect MSD 1 2 3 4 5 6 7 9 10 8 ...

Page 530: ... are C CAN A CAN and CH CAN 1 Communicate with CSCs through C CAN acquire voltage temperature and working condition of each cell When it meets the equilibrium condition CSC will driven into equilibrium controlled by BMU through C CAN 2 Communicate with HCU through A CAN which accept command of HCU and status information 3 Communicate with charger through CH CAN ...

Page 531: ...ion Module PDM 2019 12 17 CATL Confidential Page 21 To distribute 24V DC LV power to battery management system BMS Distributable power and its priority 24V DC charger 24V AC charger 24V lead acid battery or DC AC LV power ...

Page 532: ...2 14 Cell Supervision Circuit CSC 2019 12 17 CATL Confidential Page 22 To supervise cell voltage and module temperature and execute active equalizing function under the control of BMU ...

Page 533: ...2 15 Backup Power BPM 2019 12 17 CATL Confidential Page 23 An 18V DC LV backup power inside S box 5 LCO cell the single cell voltage is 3 6V ...

Page 534: ...Confidential Page 24 CSC Wiring harness Heating accessory optional Module 电芯 Several battery box S BOX CSC Wiring harness Module 电芯 BMU PDM Lead acid battery Charging pile Battery B B HV HV A CAN CH CAN C CAN MSD MSD MSD Current sensor relay etc BPM C CAN ...

Page 535: ...2019 12 17 CATL Confidential Page 25 Introduction of Battery Management System BMS Chapter 3 ...

Page 536: ...m Active passive balance mode Low power consumption Historic data record Cascade extension CRC data calibration Cell voltage current temperature inspection and analysis HVIL High voltage insulation monitor SOC calculation SOH calculation Capacity integration Overcharge overdischarge protection Overcurrent high low temperature protection Multi stage fault diagnosis protection ...

Page 537: ...3 2 Electrical Schematic Diagram Example 2019 12 17 CATL Confidential Page 27 ...

Page 538: ...3 3 Principle Diagram of Battery Management System BMS 2019 12 17 CATL Confidential Page 28 ...

Page 539: ...CATL AMD CODE FOR DAILY USE OF EV BATTERY SYSTEM KongCF ...

Page 540: ...e maintenance certificates issued by CATL Wear insulating gloves in operation and maintenance of the battery system Do not wear metal ornaments Any behavior of damaging the batter system such as extrusion puncturing and burning will be prohibited The positive and negative terminals of the battery box mustn t be simultaneously touched by both hands at any time The working environment of the battery...

Page 541: ...if conditions permitting disconnect the manual maintenance switch by professionals Step 2 Handle the traffic accident according to relevant requirements of the national road traffic safety laws and egulations Step 3 Notify our after sales service department The vehicle must not be used until the after sales service epartment provides the battery safety results ...

Page 542: ...ery harness is smoking use the carbon dioxide or dry powder extinguisher If the battery is on fire use the high pressure water hose at a long distance In case of inhalation of dense smoke rapidly transfer the victims and seek medical help Step 3 Notify the auto brand dealer to obtain the opinions on further handling PROMPT If the fire is caused by charging anomaly immediately turn off the power su...

Page 543: ...enario Vehicle wading in water Pay attention to the following items if the vehicle runs on the road with water Depth Speed Time 35cm 10km h 10min Note The vehicle must not run on the road with the water depth more than 30cm ...

Page 544: ...the vehicle accidentally falls into water or is immersed in water 1 Do not turn on the power supply 2 Notify the auto brand dealer PROMPT If immersed in water for weather or special reasons the vehicle must not be energized otherwise safety risks or secondary damage may be caused ...

Page 545: ... fixed frequency each month or not charged and discharged each day Long time stationary vehicle refer to the vehicle which is not operated in more than 15 consecutive days SOC refer to the proportion of residual capacity of the battery CATL Ningde Contemporary Amperex Technology Limited CATL authorized maintenance unit refer to the authorized service provider dealer or OEM signed by CATL ...

Page 546: ...STICS 30 55 Range of battery work environment temperature 40 55 Range of battery storage environment temperature 0 55 Range of battery charging environment temperature 25 45 Range of the best battery charging environment temperature ...

Page 547: ... is more than 50 it means goods conditions are met for driving It is recommended to fully charge the vehicle before driving if possible If the SOC value is less than 30 it means that the battery power is low The vehicle should be charged until the SOC value is more than 50 before driving Don t pull out the charging gun when it s working Attention ...

Page 548: ...ducted once a year in order to prevent damage to the battery Pure electric vehicles should do at least one automatic full charge every three days hybrid vehicles do not require this If the battery is damaged as a result of nonconformity to the operating requirements the three guarantees will be invalid PROMPT The vehicle should be charged twice at most and maximum 30min each time in the daytime in...

Page 549: ...e of the normally operating vehicle PROMPT If the air temperature is 0 C or below the vehicle should be charged as soon as possible after operation in order to prevent the influence on operation as a result of long charging time in the case of too low temperature ...

Page 550: ...and dry place free from sunlight rain or heat source The vehicle should be fully charged once every three months in order to prevent the battery from damage Before operating the long time stationary vehicle battery maintenance should be performed at least once in order to activate the battery system and recover the best performance of the battery ...

Page 551: ...TRUCTIONS OF CHARGER Use the charger conforming to the national standards Use the Auto charge function to charge the vehicle Do not use the Manual charge function Do not pull out the charger when charging ...

Page 552: ... key into the ON position to stand for 12 to 15 hours without manual guard A full charge is required after the end of the rest PROMPT Do not use the vehicle or any electrical appliances during step 3 If the standing time requirement cannot be met because of the tight operation time the maintenance operation can be divided into 2 3 times and completed within a month The accumulated standing time sh...

Page 553: ...dor or is subject to deformation or expansion Whether the pneumatic balance valve or explosion proof valve of the battery box is damaged Whether the battery box and high pressure box are securely connected with the frame PROMPT Wear the insulating shoes insulating gloves goggles and other protective articles in order to ensure the personal safety before inspection If any anomaly is found in inspec...

Page 554: ...id and then check if the water circulation is normal Check the air inlet of the unit for any blockage If it is found to be abnormal clean it and wipe the filter with a clean cloth PROMPT For vehicles equipped with water cooled units if the average battery temperature exceeds 50 C during high temperature operation in summer it is an abnormal situation please check the water cooled unit as required ...

Page 555: ...a kind of orange electrical component which is used for manually cutting off the high voltage line and achieving the function of safety protection see the right figure The manual maintenance switch should be disconnected before overhaul and installed in place after overhaul ...

Page 556: ...nue to press the position indicated by the arrow A using the thumb of the left hand At the same time pull the handle of the maintenance switch in the direction indicated by the arrow B into the angle in Fig 3 that is a 90 degree angle is formed between the handle and maintenance switch As shown in Fig 4 hold the handle of the upper cover of the maintenance switch using the right hand and carefully...

Page 557: ...cated by the arrow A As shown in Fig 2 slowly push the handle of the maintenance switch in the direction indicated by the arrow B using the thumbs of the left and right hand until the snapping sound is uttered As shown in Fig 3 the maintenance is installed in place As shown in Fig 4 hold the upper cover of the maintenance switch using the right hand and pull the upper cover in the direction indica...

Page 558: ...o drive out until the SOC value is more than 50 Check instrument panels make sure if there is any warning signal or not the signal of please maintenance appears routine maintenance should be done quickly Ensure if there is any other abnormal phenomena Ensure bus s SOC status and alarm situation ...

Page 559: ...he outside of the box if it is deformed or destroyed open the box and check the module Check the window shades of the box if blocked clear it timely Check if there is any dust water or other liquid If there is clear it with dry cloth ...

Page 560: ...mal or not Check if the PACK is deformed destroyed or not Check if the harness is loose or not Check if the HV cable is aging destroyed or not Check if the PACK has any smell or liquid leakage Check the fix screw is loose or not Harness status MSD is loose Heating Screw loose Balance valve status ...

Page 561: ...s loose or heating Check if the terminal of the HV box is loose or heating Check if the HV box is deformed Check if the HV harness is aging or destroyed Check if the locking screws are loose MSD status Status of the terminal of the HV box ...

Page 562: ...ce Maintenance operating processes 1 Keep the SOC value at the range of 25 40 if we don t use it 2 Please turn off the power supply before charging then turn on the key and turn off all electrical equipment like air condition radio and so on 3 Keep this status for 12 15 hours then key off one full charging is needed after the maintenance ...

Page 563: ...e maintenance The high voltage electrical equipment will break off itself during the maintenance if you use it if happens you should restart maintenance operation If the warning alarm appears more than twice when the maintenance finished after one month please call us for help ...

Page 564: ...Thank you for watching Web http www catlbattery com Tel 400 918 0889 Any questions ...

Page 565: ...AFSP A User Manual of E BUS Power Battery System Level 3 Privacy Level 2 High Density Level 1 Low Density Level 0 Public Contemporary Amperex Technology Co Limited After sales Service File File Name User Manual of E BUS Power Battery System File NO AFSP OM 01 File Liability Guide User Usage and Warranty Instructions ...

Page 566: ... Normal Operation of Vehicle 4 1 3 Instructions of Temporarily Operating Vehicle 4 1 4 Instructions of Long time Stationary Vehicle 5 1 5 Instructions of Charger 5 1 6 Battery Maintenance Procedures 5 1 7 Instructions of Routine Inspection 6 1 8 Functions of Manual Maintenance Switch 6 1 9 Operating Requirements of Manual Maintenance Switch 7 1 9 1 Removal Procedures 7 1 9 2 Installation Procedure...

Page 567: ...ct the personal safety 1 The positive and negative terminals of the battery box mustn t be simultaneously touched by both hands at any time 2 The maintenance personnel must have the electrician certificates issued by the safety supervision bureau and the maintenance certificates issued by CATL 3 Wear insulating gloves in operation and maintenance of the battery system Do not wear metal ornaments 4...

Page 568: ... turn off the main power switch and if conditions permitting disconnect the manual maintenance switch by professionals Step 2 Handle the traffic accident according to relevant requirements of the national road traffic safety laws and regulations Step 3 Notify our after sales service department The vehicle must not be used until the after sales service department provides the battery safety results...

Page 569: ...icle which is operated charged and discharged each day Temporarily operating vehicle refer to the vehicle which is not operated at the fixed frequency each month or not charged and discharged each day Long time stationary vehicle refer to the vehicle which is not operated in more than 15 consecutive days SOC refer to the proportion of residual capacity of the battery CATL Ningde Contemporary Amper...

Page 570: ...ration of Vehicle The daily cumulative charging power should not exceed 1 5 times of the rated total power If there is the prompt for battery maintenance on the dashboard please conduct battery maintenance as soon as possible to recover the normal conditions of the battery system The battery maintenance of the vehicle must be conducted once a year in order to prevent damage to the battery Pure ele...

Page 571: ...dures Place broad flat and safe with the charger Procedures 1 Adjust the battery capacity SOC to be 25 to 40 2 Stop the vehicle stably turn off the power supply turn the key into the OFF position and then turn on the power supply turn the key into the ON position Check whether all electrical appliances of the vehicle are OFF 3 Keep the vehicle power on turn the key into the ON position to stand fo...

Page 572: ...service department or service station for help Do not repair the vehicle without permission 1 7 2 A comprehensive inspection of the water cooled unit is required before the summer season The specific items are as follows Check if the liquid level of the expansion tank is normal should be 2 3 or more liquid level If it is not enough please refill the liquid and then check if the water circulation i...

Page 573: ...ngle is formed between the handle and maintenance switch c As shown in Fig 4 hold the handle of the upper cover of the maintenance switch using the right hand and carefully pull out the upper cover in the direction indicated by the arrow A Thus the maintenance switch is removed 1 9 2 Installation Procedures a As shown in Fig 1 hold the handle of the upper cover of the maintenance switch using the ...

Page 574: ...ingle cell maximum voltage to 3 65V 5 stand for 30min 6 0 3C discharge to a single cell minimum voltage to 2 5V 7 stand for 30min Repeat the above operation steps 3 times or more When the difference of the results of three consecutive tests is less than 3 of the rated capacity it may be terminated early and the average value of the last two discharge capacities is taken as the discharge capacity o...

Page 575: ... specified in the vehicle warranty manual 3 MSD As specified in the vehicle warranty manual 4 Fuse As specified in the vehicle warranty manual 2 1 2 Warranty period of parts sold on aftermarket 1 Definition of parts sold meaning the parts to be purchased by the customer from the part vendor designated by CATL 2 Starting date of the warranty period the date on the part invoice issued by CATL s afte...

Page 576: ...value IP67 products exceed 30 minutes IP68 products exceed 2 hours 6 Modify add remove and adjust the battery system without authorization from CATL after sales service department and service agent 7 The product is damaged as a result of handling of battery system faults without permission of the after sales service department or service station of CATL 8 The associated or indirect losses are caus...

Page 577: ...11 1 ...

Page 578: ... 本电器图册所包含的信息和规格资料全部出自编写时的最新产品信息金旅公司的产品处于不断更新提升中因此零部件编号规格数量以及各个零件的工艺图形外观可能会有所变更厦门金龙旅行车有限公司有权在不预先通知的情况下随时做出变更如有变更请以变更的为准 All of ordering information and specifications in this products catalogue are latest products information while this Catalogue is being compiled Parts numbers specifications quantities and process outlines and appearances of parts in this catalogue may not be in accord...

Page 579: ...NG WATER PUMP 9 06 FOUR IN ONE CONTROLLER 11 07 MOTOR CONTRILLER 13 08 PRINCIPLE DIAGRAM OF HIGH VOLTAGE ELECTRIC 15 09 LOW VOLTAGE ELECTRICAL DIAGRAM 17 10 NETWORK TOPLOGY DIAGRAM 19 11 HANDBRAKE DOOR PUMP PRESSURE 21 12 CONNECT NEW ENERGY SYSTEM 23 13 FRONT REAR BRAKE PRESSURE SENSOR 25 14 ECAS 27 15 POWER DISTRUIBUTION 29 16 EBS 31 17 BRAKE SHOE WEAR ALARM 33 11 3 ...

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Page 592: ...ea HW 1706 DC lug Positive HW 1945 DC Lug Negtive 3 Area T 15Nm T 12Nm Product nameplate mounting position Emergency stop Technical Requirement 1 Cooling a 40 water 60 glycol b The temperature of the coolant of inlet should never exceed 65 C 2 The length of grounding strap should as short as possible Prepared by user AWG 1 0 50mm 2 is recommended 3 Phase cable between controller and motor Prepared...

Page 593: ...11 17 ...

Page 594: ...surance Input Precharge relay Main motor controller Input U V W Defrost Precharge resistor Input Steering pump controller Input U V W Input Air pump controller Input U V W DCDC 24V 24V Input Input AC main motor Insurance Battery positive electrode Battery negative electrode Insurance DCDC Relay DC AC Relay 11 18 ...

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Page 596: ...end face end face 18 16 17 19 20 14 15 9 3 13 7 8 2 1 10 11 12 4 5 6 gear switch accelerator K3 K2 BMS charging socket charge wake up work battery drive wake up 11 20 ...

Page 597: ...GOLDEN DRAGON A 11 21 ...

Page 598: ...GOLDEN DRAGON CAN2 内CAN 整车CAN1 外CAN Explain 1 This drawing is hereby made for presentation If any change is made the design of the order shall prevail 120欧 120欧 120欧 120欧 CAN2 L CAN2 H 11 22 ...

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Page 601: ...G H T w Air outlet 3 8 产品铭牌安装位置产品铭牌安装位置 11 25 ...

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Page 603: ...GOLDEN DRAGON 电源故障火警负极电源故障火警正极 18 32VDC 负极进风口 11 27 ...

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