Introduction on ZF Drive Axle Configuration Shandong Lingong Import & Export Corp. Training Room 2011

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 2 Contents Features and Main Technical Parameters Introduction on Components Maintenance on ZF Drive Axle Introduction on Special Tools and Key Part Repair Maintenance Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 3 1. Features and Main Technical Parameters 1. AP-400 Series Wet Brake Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 4 2. Features of AP-400 Series Axle Wheel Hub great speed ratio Compact structure Integration of planet carrier and gear Wet brake No effect of piston thrust on wheel hub bearing Short wheel hub bearing distance Maintenance on brake without removal of hub 1. Features and Main Technical Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 5 3. Features of AP-400 Series Axle Main Transmission Part Spiral bevel gear Small bearing Small speed ratio Great ground clearance Small diameter of semi axis Small size of differential 1. Features and Main Technical Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 6 4. Advantages of AP-400 Series Axle （ 1 ） Over 30 years of drive axle production and 15 years of application experience on wet brake （ 2 ） Continuous product development and quality improvement （ 3 ） being equipped with worldwide application experience, excellent technology and best configuration （ 4 ） Cooperating with the world famous manufacturers （ 5 ） Leading in material application and production technology （ 6 ） Wheel wet brake facilitating the dismantling of tire during the replacement of brake sheet （ 7 ） Tightening efficiency of 45% limited-slip differential 1. Features and Main Technical Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 7 NameRear Axle Front Axle Maximum Static Load (T) Maximum Dynamic Load (T) Output Torque (N.m) Braking Torque (N.m) Speed Ratio23.5 Braking Oil Pressure (Mpa)Minimum 4.0, Working Oil Pressure 6.67 Mass (kg)800 (without oil)1024 (without oil) Performance Parameters of ZF Drive Axle 5. Performance Parameters 1. Features and Main Technical Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 8 Contents Features and Main Technical Parameters Introduction on Components Maintenance on ZF Drive Axle Introduction on Special Tools and Key Part Repair Maintenance Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 9 1. Design of AP-400 Series Axle----Drive Axle 2. Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Introduction on AP-400 Series Axle Components----Differential 2. Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 11 ModelDL1000DL1200DL1600DL2400DL3500DL5000 Assembly No Rated Torque (for the large helical gear) N.m Weight Kg Installation Size (mm) Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 12 3 、 ZF DL Multi-chip Limited-slip Differential 1 ） Large Helical Gear 2 ） Differential Shell 3 ） Cap 4 ） Bevel Gear 5 ） Small Bevel Gear 6 ） Cross 7 ） Thrust Collar 8 ） Pin 9 ） Outer Friction Disc 10 ） Inner Friction Disc 11 ） Thrust Plate 12 ） Retainer Ring 13 ） Bevel on Thrust Collar 2. Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 13 Different lock coefficients result in different driving power on the ground. If using a ordinary differential, right wheel will slip, and left wheel will stop running. The vehicle could not move. 4. Working Principle of ZF Limited-slip Differential 2. Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 14 Torque flow with same adhesion for straight running Torque flow with different adhesion for left turning or on two ends 2. Introduction on Components

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 15 Contents Features and Main Technical Parameters Introduction on Components Maintenance on ZF Drive Axle Introduction on Special Tooling and Key Part Repair Maintenance Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Oil for Drive Axle:  Recommended oil (Caltexoils extra EP gear oil 90 Thuban GL5 EP 90) in SDLG Operation & Maintenance Manual. 2. Oil Level Checking:  The vehicle is in a horizontal position. Clean all the refueling parts before checking. Dump the oil after the vehicle runs for some time.  Caution: When dumping or filling oil, avoid the oil splashing once opening the plug. 3. Maintenance on ZF Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 17 Kinds of Oil Levels  Wheel Hub Oil Level: When checking the wheel hub oil level, rotate the hub until the words “oil level” on it is on a horizontal position. The oil level shall prevail when the oil overflows a plug hole.  Bridge Body Oil Level: The oil level shall prevail when the oil overflows the centered refueling hole or plug hole as the final.  Checking: Several minutes later, continue refueling if the oil level reduces, until the oil level reaches the stipulated position and becomes stable, especially for the new vehicle axle and newly-repaired axle as well as the case in which the axle parts are changed.  Check the oil level at least once a month! 3. Maintenance on ZF Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Oil Change:  New vehicle shall change the drive axle oil for the first time after running 250 hours. Then change the oil once for running 1,000 hours. Change the oil at least one time in a year! 3. Maintenance on ZF Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Maintenance on ZF Drive Axle  According to the lubrication oil management rules, when refueling the axle, the axle assembly shall ordinarily lie on a horizontal position for working status (the gradient of the main transmission parts position is allowed to fluctuate within 5°). Clean up all the refueling positions before opening. The oil dumping shall be taken at once after the vehicle runs for a long time. Oil Level:  Hub: Rotate the hub until the “oil level” can be seen on a horizontal position. Refuel until the oil overflows the plug hole.  Axle: Refuel until the oil overflows the refueling hole and plug hole at the centered part of the axle. Oil change rules apply to ZF Axle of self-lock differential!

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Oil for Brake:  Use mineral oil SAE10. Never use braking fluid. Recommend to use Mobil Delvac 1310 (Grade SAE 10W). Details can be seen in (the Loader Operation & Maintenance Manual delivered together with the loader ).  Check the friction of braking lining once in a month to guarantee the driving safety.  Caution: Do not allow to use other braking fluid without ZF permit!  Deflate the axle brake after the replacement with a new axle or the repairing on the oil circuit of the axle brake. 3. Maintenance on ZF Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Working Temperature:  The temperature for the axle’s continuous working shall not exceed 90 ℃. If the temperature exceeds 130 ℃, stop the vehicle and check the system and the axle. 6. Lubricating Grease: Use the multi-purpose lubricating grease with the following features:  Lithium base saponified fat with the drop point of 170 ℃ and NLGI Grade 2.  Lubricating grease must have the properties of corrosion resistance, water-proof and extrusion stability.  Forcibly fill the grease into the grease fitting place every week. 3. Maintenance on ZF Drive Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Maintenance on ZF Drive Axle 7. Notes:  For ZF-Axle of self-locking differential with a friction plate, use the lubricant with limited-slip differential agent. The connecting bolts of all the axle, frame, transmission shaft and rim shall be checked periodically on the tightening torque. (The first check shall be taken after running for 50 hours)!  For the loader in frequent braking or under bad conditions or the equipment works in a ambient temperature of over 40 ℃, the oil of drive axle shall be replaced one time every 500 hours or at least one time in half a year!

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 23 Contents Features and Main Technical Parameters Introduction on Components Maintenance on ZF Drive Axle Introduction on Special Tools and Key Part Repair Maintenance Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 25 1 、 Tighten slotted nut while rotating the hub  Torque Value AP-407/409= Nm AP-411/415= Nm AP-417/420= Nm Measurement on resistance of wheel hub bearing: Force gained from the formula ， F=T/R T=Rolling Resistance Torque （ Nm ） F=Force （ N ） R=Radius （ m ） 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Rolling Resistance Torque AP-407/409/411/ Nm AP-417/ Nm  Find the appropriate minimum value  Reselect the pad thickness if the resistance torque is not appropriate  Dismantle the hub for readjustment after the thickness is appropriate 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 27  Install the bearing inner ring, and assemble the internal friction slices support on the spline along the semi axis (with the sun gear)  Adjust the space between the friction slices according to the following table Inner Friction Slices Friction Surface Space （ mm ） Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Measurement of Piston Stroke (Normal Value mm)  Get A value from the connecting surface of the hub to the piston plane.  Size A ： mm  Notes: Note the normal position of the piston in the annular gear.  Get size B from the connecting surface of the hub to the inner surface of the clasp slot of the annular gear.  Size B ： 75.20mm 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Check the seal of the braking hydraulic system  Cautions: 1. Exhaust the brake. 2. Brake 10 times and check the pressure after exhausting. 3. Adopt the build-up pressure of the hydraulic pump in 120bar and then tighten the switch. 4. Keep the pressure for 5 minutes with no lower than 117bar. 5. Then keep the pressure of 5bar for 5 minutes with no decrease in the pressure. 6. Install the exhaust valve. 4. Introduction on Special Tools and Key Part Repair Tighthen the oil drain plug, and tighten the torque: 50Nm Caution: Pay attentions to the relevant oil usage rules before using the axle!

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Measurement on Abrasion:  Turn A plug to the position as shown in the picture to measure the abrasion of the friction slices  Get out the plug and step on the brake (oil pressure of bar). Screw on the measuring tools with the thread tightening torque of 25Nm.  Measure the length of “X” under the braking status (the distance from the hexagon head to the planet carrier surface). Retighten the tools (with 25Nm torque) after loosening the brake. 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 31  Measure the length of “Y” (from the hexagon head to the planet carrier surface) to calculate the length difference before and after the braking, namely the piston stroke. AP-407(2 DISCS) mm AP-410(3 DISCS) mm AP-412(3 DISCS) mm AP-412(4 DISCS) mm AP-415(5 DISCS) mm AP-417(3 DISCS) mm AP-420(4 DISCS) mm Piston Stroke(mm ） = “X” – “Y” 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 32 M16×1.5×170Bolt Size M16×1.5×120Bolt Size HERGESTELLT AUS 6KT-SCHRAUBE Hexagon - headed Bolt AP AP-407/409 SACH-NR(OZ)AEL AUFTRAGS -SERIE-NR. 4. Introduction on Special Tools and Key Part Repair

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 33 Contents Features and Main Technical Parameters Introduction on Components Maintenance on ZF Drive Axle Introduction on Special Tools and Key Part Repair Maintenance Parameters

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD Maintenance Parameters  Table of ZF Drive Axle Bolt Tightening Torque and Adjustment Space NO.ComponentInstallation Position Installation of Parts Specifications of Parts Torque （ Nm ） Adjustment Space （ mm ） 1Front AxleBracket Tightening Nut Front Axle Bracket Connecting Bolt M14×40, Front Axle Wheel Hub Tightening Nut M24×80, Front Axle Wheel Hub Support Axle Bolt M14×1.5×40, Front Axle Planet Carrier Connecting Bolt Front Axle Adjustment Space of Wheel Hub Friction Slice Front Axle Adjustment Space of Sun Gear Axle

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 35  Table of ZF Drive Axle Bolt Tightening Torque and Adjustment Space NO.ComponentInstallation Position Installation of Parts Specifications of Parts Torque （ Nm ） Adjustment Space （ mm ） 8Rear AxleBracket Tightening Nut Rear Axle Bracket Connecting Bolt M14×1.5×40, Rear Axle Wheel Hub Tightening Nut Rear Axle Wheel Hub Support Axle Bolt M18×60, Rear Axle Planet Carrier Connecting Bolt M14×40, Rear Axle Adjustment Space of Wheel Hub Friction Slice Rear Axle Adjustment Space of Sun Gear Axle Maintenance Parameters  Notes: In case of any problem on ZF drive axle, please contact the local agent of Shandong Lingong or directly contact Shandong Lingong to get the permit of Shandong Lingong for maintenance. Do not dismantle without permission, otherwise Shandong Lingong will not guarantee the maintenance!

RELIABILITY IN ACTION SHANDONG LINGONG CONSTRUCTION MACHINERY CO.,LTD 36 The End Corporate vision To be a most satisfied and most recommendable brand in China’s construction machinery industry Corporate mission To provide reliable product and service making customers get persistent return with maximum value through consistent innovation