Output hubs, internal gears, the differential, the input pinion and three brake versions (Simplex, Servo and BHF) are walked from teardown to reassembly in this 130-page ZF AP-R 715 repair manual for the planetary steering axle, OEM number 5871 419 002. Disassembly and assembly take up the bulk of the book, backed by illustrated tool tables that tie each ZF special tool to the input, differential, output or brake job it serves. Gleason contact-pattern examples show drive and coast sides as they should look, so you can set pinion distance and fit the 100% locking slide before the housing closes. Hold axial clearance at 0.2 mm, and torque the M24 x 1.5 drain and filler plugs to 70 Nm. Guess a shim, and you buy the bevel set twice. Bookmarked and text-searchable, the file also prints cleanly, so the pages can sit on your bench and soak up gear oil.
What's Inside This ZF AP-R 715 Manual
| System | Pages | Key Topics |
|---|---|---|
| Information to the Repair Instructions | 2 | |
| Preface | 3 | |
| General | 4 | |
| Structure of the Service Manual | 5 | Work Safety |
| Lubrication and Maintenance Instructions | 6-7 | Oil Quality, Oil Change, Grease Lubrication Points, Breather, Oil Level Check, Brake Oil |
| Technical Data and Setting | 8 | Axle Arrangement, Differential Types, Oil Filling Volume |
| Examples of Gear-Tooth-Contact Patterns | 9-10 | Gleason Gear-Tooth System, Coast Side, Drive Side, Pinion Distance |
| Lettering of the Type Plate | 11 | Axle Type, Serial Number, Parts List Number |
| Conversion Table | 12 | Length, Mass, Torque |
| Denomination of Standard Dimensions | 13 | Mass, Force, Work |
| Torque Limits for Screws | 14 | Metric ISO-standard Thread, Metric ISO Fine Thread, Friction Coefficient |
| List of Tools for Disassembly and Assembly | 15-21 | Assembly Carriage, Hot-Air Blower, Clamping Fork, Socket Spanner, Adjusting Screws, Puller Tools |
| Illustrated Tool Tables | 22-31 | Input, Differential, Axle Casing, Output, M-Disc Brake, Brake |
| Disassembly of the ZF-Axle | 32-60 | Axle Versions, Standard Version, Hydr. Simplex-Brake, BHF-Brake, Axle Transmission Case, Output |
| Assembly of the ZF-Axle | 61-85 | Differential, Input Pinion, Locking Slide, Hub, Internal Gear, Sun Gear Shaft |
| Axle Equipment with Flange Brake | 86-89 | Hydr. Simplex-Brake, Hydraulic Servo-Brake, BHF-Brake, Brake Lining Wear Measurement, Emergency Towing |
| Hydraulic-Simplex-Brake | 90-99 | Slack Adjuster, Wheel Cylinders, Brake Shoes, Brake Drum, Brake Anchor Plate, Tension Springs |
| Hydraulic-Servo-Brake | 100-130 | Resetting Device, Wheel Cylinders, Brake Shoes, Brake Drum, Piston, Shaft Sealing Ring |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque (M24 x 1,5) for filling- or control screw | 70 Nm | p. 6 |
| Tightening torque (M24 x 1.5) for drain plug | 70 Nm | p. 7 |
| Backlash (Pinion/Crown wheel) | 0.15 ... 0.27 Nm | p. 8 |
| Axial clearance | 0.2 mm | p. 62 |
| Tightening torque (cylindrical screws) | 68 Nm | p. 63 |
| Planetary carrier cylindrical bolt tightening torque | 32 Nm | p. 85 |
| Oil filling volume - Axle casing | 3.5 - 4.0 litres | p. 8 |
| Oil filling volume - per planetary drive | 0.3 - 0.4 litres | p. 8 |
| Oil filling volume - axle transmission case | 1.0 litre | p. 8 |
| Rolling moment - input pinion support | 1.5 - 2.5 Nm | p. 8 |
| Rolling moment - differential support | 1.0 - 4.0 Nm | p. 8 |
| Tightening torque - input flange | 400 Nm | p. 8 |
ZF AP-R 715 Common Problems This Manual Covers
ZF AP-R 715 axle casing and planetary drive oil level low at the control screw check
Check oil level at the control screw following the procedure on page 6. Fill the axle casing to 3.5 to 4.0 litres and each planetary drive to 0.3 to 0.4 litres (depending on version) per page 8. Check the breather, then torque the M24 x 1.5 filling and control screws to 70 Nm.
Manual Section: Lubrication and Maintenance Instructions p. 6Crown wheel and input pinion gear-tooth contact pattern off on drive side or coast side
Check the drive side and coast side patterns against the Gleason examples on page 9, then correct the pinion distance as shown. Measure input pinion support rolling moment without the shaft sealing ring against 1.5 to 2.5 Nm, per page 8. Torque the input flange to 400 Nm before rechecking backlash.
Manual Section: Examples of Gear-Tooth-Contact Patterns p. 9Hub and internal gear reassembled on planetary drive, sun gear shaft axial play out of range
Torque the internal gear locking bolts to 90 Nm following page 83. Measure sun gear shaft axial play and set it to 0.3 to 0.6 mm as described on page 84. Tighten the planetary carrier cylindrical bolts to 32 Nm per page 85. Fill each planetary drive with 0.3 to 0.4 litres of oil afterward.
Manual Section: Assembly of the ZF-Axle p. 84Differential disc pack axial clearance and differential support rolling moment out of spec
Measure disc pack axial clearance during differential assembly and set it to 0.2 mm following page 62. Torque the M10/10.9 cylindrical screws to 68 Nm as shown on page 63. Check differential support rolling moment against 1.0 to 4.0 Nm from page 8, and correct the setting if it falls outside that range.
Manual Section: Assembly of the ZF-Axle p. 62Worn brake linings on flange brake with release play approaching the wear limit
Measure release play using the brake lining wear procedure on page 125. A new brake reads 1.0 to 1.4 mm; at 2.0 mm the linings have hit the maximum wear limit value, so renew them. Inspect brake shoes and brake drum while the brake is apart, following the repair steps for your brake version.
Manual Section: Brake lining wear measurement p. 125Frequently Asked Questions
How do I reset the AP-R 715 brake adjustment?
To reset the brake, jack up the vehicle so the wheel turns freely. Tighten the self-locking bolt (WAF 17) in the expansion wedge clockwise until the brake drum cannot be turned by hand, then unscrew the bolt until the wheel turns without audible dragging. For detailed steps, refer to page 94. p. 94
What is the torque specification for the AP-R 715 resetting wheel bolt?
The tightening torque for the resetting device bolt is 90 + 10 Nm. This is specified for the brake anchor plate assembly. p. 96
How do I adjust the ZF AP-R 715 brake shoes?
Brake shoe adjustment is performed by setting the brake control cables so they do not drag in the drum when the wheel is rotated. After installation, the hand brake lever must be tightened according to the vehicle manufacturer's instructions, ensuring wheels permit uniformly heavy turning. p. 94
What is the oil filling volume for the ZF AP-R 715 axle components?
The oil filling volume depends on the component: the axle casing requires approximately 3.5 to 4.0 litres, each planetary drive requires 0.3 to 0.4 litres, and the axle transmission case requires 1.0 litre. p. 8
What is the tightening torque for the input flange bolt on the ZF AP-R 715?
The tightening torque for the input flange bolt (depending on version, cylindrical or hexagon bolt M20x1.5/10.9) is 400 Nm. p. 8
Is this ZF AP-R 715 manual a download or a disc?
A single searchable PDF file of 130 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Is printing allowed for this ZF AP-R 715 repair manual?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Reviews
There are no reviews yet.