Operating Instruction Rear Axle, 4472.758.101c

OPERATING INSTRUCTIONS
AV 110, AV 133, AV 133 T
BUSES
Copyright © ZF Friedrichshafen AG
This document is protected by copyright.

Complete or partial reproduction or distribution of this document is not
permitted without the approval of ZF Friedrichshafen AG.
Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Table of Contents
1 Preface ....................................................................................................................... 4
1.1 Document overview .......................................................................................................................... 4
2 Safety ......................................................................................................................... 5
2.1 Signal words and symbols .............................................................................................................. 5
2.2 General safety instructions .............................................................................................................. 6
3 Technical Data ............................................................................................................ 8

3.1 Oil ........................................................................................................................................................... 8
3.1.1 Oil grade .............................................................................................................................................. 8
3.1.2 Oil purity ............................................................................................................................................... 8
3.1.3 Oil Quantity ......................................................................................................................................... 8
3.2 Grease ................................................................................................................................................... 8
3.3 Type plate ............................................................................................................................................. 9
4 Operation ................................................................................................................... 10
4.1 Towing a vehicle ................................................................................................................................ 10
4.2 Water contamination of the axle ................................................................................................... 10
5 Maintenance ............................................................................................................. 12
5.1 Checking oil level ............................................................................................................................... 12
5.2 Oil change ........................................................................................................................................... 13
5.2.1 Changing oil on the AV 110 and AV 133 .................................................................................... 13
5.2.2 Changing oil on the AV 133 T ........................................................................................................ 15
5.3 Breather ................................................................................................................................................ 17
5.3.1 Checking breather ............................................................................................................................. 17
5.3.2 Replacing filter (version with mounted breather) ..................................................................... 18
5.4 Change grease ................................................................................................................................... 18
6 Inspection .................................................................................................................. 19
6.1 Lifting vehicle ...................................................................................................................................... 19
6.1.1 Lifting vehicle with axle AV 110 or AV 133 ................................................................................ 19
6.1.2 Lifting vehicle with axle AV 133 T ................................................................................................. 20
6.2 Check shaft seal of the hub ............................................................................................................ 20
6.3 Checking compact bearing ............................................................................................................. 20
6.4 Check wheel studs and wheel nuts .............................................................................................. 22
7 Workshop Equipment ................................................................................................. 23

7.1 New parts ............................................................................................................................................ 23
8 Tightening Torques ..................................................................................................... 24
9 Annex ......................................................................................................................... 25
9.1 Overview of revisions ........................................................................................................................ 25
EN 4472.758.101c - 2017-03 3
Preface
1 Preface
Please read the operating instructions carefully. The operating instructions contain important information
about safety, operation, and maintenance of the ZF product. Also observe the special information provided
by the vehicle manufacturer or the body manufacturer.
Object of documentation is a ZF product. State of design acc. to date of issue.
The figures serve to illustrate the operation or the workflow and may deviate from your ZF product.
Illustrations and figures are not drawn to scale; therefore, no conclusions about size and weight can be
drawn.
As a result of type diversity, the figures contained in these operating instructions may deviate from your ZF
product as, in some instances, only the standard versions are presented as an example.
ZF Friedrichshafen AG
1.1 Document overview
The specifications listed in these documents must be observed, because they are a prerequisite for fault-
free operation of the product and for the warranty granted by ZF Friedrichshafen AG. Please get in touch
with your contact if you need binding documents.
Document no. Designation Technical information

4472.751.002 Repair Instructions (Repair stage 2) AV110
4472.751.003 Repair Instructions (Repair stage 3) AV110
4472.751.001 Repair Instructions AV 133, AV 133 T
Tab. 1
4 EN 4472.758.101c - 2017-03
Safety
2 Safety
2.1 Signal words and symbols
This document contains particularly highlighted safety instructions which are marked with one of the
following signal words depending on the severity of the danger.
DANGER
The signal word DANGER indicates a dangerous situation that, if not prevented, will lead to a severe
injury or death.
ð Information as to how the danger can be prevented.
WARNING
The signal word WARNING indicates a dangerous situation that, if not prevented, can lead to a severe
injury or death.
CAUTION
The signal word CAUTION indicates a dangerous situation that, if not prevented, can lead to a slight or
moderate injury.
The signal word NOTICE indicates a situation that, if not prevented, can lead to property damage.
ð Information as to how the property damage can be prevented.
The following symbols are additionally used:
This symbol refers to additional, safety-relevant information.
This symbol indicates information concerning special workflows, methods, application of aids, etc.
EN 4472.758.101c - 2017-03 5
Safety
2.2 General safety instructions
Read all safety instructions and information. Failure to comply with safety instructions and information may
lead to property damage, serious injuries or death.
Intended use
The ZF product is exclusively intended for the application as defined in the contract and as agreed on the
time of delivery. Any other or extended form of use does not comply with this definition of intended use.
The intended use includes compliance with this documentation and other applicable documents, in order
to avoid malfunctions and damage in operation.
The ZF product is designed and produced in line with state-of-the-art technology. The ZF product in its
delivery status is safe to operate. However, the ZF product may pose dangers if improperly used by
unauthorized, untrained and uninstructed staff or if not used according to its intended use.
Figures might deviate from the ZF product and are not drawn to scale. No conclusions can be drawn 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 genuine ZF special tools.
▪ Unauthorized changes and modifications lead to the expiry of the operator's license, warranty or
guarantee.
In case of damage, contact ZF and have the following information on the product ready:
▪ Type
▪ Parts list [BoM] number
▪ Serial number
▪ Operating hours
▪ Description of damage
Observe safety instructions, valid safety regulations and legal conditions to prevent malfunctions and
damage.
The country-specific safety regulations, accident prevention regulations and environmental protection
provisions apply additionally.
Wear safety-relevant workwear for all work. Depending on the work, also wear personal protective
equipment.
After completing the work, check correct function and functional security.
6 EN 4472.758.101c - 2017-03
Safety
Handling of ZF product
Unauthorized changes and modifications might impair functional security. Changes, modifications and
applications are only permissible upon written approval by ZF Friedrichshafen AG.
Observe the following when working on the ZF product:

▪ Secure workspace.
▪ Only carry out work at the unit when in a voltage-free state.
▪ Protect unit against being started accidentally. Attach instruction plate where it is clearly visible.
▪ Perform work when engine is switched off.
▪ Protect engine against being started accidentally. Attach instruction plate where it is clearly visible.
▪ Do not stand beneath a suspended load.
▪ Do not work on a suspended load.
▪ Only use permitted means of transport and lifting devices with sufficient load-bearing capacity.
▪ Close open tubings and hoses and avoid damage.
▪ Observe tightening torques.
▪ 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 environmental damage.
Observe the following when selecting operating supplies and aids:

▪ Health risks
▪ Environmental compatibility
▪ Material safety data sheets
Observe the following when handling operating supplies and aids:

▪ Store operating supplies and aids in suitable and correctly labeled containers.
▪ Seek medical help in case of injuries due to hot, cold or caustic operating supplies or aids.
Observe the following to protect the environment:

▪ Collect leaking operating supplies and aids in sufficiently large containers.
▪ Observe disposal regulations.
▪ Observe material safety data sheets.
EN 4472.758.101c - 2017-03 7
Technical Data
3 Technical Data
3.1 Oil
3.1.1 Oil grade
Damage to ZF product due to incorrect oil possible.

ð Only use oils listed in the valid ZF List of Lubricants.
Observe the information on the type plate.
Oils approved and listed in the ZF List of Lubricants TE-ML 12 are binding.
The latest ZF List of Lubricants can be obtained from all ZF Service Centers and viewed at www.zf.com.
3.1.2 Oil purity
The oil must not contain any visible solid impurities.
3.1.3 Oil Quantity
The quantities specified are reference values. The oil quantity after the oil level check is decisive.
Observe the information on the type plate.
Axle Comment Oil quantity in liters (approx.)

after an oil change for initial fill
after repair
AV 110, AV 133, AV 133 T 17.5 17.5
Tab. 2 Oil quantity
3.2 Grease
Hub
Axle Assembly Grease quantity in g (approx.)
AV110 Hub On each hub 90 up until 102
AV 133, AV 133 T On each hub 125 up until 150
Tab. 3 Grease quantity
Hub
Hubs are supplied filled with lubricant. Only use lubricants according to manufacturer's instructions. The
specified lubricating greases are listed in the ZF List of Lubricants: TE‑ML 12.
8 EN 4472.758.101c - 2017-03
Technical Data
3.3 Type plate
Position of the type plate

The type plate is on the axle housing.
1 Product designation
ZF Friedrichshafen AG 2 Serial number
Made in Germany 3 Parts list number
4 Transmission ratio
Type Serial-No.
1 2
5 Oil specification
Parts List No. Total Ratio / Version
6 Approx. oil quantity for initial filling
3 4
7 Number of List of Lubricants
ltr. List of lubricants
8 Customer spec. number, if known to ZF
Oil
5 6 TE-ML 7
TE-ML The following data should be quoted when making inquiries
TE-ML or undertaking repairs: 1, 2, 3
Customer´s 8
Code No.
40_010070_01
Fig. 1 Type plate
EN 4472.758.101c - 2017-03 9
Operation
4 Operation
4.1 Towing a vehicle
Before towing the vehicle, disconnect the driveline to prevent further mechanical damage. The named
parts are needed on the AV 133 and AV 133 T axles to create an oil-tight seal.
The specifications in the Operating Instructions of the vehicle manufacturer are binding.
1. Loosen (1) bolted connection.
2. Pull flange shaft (2) out of the hub and

remove it.
3. Grease 0634.303.940 [O‑ring] and insert it

into the annular groove on 4472.235.021
[Cover].
4. Insert 4472.235.021 [Cover] into the hub.
5. Fix 4472.235.021 [Cover] with two Torx

screws (1).
Tightening torque: 100 Nm
Fig. 2
4.2 Water contamination of the axle
In case of extreme influences water can penetrate into the axle. In case of normal weather and road
conditions splash water does not cause any problems.
Possible damage to ZF product due to penetrating water.

ð If water is suspected in the ZF product, check oil.
10 EN 4472.758.101c - 2017-03
Operation
If water has been detected in the axle, dismantle, clean and reassemble the compact bearing. The
procedure is described in the Repair Instructions.
Observe the following points:

▪ In the following areas do not work with high
pressure cleaner or steam cleaner:
– Hubs(1)
– Breather or breather connection (2)
– Input flange(3)
▪ Do not use washing systems with high levels of
water spraying in the areas (1), (2) and (3) e. g.
intense underbody washing.
▪ Do not drive through floods or exceptional water
accumulations.
Fig. 3 AV 133, AV 133 T
Further potential reasons for penetration of water:

▪ Missing, wrongly installed or damaged breather hose
▪ Loose or damaged breather hose connections
▪ Blocked or damaged breather
▪ Damaged or worn seals
▪ Missing or wrongly installed cover when towing the vehicle and dismantled flange shafts
▪ Driving during very severe weather conditions
For further information refer to Service Information 08/09.
EN 4472.758.101c - 2017-03 11
Maintenance
5 Maintenance
5.1 Checking oil level
▪ At least once a year

▪ When putting the vehicle into operation
▪ In case of new or repaired axles
Requirements:
▪ Axle is installed horizontally into the vehicle
▪ Vehicle is in horizontal position.
▪ Air pressure of all tires corresponds to the maximum value.
Observe the environmental regulations (refer to section General safety instructions, page 6).
1.
Risk of burn injuries due to contact with hot

surfaces.
Slight or moderate injury possible.
ð Wear protective gloves.
Thoroughly clean the screw plug oil level

check.
2. Place a suitable container under the screw

plug oil level check.
3. Fig. 4 Oil level check
1 Screw plug for ATF level check

Risk of burns due to contact with hot oil.
ð Wear protective goggles.
Remove the screw plug oil level check (1)

and remove the O‑ring.
In case of the version with mounted
breather, slight overpressure can build
up in the axle.
4. Check the oil level. The oil level must

correspond to the bottom edge of the oil level
check hole.
12 EN 4472.758.101c - 2017-03
Maintenance
If the oil level is not correct, fill or drain

oil accordingly. Further information
(refer to section Oil change, page 13).
5. Renew O‑ring on the screw plug oil level

check (1).
6. Screw in screw plug oil level check (1) and

tighten.
5.2 Oil change
5.2.1 Changing oil on the AV 110 and AV 133
Requirements:
▪ The axle is installed into the vehicle horizontally.
▪ Axle is at operating temperature.
For intervals refer to ZF List of Lubricants TE-ML 12
EN 4472.758.101c - 2017-03 13
Maintenance
Fig. 5 AV133
1 Oil level screw plug 2 Oil drain screw plug

3 Oil fill screw plug
1.
Risk of burn injuries due to contact with hot surfaces.

Thoroughly clean all screw plugs.
2. Place a suitable container under the oil drain screw plugs.
3.

Remove screw plug oil filling (3) and O‑ring.

In case of the version with mounted breather, slight overpressure can build up in the axle.
14 EN 4472.758.101c - 2017-03
Maintenance
4. Remove screw plug oil level (1) and O‑ring.
5. Remove screw plugs oil drain (2) and O‑ring.
6. Completely drain oil into the containers.
7. Renew O-rings on all screw plugs.
8. Screw in screw plugs oil drain (2) and tighten.

9.
The use of a non-approved lubricant can lead to property damage.

ð Only use lubricant from the currently valid ZF List of Lubricants.
Slowly fill in oil at the oil filling hole until the bottom edge of the oil level hole (1) is reached.
10. Check oil level after some minutes and correct if necessary.
11. Screw in screw plug oil filling (3) and tighten.

12. Turn in screw plug oil level (1) and tighten.

5.2.2 Changing oil on the AV 133 T
Requirements:
▪ The axle is installed into the vehicle horizontally.
▪ Axle is at operating temperature.
EN 4472.758.101c - 2017-03 15
Maintenance
Fig. 6 AV 133 T
1 Screw plug oil level 2 Oil drain screw plug

3 Oil fill screw plug
1.
Risk of burn injuries due to contact with hot surfaces.

Thoroughly clean all screw plugs.
2. Place a suitable container under the oil drain screw plugs.
3.

Remove screw plug oil filling (3) and O‑ring.

In case of the version with mounted breather, slight overpressure can build up in the axle.
16 EN 4472.758.101c - 2017-03
Maintenance
4. Remove screw plug oil level (1) and O‑ring.
5. Remove screw plugs oil drain (2) and O‑ring.
6. Completely drain oil into the containers.
7. Renew O-rings on all screw plugs.
8. Screw in screw plugs oil drain (2) and tighten.

9.
The use of a non-approved lubricant can lead to property damage.

ð Only use lubricant from the currently valid ZF List of Lubricants.
Slowly fill in oil at the oil filling hole until the bottom edge of the oil level hole (1) is reached.
10. Check oil level after some minutes and correct if necessary.
11. Screw in screw plug oil filling (3) and tighten.

12. Turn in screw plug oil level (1) and tighten.

5.3 Breather
5.3.1 Checking breather
During maintenance work on the axle check breather.
1. Check breather for damage.

Check tubes on the breather for:
▪ Chafe marks
▪ Kinks
▪ Bottlenecks
▪ Cracks and holes
2. Check to ensure that end of breather hose is in a dust-free and dry room.
Repair damage.
Change position of end of breather hose.
Check oil for water contamination.
EN 4472.758.101c - 2017-03 17
Maintenance
5.3.2 Replacing filter (version with mounted breather)
During maintenance work on the axle, replace the breather filter.
1. Press fixing clamps on the bracket apart and

pull the cover (1) from the bracket.
2. Remove filter.
3. Apply light coat of grease to O-ring on filter.
4. Insert new filter into the bracket with the

handle pointing outwards until contact is
obtained.
5. Push the cover (1) onto the bracket, until the

fixing clamps engage.
Fig. 7 AV 133 Breather
5.4 Change grease
The grease in the hub can only be changed, if the hub is removed and completely dismantled. The
procedure is described in the Repair Instructions (see document overview).
Change the grease:

▪ If grease is leaking on the shaft seal on the brake disk side
▪ If the brake has overheated. This is the case, for example, with burnt pressure piece bellows.
▪ After the regular interval
18 EN 4472.758.101c - 2017-03
Inspection
6 Inspection
6.1 Lifting vehicle
When the vehicle is lifted on the axle, permitted max. axle load is 10 t. Do NOT position lifting jacks
on other points than those marked:
6.1.1 Lifting vehicle with axle AV 110 or AV 133
Fig. 8 AV 133
Depending on the lifting jack point, the contact surface of the lifting jacks must have the following
minimum sizes:
▪ On the small lifting jack points (2) 35 cm2, e.g. 5 cm x 7 cm or Ø 7 cm
▪ On the large lifting jack point (1) 160 cm2, e.g. 40 cm x 4 cm
EN 4472.758.101c - 2017-03 19
Inspection
6.1.2 Lifting vehicle with axle AV 133 T
Fig. 9 AV 133 T
Ensure that the contact surface (1) of the lifting jacks is at least 35 cm2, e. g. 5 cm x 7 cm or Ø 7 cm.
6.2 Check shaft seal of the hub
When exchanging the brake disk, check the shaft seal at the brake disk side.
1. A slight grease collar of approx. 1 mm is permitted.
Check shaft seal at the brake disk side for grease leakage.
If grease is leaking, check the compact bearing.
6.3 Checking compact bearing
Check axial play of the compact bearing in case of:

▪ ABS-error message
▪ Increasing noise development with increasing speed
20 EN 4472.758.101c - 2017-03
Inspection
▪ Exchange of brake disk

▪ Repairs on the brake
Requirements:
▪ The wheel is lifted.
▪ The brake linings do not make contact with the brake disk.
1. Loosen wheel nuts and remove the wheel.
2. Loosen screws on the flange shaft.
3. Pull flange shaft out of the hub (2) and

remove it.
4. Fix magnetic stand (1) on the hub (2).
5. Place dial gauge (3) on the front side surface

of the hub carrier.
6. Push hub (2) towards the axle with both

hands and rotate it by approx. 20° to 30° in
Fig. 10
both directions several times.
7. Set dial gauge (3) to zero.
8. Use both hands to pull hub (2) away from the

axle and rotate it approx. 20° to 30° in both
directions several times.
9. Read axial play on the dial gauge (3).
10. Repeat measurement three times. Between

the individual measurements rotate the hub
(2) several times in both directions.
11. Calculate mean value of the four values. The

result is the axial play of the compact
bearing.
In case of an axial play of more than
0.20 mm change compact bearing. For
the procedure refer to the Repair
Instructions (refer to section Document
overview, page 4).
EN 4472.758.101c - 2017-03 21
Inspection
6.4 Check wheel studs and wheel nuts
During maintenance work on the axle check wheel studs and wheel nuts.
Do not oil or grease wheel studs or wheel nuts.
1. Check wheel studs and wheel nuts for corrosion.

Exchange severely corroded wheel studs and wheel nuts. For the procedure refer to the Repair
Instructions.
22 EN 4472.758.101c - 2017-03
Workshop Equipment
7 Workshop Equipment
7.1 New parts
The following new parts are not listed in the spare parts catalog.
Order no. For axle Quantity Designation Chapter/Section

4472.235.021 AV 133, AV 133 T 2 Cover (refer to section Towing a vehicle,
page 10)
0634.303.940 AV 133, AV 133 T 2 O‑ring (suitable for (refer to section Towing a vehicle,
cover) page 10)
0501.330.611 AV 110, AV 133, 1 Filter incl. O‑ring (refer to section Replacing filter (version
AV 133 T with mounted breather), page 18)
Tab. 4
EN 4472.758.101c - 2017-03 23
Tightening Torques
8 Tightening Torques
Designation Tightening torque Measuring Comment

instrument Chapter/Section
Torx screws M18 x 1.5 x 45 100 Nm Torque wrench Securing of cover 4472.235.021
▪ Towing a vehicle, page 10

Screw plug oil filling 70 Nm Torque wrench ▪ Checking oil level, page 12
M24 x 1.5
Oil drain screw plug 130 Nm Torque wrench ▪ Changing oil on the AV 110 and
M36 x 1.5 AV 133, page 13
▪ Changing oil on the AV 133 T, page 15
Oil fill screw plug M24x1.5 70 Nm Torque wrench ▪ Changing oil on the AV 110 and
AV 133, page 13
Screw plug oil level M24 x 1.5 70 Nm Torque wrench ▪ Changing oil on the AV 110 and
AV 133, page 13
24 EN 4472.758.101c - 2017-03
Annex
9 Annex
9.1 Overview of revisions
index Date of issue Initiator Chapter/Section Comment

a 09.2015 — — First issue
b 09.2016 — All Document no. corrected in footer and on cover page.
Oil change Editorial adaptations implemented.
Oil grade Editorial adaptations implemented.
c 03.2017 — — AV 133 T added.
All Editorial adaptations implemented.
Tab. 5
EN 4472.758.101c - 2017-03 25
ZF Friedrichshafen AG
ZF Aftermarket
Donaustraße 71
94034 Passau
Deutschland · Germany
Telefon/Phone +49 851 494-0
www.zf.com/contact
EN 4472.758.101c - 2017-03

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OPERATING INSTRUCTIONS

AV 110, AV 133, AV 133 T

This document is protected by copyright.

3 Technical Data ............................................................................................................ 8

7 Workshop Equipment ................................................................................................. 23

8 Tightening Torques ..................................................................................................... 24

Object of documentation is a ZF product. State of design acc. to date of issue.

1.1 Document overview

Document no. Designation Technical information

2.1 Signal words and symbols

The following symbols are additionally used:

This symbol refers to additional, safety-relevant information.

2.2 General safety instructions

Installation, commissioning, maintenance and repair

Observe the following points:

Observe the following when working on the ZF product:

Observe the following when working on the ZF product:

Operating supplies and aids

Observe the following when selecting operating supplies and aids:

Observe the following when handling operating supplies and aids:

Observe the following to protect the environment:

3.1.1 Oil grade

Damage to ZF product due to incorrect oil possible.

Observe the information on the type plate.

3.1.2 Oil purity

The oil must not contain any visible solid impurities.

3.1.3 Oil Quantity

Axle Comment Oil quantity in liters (approx.)

3.3 Type plate

Position of the type plate

Fig. 1 Type plate

4.1 Towing a vehicle

1. Loosen (1) bolted connection.

2. Pull flange shaft (2) out of the hub and

3. Grease 0634.303.940 [O‑ring] and insert it

4. Insert 4472.235.021 [Cover] into the hub.

5. Fix 4472.235.021 [Cover] with two Torx

4.2 Water contamination of the axle

Possible damage to ZF product due to penetrating water.

Observe the following points:

Fig. 3 AV 133, AV 133 T

Further potential reasons for penetration of water:

For further information refer to Service Information 08/09.

5.1 Checking oil level

▪ At least once a year

Risk of burn injuries due to contact with hot

Thoroughly clean the screw plug oil level

2. Place a suitable container under the screw

3. Fig. 4 Oil level check

1 Screw plug for ATF level check

Remove the screw plug oil level check (1)

4. Check the oil level. The oil level must

If the oil level is not correct, fill or drain

5. Renew O‑ring on the screw plug oil level

6. Screw in screw plug oil level check (1) and

5.2 Oil change

5.2.1 Changing oil on the AV 110 and AV 133

For intervals refer to ZF List of Lubricants TE-ML 12

1 Oil level screw plug 2 Oil drain screw plug

Risk of burn injuries due to contact with hot surfaces.

Thoroughly clean all screw plugs.

2. Place a suitable container under the oil drain screw plugs.

Risk of burns due to contact with hot oil.