ZF-ECOSPLIT 16 S 251 Repair Manual 1316751102a – PDF DOWNLOAD

Reparaturanleitung Repair Manual Manuel de Réparation Manual de Reparaciones Manuale di Riparazione

16 S 251

1316 751 102a

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Subject to alterations in design

Copyright by ZF The present documentation is protected by copyright.

Any kind of reproduction or dissemination in whatever form that does not exclusively correspond to documentation objectives will be prosecuted if no prior approval by ZF Friedrichshafen AG was granted.

Printed in Germany ZF Friedrichshafen AG, MC-C / 1998-11

Edition: 2007-08

1316 751 102a

16 S 251

Contents Page

Preface........................................................................................................................................................

Important information.................................................................................................................................

Instructions for carrying out repairs............................................................................................................

Tightening torques ......................................................................................................................................

Consumables ...............................................................................................................................................

Adjustment data ..........................................................................................................................................

Table of springs ...........................................................................................................................................

Special tools ................................................................................................................................................

5 6 7 9 11 12 17 18

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Components / range-change ..................................................................................................................... 1- 1 Plastic pipes ................................................................................................................................................ 1- 1 Output flange .............................................................................................................................................. 1- 2 Cover........................................................................................................................................................... 1- 3 5/2-way valve .............................................................................................................................................. 1- 5 Shift cylinder............................................................................................................................................... 1- 6 Housing....................................................................................................................................................... 1- 8 Planetary drive ............................................................................................................................................ 1-11

2 2.1 2.2

Servoshift ................................................................................................................................................... 2- 1 Non-integrated version................................................................................................................................ 2- 1 Integrated version........................................................................................................................................ 2- 2

3 3.1 3.2 3.3 3.4 3.5 3.6

Shift mechanism ........................................................................................................................................ 3- 1 Double “H” shift pattern ............................................................................................................................. 3- 1 Superimposed “H” shift pattern .................................................................................................................. 3- 4 Shift system for integrated Servoshift......................................................................................................... 3- 9 Shift pattern without Servoshift .................................................................................................................. 3-14 Shift pattern with Servoshift ....................................................................................................................... 3-18 Assembling complete shift housing ............................................................................................................ 3-22

4 4.1 4.2 4.3 4.4

Components / clutch housing ................................................................................................................... 4- 1 Release fork and connection plate............................................................................................................... 4- 1 Pump housing with integral pump .............................................................................................................. 4-10 Clutch housing ............................................................................................................................................ 4-11 Removing components................................................................................................................................ 4-13

5 5.1 5.2 5.3

Components / centre housing ................................................................................................................... 5- 1 Splitter (GV) cylinder ................................................................................................................................. 5- 1 Splitter shift rail .......................................................................................................................................... 5- 2 Removing shafts and components............................................................................................................... 5- 4

16 S 251

Contents Page

6

Input shaft.................................................................................................................................................. 6- 1

7

Mainshaft................................................................................................................................................... 7- 1

8

Layshaft...................................................................................................................................................... 8- 1

9

Synchronizer.............................................................................................................................................. 9- 1

10 10.1 10.2 10.3 10.4

Adjusting shafts......................................................................................................................................... 10-1 Mainshaft .................................................................................................................................................... 10-1 Input shaft and connection plate.................................................................................................................. 10-2 Layshaft....................................................................................................................................................... 10-3 Planetary drive ............................................................................................................................................ 10-4

11 Compressed air test................................................................................................................................... 11-1 11.1 Compressed air test for piston and splitter cylinder .................................................................................... 11-1 11.2 Compressed air test on breather .................................................................................................................. 11-1

Repair manual NOTE: If clamping fixture 1X56 137 944 is used for dismantling the transmission, remove the reverse gear cover before attaching the clamping fixture.

When reassembling the transmission, insert the reverse gear wheel before fitting the shaft set.

Then install the reverse idler gear pin.

Preface This manual is intended for skilled personnel who have been trained by ZF Friedrichshafen AG to carry out maintenance and repair work on ZF products.

This manual deals with the standard ZF product in accordance with the state of development on the date of issue.

However, due to continuing development of the product, repair work might require work practices and test or adjustment data which are not contained in this manual.

We therefore recommend that work done on your ZF product is carried out only by skilled mechanics who have had their practical and theoretical knowledge updated on a regular basis at our After-Sales Service training courses.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Well-trained personnel 2. Specified equipment, e.g. special tools 3. Genuine ZF spares, to our latest specifications

All work performed at these service points is carried out conscientiously and with care.

Repair work carried out at ZF service points is guaranteed in accordance with the prevailing contractual conditions.

ZF FRIEDRICHSHAFEN AG Division Comm. Vehicle/Special Transmissions Service Werk 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726

Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner, together with follow-on costs caused by such work, is excluded from the contractual guarantee agreement.

This also applies where genuine ZF spares have not been used.

5

Important information SAFETY NOTICE

GENERAL INFORMATION

Companies who repair ZF units are responsible for their own work safety.

Read this manual carefully before starting any tests or repair work.

To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to.

Before starting work, mechanics must familiarize themselves with these regulations.

Personnel required to carry out repairs on ZF products must receive appropriate training in advance. It is the responsibility of each company to ensure that their repair staff is properly trained.

The following safety instructions appear in this manual:

NOTE Refers to special processes, techniques, data, use of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional working practices could damage the product. ! DANGER This is used when lack of care could lead to personal injury or death.

CAUTION Pictures, drawings and components do not always represent the original object, but are used to illustrate working procedures.

Pictures, drawings and components are not to scale and no information about size and weight should be inferred (even within a complete illustration).

Always follow the working steps as described in the text.

After completion of repair work and testing, skilled staff must satisfy themselves that the product is functioning correctly. ! THREATS TO THE ENVIRONMENT !

Lubricants and cleaning agents must not be allowed to enter the soil, ground water or sewage system.

• Ask your local environment agency for safety information on the relevant products and adhere to their requirements.

• Collect used oil in a suitably large container.

• Dispose of used oil, dirty filters, lubricants and cleaning agents in accordance with environmental protection guidelines.

• When working with lubricants and cleaning agents always refer to the manufacturer’s instructions.

CAUTION The transmission must NOT be hung on the input shaft NOR on the output flange.

6

Instructions for carrying out repairs In any cases of doubt always turn to the the relevant department within ZF After-Sales Services for advice.

After removing the transmission from the vehicle clean thoroughly before opening.

Pay particular attention to the corners and angles of housings and covers when cleaning.

Parts held on with Loctite can be slightly loosened if warmed with a hot air blower.

GASKETS, LOCKING PLATES Parts which cannot be removed without being damaged must always be replaced with new parts (e.g. gaskets and locking plates).

SHAFT SEALS Always change shaft seals with rough, ripped or hardened packing washers. Seal contact surfaces must be totally clean and in perfect condition.

CLEANING PARTS Remove the old remains of gaskets on all gaskets.

Carefully remove burrs or other similar patches of roughness using a oil-stone Lube bores and grooves must be free of anti-corrosion agents and foreign matter, check that they can move without encountering any problems.

Carefully cover opened transmissions to prevent the entry of foreign matter..

RE WO RK I NG Rework may only be carried out on the seal contact surfaces using plunge-cut grinding, never use an emery cloth. Ensure that there are no traces of grinding traces or rifling from grinding.

If rework is needed on distance washers, shims etc. because of clearance settings, ensure that the reworked areas contain no face runout and have the same surface quality.

REUSING PARTS TRANSMISSION ASSEMBLY Parts such as ball or roller bearings, multi-discs, thrust washers etc., must be inspected by a competent person, who should decide whether or not they can be re-used.

Replace parts which are damaged or have suffered from excessive wear.

Find a clean site to assemble the transmission. Gaskets are installed without the use of sealing compound or grease. When measuring silicon-coated gaskets, take care not to include the silicon layer in the measurement.

During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual.

7

Instructions for carrying out repairs B E AR I NG S If the bearings are filled while hot, these should be warmed up accordingly (e.g. in a heating cabinet).

The temperature should be approx. 85 °C and may not exceed 120 °C. All bearings must be coated with transmission oil after assembly.

S EALI NG If a sealing agent* is to be used for carrying out sealing, comply with the manufacturer’s directions for use.

Apply a thin layer of sealing agent to the surfaces and spread evenly. Do not allow sealing to enter oil ducts and bores. On oil-carrying ducts and bores wipe off the sealing agent on the surfaces to be sealed near apertures to ensure that no sealing agent penetrates the oil feeds when the surfaces are sealed.

d) Duo shaft seals have two packing washers. The dust-proof packing washer (X) must face outwards.

X

e) Fill the gap between the packing washers so it is 60% filled with grease (use a grease e.g. produced by Aral such as Aralub HL2 or by DEA such as Spectron FO 20). f) If possible heat shaft seal bores to between 40 and 50°C (this makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan.

RE TAI NI NG AG E NT S Retaining agents* may only be used in places as specified in the parts list.

Always comply with manufacturer’s directions for use when using retaining agents (e.g. Loctite).

During assembly, comply with all adjustment data, checking data and tightening torques.

SHAFT SEALS a) Apply a light coat of sealing agent on outer edge of shaft seals with “steel surround”. b) Never apply sealing agent to shaft seals with “rubber surround” but apply a thin coat of Vaseline 8420 to the outer edge or wet with a lubricant, e.g. a water-soluble, concentrated washing-up liquid (e.g.

Pril, Coin, Palmolive). c) Shaft seals with steel and rubber surrounds should be treated on the outer edge of the rubber surround as described above in section b).

TRANSMISSION OIL After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TE-ML (refer to identification plate) which are available from any ZF After-Sales Service Point.

After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.

* refer to expendable material

8

Tightening torques Tightening torques for nuts and bolts, extract from ZFN 148 This Standard applies for bolts to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts to DIN 934.

This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12.

Surface condition of bolts: heat-treated blackened finish and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.

This Standard contains data on tightening torques (MA) for bolts in strength categories 8.8, 10.9 wrench.

NOTE Divergent tightening torques are listed separately in the Repair Manual.

Metric coarse pitch thread

Metric coarse pitch thread

Size

Size

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

Bolt Nut

Tightening torque MA (Nm) for 8.8 10.9 8 10

12.9 12

M 4 M 5 M 6

2,8 5,5 9,5

4,1 8,1 14

4,8 9,5 16,5

M 8x1 M 9x1 M 10 x 1

24 36 52

36 53 76

43 62 89

M 7 M 8 M 10

15 23 46

23 34 68

28 40 79

M 10 x 1,25 M 12 x 1,25 M 12 x 1,5

49 87 83

72 125 122

84 150 145

M 12 M 14 M 16

79 125 195

115 185 280

135 215 330

M 14 x 1,5 M 16 x 1,5 M 18 x 1,5

135 205 310

200 300 440

235 360 520

M 18 M 20 M 22

280 390 530

390 560 750

460 650 880

M 18 x 2 M 20 x 1,5 M 22 x 1,5

290 430 580

420 620 820

490 720 960

M 24 M 27 M 30

670 1000 1350

960 1400 1900

1100 1650 2250

M 24 x 1,5 M 24 x 2 M 27 x 1,5

760 730 1100

1100 1050 1600

1250 1200 1850

M 27 x 2 M 30 x 1,5 M 30 x 2

1050 1550 1500

1500 2200 2100

1800 2550 2500

Edition: August 1991 / checked 1997 Index: 98-01-12

9

Tightening torques Screw plugs DIN 908, 910 and 7604

Union screws DIN 7643

The screw plug tightening torques MA were determined according to DIN 7604, for screwing into steel, grey cast, and aluminium alloys.

The values are based on experience, and are intended as reference values for the designer.

The values for the tightening torque MA shall also be used for screw plugs according to DIN 908 and DIN 910, as the thread geometries are almost identical.

General rule: Screw/bolt class 5, ZFN 148-1 Screw/bolt material: steel acc. to DIN 7604. Surface condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled

The tightening torques MA were determined for screwing into steel, grey cast and aluminium alloys.

The values are based on experience and are intended as reference values for the designer.

General rule: screw/bolt class 5, ZFN 148-1 Material 9SMnPb28K acc. to DIN 1651 Surface conditions: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled

Screw plugs (DIN 908, 910, 7604) Dimensions

M 8x1 M 10 x 1 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 26 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M 33 x 2 M 36 x 1.5 M 38 x 1.5 M 42 x 1.5 M 42 x 2 M 45 x 1.5 M 45 x 2 M 48 x 1.5 M 48 x 2 M 52 x 1.5 M 60 x 2 M 64 x 2

Union screws (DIN7643)

Tightening torque screwed into steel/grey cast Al alloy 20 25 / 30* 35 35 40 50 55 60 / 80* 70 80 / 105* 80 100 / 130* 95 120 130 140 150 145 160 150 170 160 180 195 205

10 15 / 20* 25 25 30 35 45 50 / 65* 60 70 / 90* 70 90 / 130* 85 110 115 120 130 125 140 130 145 135 150 165 175

Pipe outer diameter

Thread

Tighteningtorque MA in Nm

4-5

M8x1

30

6

M 10 x 1

35

8

M 12 x 1.5

40

10

M 14 x 1.5

40

12

M 16 x 1.5

45

15

M 18 x 1.5

50

18

M 22 x 1.5

60

22

M 26 x 1.5

90

28

M 30 x 1.5

130

35

M 38 x 1.5

140

* DIN 7604 Form C

Status October 1995 10

16 S 251

Description ZF reference no.

Consumables

Name

Approx. quantity

Application

Remarks

Sealing compound 0666 690 017

Loctite Nr. 241

0,25 g 5g 300 mm3

cover breather articulation bolt

shift system selector housing planetary range

Sealing compound 0666 690 022

Loctite Nr 262

120 mm3

threaded insert M10, M12

GP-housing

Sealing compound 0666 790 017

Wevo-L100 A

6g

shaft sealing ring

connection plate

Sealing compound 0666 790 033

Loctite Nr. 574

1g 1g

M10x70 M10x140 pump cover sealing plug sealing cover

trans.-housing trans.-housing

6 mm3 80 mm3 Grease 0671 190 016

Vaseline 8420

Grease 0671 190 050

Olista Longtime 3EP

Grease 0750 199 001

for example: Spectron FO 20

Anti-corrosive oil 0750 199 008

for example: Renolin MR 40 Z

pulse sensor IT planet carrier

slightly grease vulcanized sheathing of shaft sealing rings

2g

bush

connection plate

4g 5g 5g 5g 3g 6g

bearing inner ring scraper bearing bush cap collar double u-packing sealing ring for general assembly

main shaft shift turret Ausleger GV-shift system GV-shift system GP-shift system

0,50 ml

external rotor

pump shaft

NOTE: Inquire about the size of bundles that can be delivered before placing any orders!

Index: 98-01-12

11

Adjustment data

16 S 251

Description

Tolerance

Measuring device

Remarks

01. Axial play on layshaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on output end.

02. Combined axial play of mainshaft and input shaft

0.0 - 0.10 mm

Depth gauge or dial gauge

Centre bearings (zero play) and measure play. Adjust using shims on roller bearing outer race on input shaft.

03. Axial play / prestress of split ring on input shaft and mainshaft (only in older version)

- 0.05 to + 0.05 mm

Micrometer or feeler gauge

Always use correct tool.

04. Insertion depth for shaft seal in output flange cover

12.5 + 1.0 mm

Depth gauge and/or drift 1X56 137 124

Measure depth of insertion between outside of cover and face of shaft seal. If drift is used with ring, depth is automatically given (must be flat).

05. Axial play on ball bearing in cover (range-change)

0 - 0.10 mm

Depth gauge/sliding caliper

Adjust using appropriate shims in cover.

06. Axial play on helical gear on input shaft

Min. 0.20 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

07. Axial play on helical gears on mainshaft

Min. 0.20 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

08. Axial play on 4th-speed helical gear

Min. 0.05 mm

Depth gauge or feeler gauge

Not adjustable. Measure as check only.

09. Axial play on circlips on layshaft and mainshaft

0 - 0.05 mm

Micrometer or feeler gauge

Use appropriate circlip.

10. Axial play of reverse idler gear

0.4 - 1.10 mm

Feeler gauge

Not adjustable. Measure as check only.

11. Permitted axial play on planet gears in planet carrier

0.4 to 1.30 mm

Feeler gauge

Tolerance includes permitted wear on thrust washers.

If wear limit exceeded exchange thrust washers

12

16 S 251

Description

Adjustment data

Tolerance

12. Wear limit for synchronizer ring and clutch body, measured between flat surfaces of ring and body with cones firmly nested together.

Measuring device

Remarks

Feeler gauge

Exchange synchronizer ring and/or clutch body if dimension too small

4-gear section and splitter Range-change

0.80 mm

13. Wear limit for 1st/2nd gear synchronizer parts, measured between outer ring and clutch disc, measured with cones nested firmly together and force F = 50 N applied on the outer ring.

1.5 mm

Feeler gauge

Exchange intermediate ring and/or outer ring and inner ring if wear limit is excluded.

14. Max. permitted play on fulcrum pads in sliding sleeves

0.6 - 1.2 mm

Feeler gauge

Exchange if play is excessive

15. Adjusting mainshaft and determining thickness of ring and shim

+ 0.07 to - 0.08 mm (Shim) 4.6 -0.4 mm (Ring)

Depth gauge

Measure and determine thickness of shim first. Then, measure and select ring.

16. Temperature for shrinkfitting helical gears onto layshaft

160 - 180°C

Temperature probe

Gears and shaft seats must be free of oil and grease during assembly

17. Tightening torque for breather

10 Nm

Torque wrench

18. Tightening torque for M12 x 1.5 screws in housing

30 Nm

Torque wrench

Use new seal rings

19. Tightening torque of union screws for plastic pipes

35 Nm

Torque wrench

Use new seal rings

1.20 mm

13

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