ZF-Ecosplit Synchromesh Transmission 12-speed Repair Manual 1325751101 – PDF DOWNLOAD

Reparaturanleitung Repair Manual Manuel de Reparation Manual de Reparaciones Manuale di Riparazioni

ZF Synchromesh Transmissions 12-speed 1325 751 101_en

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Subject to technical changes

Copyright by ZF This documentation is protected by copyright. Any reproduction or dissemination in any form that does not fully agree with the intended purpose of this documentation is prohibited without the consent of ZF Friedrichshafen AG. Printed in Germany ZF Friedrichshafen AG / 2009

Edition: 2009-03

1325 751 101

ZF-Ecosplit

Table of Contents Page

Overview of Changes ........................................................................................................................

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

Safety Instructions..............................................................................................................................

Instructions for Repair .......................................................................................................................

Tightening Torques.............................................................................................................................

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

Setting Data ........................................................................................................................................

ZF-Ecosplit Tightening Torques .........................................................................................................

Spring Table........................................................................................................................................

Special Tools .......................................................................................................................................

5 6 7 8 10 11 12 14 17 18

1

Polyamide tubes for range change group and valve ....................................................................... 1-1

2

Shift turret ........................................................................................................................................ 2-1

3

Range change group (R/C)................................................................................................................ 3-1

4

Planetary drive with synchronizer................................................................................................... 4-1

5

Splitter group piston and 5/2-way valve.......................................................................................... 5-1

6

Connection plate .............................................................................................................................

6-1

7

Clutch housing .................................................................................................................................

7-1

8

Shafts and selector rails .................................................................................................................

8-1

9

Transmission housing ....................................................................................................................

9-1

10

Input shaft ....................................................................................................................................... 10-1

11

Countershaft ................................................................................................................................... 11-1

12

Main shaft ....................................................................................................................................... 12-1

13

Bearing setting on main shaft, input shaft and countershaft ...................................................... 13-1

14

Synchronizers .................................................................................................................................. 14-1

1325 751 101 - 2009-03

3

ZF-Ecosplit

Transmission overview

The following transmissions and variants are covered in this manual: Transmission types: 12 S 2130 TD 12 S 2330 TD 12 S 2830 TD

1325 751 101 - 2009-03

4

ZF-Ecosplit

Index

Date of issue

1325 751 101 - 2009-03

Overview of changes: 1325 751 101

Chapter

Initiator

Comment

5

Preface Preface

Warranty

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

The work described below may only be performed by authorized, trained, and instructed staff. It is the responsibility of the user’s company or repair company to ensure that their repair staff is properly trained.

Repair work carried out at ZF Service Points is subject to the contractual conditions prevailing in the individual case.

Direct and/or subsequent costs are not covered by this contractual liability when: • work has been performed improperly or by unskilled personnel, by non-ZF-personnel, and/or

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

• use of “non” genuine ZF parts.

In case of failure it is mandatory to act immediately, so to ensure the complete function of the ZF unit and minimize the scope of damage.

However, due to continuing technical advancements 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 and fitters who have their practical and theoretical knowledge updated on a regular basis at our Service Training Center.

In case of proven unfounded delay in repair we reserve the right of partial acceptance or even a rejection of warranty claims.

Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continuously trained personnel, 2. Specified equipment, e.g.: special tools, 3. Genuine ZF spare parts in accordance with the latest volume production specifications.

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

ZF Friedrichshafen AG Driveline and Chassis Technology

2008-06

6

Safety Instructions The following safety instructions are used in this repair manual:

!

DANGER to the health!

Ensure confident handling with supplies.

Manufacturer’s instructions must be observed.

NOTE Refers to special working procedures, methods, information, use of auxiliary equipment, etc.

!

DANGER to the environment!

Lubricants, consumables, 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 regulations.

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

CAUTION Is used when the instructions are not complied with or not followed precisely and could lead to the product being damaged.

!

DANGER! Is used when lack of care could result in personal injury or danger to life.

CAUTION The transmission must NOT be suspended by the input shaft OR by the output flange/add-on parts.

Safety Instructions As a rule, repair technicians for ZF units are responsible for their own workplace safety.

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 therefore familiarize themselves with these regulations.

Incorrect

Personnel required to carry out repairs on ZF products must receive appropriate training in advance.

Compulsory training is the responsibility of the repair staff.

Correct

! DANGER! Do not walk under suspended load during parts transportation with a hoist.

2008-06

7

Instructions for Repairs General Information

Cleaning Parts

Read this manual carefully before starting tests or repair work.

Remove old sealing compound residues from all sealing faces. Carefully remove burrs or other uneven patches using an oil stone.

Lube bores and grooves must be free from anticorrosion grease and foreign matter. Check that the passage is free.

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

The ZF-Service Information details must be observed. These are available from all ZF Service Centers or from the ZF-ServiceLine.

In any cases of doubt, always contact the relevant expert departments at ZF-Service.

Whenever working on the transmission, ensure cleanliness and carry out the work as instructed.

Use specified tools to dismantle and assemble transmissions.

Reusing Parts Parts such as antifriction bearings, multidisks, thrust washers etc., must be inspected by a specialist, who should decide whether they can be re-used or not.

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

CAUTION The pictures, drawings, and components shown do not always represent the original object, but are used to illustrate working practices.

The pictures, drawings, and components are not to scale and no conclusions must be drawn about size and weight (not even within a complete illustration).

All work must be performed as described in the text.

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

Gaskets are installed without the use of sealing compound or grease. When measuring coated gaskets/seals proceed as specified.

After repair work and tests performed, skilled personnel must make sure that the product is working properly again.

• Shaft seals Always replace shaft sealing rings with rough, ripped, or hardened sealing lips. Seal contact surfaces must be totally clean and in perfect condition.

Conversions and modifications may impact the transmission’s operational safety. Therefore, customer-specific deviations must be agreed with ZF in writing.

After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the recesses of housings and covers when cleaning.

2008-06

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

8

Instructions for Repairs • Shaft Sealing Rings Press in shaft sealing ring with fixture or face plate until firmly home at relevant installation depth.

Transmission Assembly Assemble the transmission in a clean workplace.

Adhere to all adjustment data and tightening torques specified in the repair manual.

a) Apply a thin coat of sealing agent* to outer circumference of shaft sealing rings with a «steel surround».

• Bearings If the bearings are fitted while warm, these should be warmed up evenly (e.g. heating cabinet).

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

b) Never apply sealing agent to shaft sealing with a «rubber surround» but apply a thin coat of Vaseline 8420 or spirit to the outer circumference, or wet with a lubricant, e.g. a water-soluble concentrated washing-up liquid. c) Shaft sealing rings with steel and rubber surrounds should be treated on the outer circumference of the rubber surround as described for shaft seal (b).

• Sealing If a sealant* is recommended for sealing, then it is essential to adhere to the manufacturer’s directions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly. Do not allow sealing agent 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 enters the oil feeds when the parts are pressed together.

d) Duo shaft sealing rings have two sealing lips. The dust protection sealing lip (X) must face outwards.

Fill the space between the sealing lips up to 60% with grease*.

X

• Transmission Oil After completing repairs, fill the transmission with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and the List of Lubricants TE-ML (refer to type plate). These are available from all ZF Service Centers or on the Internet at www.zf.com. After filling the transmission with oil, tighten the screw plugs at the oil filling point and the oil overflow to the specified torques.

• Retaining Agents Retaining agents* may only be used where specified by the parts list.

When using retaining agents (e.g. Loctite) always comply with the manufacturer’s directions for use.

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

* refer to consumable material

2008-06

9

Tightening torques Tightening torques for screws/bolts and nuts, extract from ZFN 148 Surface condition of screws/bolts/ nuts: Heat-treated blackened finish and oiled or galvanized and oiled.

This standard applies to bolts according to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and for nuts according to DIN 934 and ISO 4032, ISO 8673.

The bolts are tightened using a calibrated torque wrench.

This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8, 10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.

NOTE Differing tightening torques are listed separately in the repair manual.

Coarse thread Measurement Screw/Bolt Nut

Fine thread Tightening torque in Nm for 8.8 10.9 12.9 8 10 12

Measurement Screw/Bolt Nut

Tightening torque in Nm for 8.8 10.9 12.9 8 10 12

M4 M5 M6

2,8 5,5 9,5

4,1 8,1 14

4,8 9,5 16,5

M8x1 M9x1 M10x1

24 36 52

36 53 76

43 62 89

M7 M8 M10

15 23 46

23 34 68

28 40 79

M10x10.25 M12x10.25 M12x1.5

49 87 83

72 125 120

84 150 145

M12 M14 M16

79 125 195

115 185 280

135 215 330

M14x1.5 M16x1.5 M18x1.5

135 205 310

200 300 440

235 360 520

M18 M20 M22

280 390 530

390 560 750

460 650 880

M18x2 M20x1.5 M22x1.5

290 430 580

420 620 820

490 720 960

M24 M27 M30

670 1000 1350

960 1400 1900

1100 1650 2250

M24x1.5 M24x2 M27x1.5

760 730 1100

1100 1050 1600

1250 1200 1850

M27x2 M30x1.5 M30x2

1050 1550 1500

1500 2200 2100

1800 2550 2500 Status: August 1991

2008-06

10

ZF-Ecosplit

Consumables

Grease 0750 199 001

For example Spectron FO 20

General assembly aid

Grease 0671 190 016

Technical vaseline 8420

General assembly aid

Grease 0750 199 019

For example Renolit CX-EP2

Jointing compound 0666 690 017 Loctite no. 241

Sealing compound 0666 790 033

Corrosion protection oil 0750 199 008

Grease 0671 190 050

Loctite no. 574

For example Renolin MR 40 Z

Olista Longtime 3EP

Quantity approx.

Comment

5 grams 3 grams 1 gram 2 grams 1 gram 3 grams 2 grams 1 gram 1 gram

S/G cap seal Double-lip seal Detent plunger Shaft sealing ring/pipe R/C cap seal R/C sealing rings Shaft sealing ring Tappet Pin

Chapter 10 Chapter 10 Chapter 10 Chapter 7 Chapter 3 Chapter3 Chapter 3 Chapter 2 Chapter 2

300 mm3

Swivel screws

Chapter 3

1 cm3

hex head screws

Chapter 2

0.50 cm3 0.20 cm3

Oil pump rotor Axial needle bearing

Chapter 7 Chapter 4

3 grams

Ball race release fork

Chapter 7

NOTE: Inquire about available package/container size before placing order!

1325 751 101 - 2009-03

Application

Loctite

Name

Loctite

Designation ZF item number

11

ZF-Ecosplit

Setting data

Designation

Dimensions

Measurement device

Comment

01. Axial clearance of the countershaft

0.01 to 0.10 mm

Depth gage

Rotate countershaft in order to center the bearing rollers.

Set zero play.

Afterwards, adjust play with suitably thick compensating disk.

02. Axial clearance of the main 0.01 to 0.10 mm and input shaft

Depth gage

Rotate input and main shaft in order to center the bearing rollers.

Set zero play.

Afterwards, adjust play with suitably thick compensating disk .

03. Axial clearance of the – 0.05 to + 0.05 mm split ring on the main shaft

Feeler gage

Select suitable ring.

04. Installation dimension of the shaft sealing ring in the bearing cover

9 ± 0.1 mm

Adapter 1X56 138 669

The installation dimension can be determined by using an adapter.

05. Installation dimension of the oil pump rotor

23 mm –0.5 mm

Depth gage

Do not separate/remove gear set, only for check.

06. Axial clearance of the snap 0 to 0.1 mm ring at deep groove ball bearing in the ring gear carrier

Feeler gage

Adjust with suitably thick snap ring.

07. Axial clearance of the 0 to 0.1 mm retaining rings on the main shaft and countershaft

Feeler gage

Adjust with suitably thick retaining ring.

1325 751 101 - 2009-03

12

ZF-Ecosplit

Setting data

Designation

Dimensions

Measurement device

Comment

08. Wear limit of synchronizer rings and/or clutch body, measured between end faces, ring, and body at centric, backlash-free abutment of the tapers

of main transmission 0.80 mm

Feeler gage

If the dimension is below specification, replace synchronizer ring and/or clutch body.

09. For information: Synchronizer clearance (axial)

> 0.60 mm

Feeler gage

Upper limit of the synchronizer clearance is determined by the wear limit of 0.80 and/or 1.20 mm.

10. Sliding pad clearance at the splitter group shift fork

0.1 + 0.2 mm

Feeler gage

Measured from the sliding pad’s bottom side to the sliding sleeve.

11. Control dimension A to adjust splitter group shift fork

short version: 93.70 mm long version: 107.20 mm

Depth gage

See assembly instructions 0000 701 102

1325 751 101 - 2009-03

Range change group 1.20 mm

13

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