ZF Ecomid 9 S 109 Repair Manual 1304751102a – PDF DOWNLOAD

9 S 109 1304 751 102a

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9 S 109

Contents Page

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

General information ..............................................................................................................................................

Safety notice..........................................................................................................................................................

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

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

Spring table ...........................................................................................................................................................

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

Sequences of removal and installation...................................................................................................................

5 6 9 10 12 16 18 23

1 1.1 1.2

Tecalan pipes for range-change group..................................................................................................... 1-1 Removal ...................................................................................................................................................... 1-1 Assembly..................................................................................................................................................... 1-1

2 2.1 2.2 2.3 2.4

Output ........................................................................................................................................................

Removal of output flange and cover............................................................................................................

Removal of bearing cover............................................................................................................................

Mounting of bearing cover ..........................................................................................................................

Mounting of output flange and cover ..........................................................................................................

2-1 2-1 2-2 2-2 2-4

3 3.1 3.2 3.3 3.4

Range-change group .................................................................................................................................

Removal of range-change group .................................................................................................................

Mounting of range-change group................................................................................................................

Dismantling range-change group................................................................................................................

Assembling range-change group.................................................................................................................

3-1 3-1 3-3 3-7 3-9

4 4.1 4.2 4.3 4.4 4.5 4.6

Planetary gear with synchronizer ............................................................................................................

Dismantling synchronizer ...........................................................................................................................

Dismantling ring gear..................................................................................................................................

Dismantling planet carrier...........................................................................................................................

Assembling planet carrier ...........................................................................................................................

Assembling ring gear ..................................................................................................................................

Assembling synchronizer............................................................................................................................

4-1 4-1 4-2 4-2 4-3 4-4 4-4

5 5.1 5.2

Sun gear ..................................................................................................................................................... 5-1 Removal of sun gear.................................................................................................................................... 5-1 Mounting of sun gear .................................................................................................................................. 5-2

6 Shift mechanism ........................................................................................................................................ 6-1 6.1 Removal of shift mechanism ....................................................................................................................... 6-1 6.2 Mounting of shift mechanism ..................................................................................................................... 6-2 6.3 Dismantling shift mechanism...................................................................................................................... 6-4 6.4 Shift mechanism assembly - summary of shift mechanism types ............................................................... 6-10 6.4.1 Driver arrangement ..................................................................................................................................... 6-11 6.4.2 Compression spring arrangement (spring packs) in acc. with parts list (spare parts catalogue) ................................................................................................................................ 6-16 6.5 Assembling shift mechanism ...................................................................................................................... 6-19

Contents

9 S 109 Page

7 7.1 7.2 7.3 7.4

Connection plate - lubricating oil pump .................................................................................................

Removal of connection plate .......................................................................................................................

Removal and dismantling of lubricating oil pump ......................................................................................

Assembly and mounting of lubricating oil pump ........................................................................................

Assembly and mounting of connection plate ..............................................................................................

7-1 7-1 7-1 7-3 7-5

8 8.1 8.2

Adjusting bearings on mainshaft, input shaft and layshaft ................................................................... 8-1 Adjusting mainshaft and input shaft............................................................................................................ 8-1 Adjusting layshaft ....................................................................................................................................... 8-3

9 9.1 9.2 9.3 9.4

Shift rails and reverse gear ....................................................................................................................... 9-1 Removal of shift rails .................................................................................................................................. 9-1 Removal of reverse gear .............................................................................................................................. 9-5 Installation of shift rails .............................................................................................................................. 9-6 Installation of reverse gear .......................................................................................................................... 9-11

10 Input shaft, mainshaft and layshaft ......................................................................................................... 10-1 10.1 Removal of the shafts .................................................................................................................................. 10-1 10.2 Installation of the shafts .............................................................................................................................. 10-4 11 Input shaft.................................................................................................................................................. 11-1 11.1 Dismantling the input shaft ......................................................................................................................... 11-1 11.2 Assembly of the input shaft......................................................................................................................... 11-2 12 Mainshaft................................................................................................................................................... 12-1 12.1 Dismantling the mainshaft .......................................................................................................................... 12-1 12.2 Assembly of the mainshaft .......................................................................................................................... 12-4 13 Layshaft...................................................................................................................................................... 13-1 13.1 Dismantling the layshaft ............................................................................................................................. 13-1 13.2 Assembly of the layshaft ............................................................................................................................. 13-2 14 Housing ...................................................................................................................................................... 14-1 14.1 Dismantling the housing ............................................................................................................................. 14-1 14.2 Assembly of the housing ............................................................................................................................. 14-2 15 Clutch housing........................................................................................................................................... 15-1 15.1 Removal ...................................................................................................................................................... 15-1 15.2 Installation .................................................................................................................................................. 15-1

9 S 109

Preface This manual is intended for skilled personnel 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 utmost 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.

Index: 98-01-12

5

General information

9 S 109

TRANSMISSION DESCRIPTION

SERVICE MANUAL AND FUNCTION

The ZF 9 S 109 synchronous transmission of the Ecomid construction range has been specially developed for use in commercial vehicles of the upper medium duty class.

This service manual describes how to overhaul a ZF 9 S 109 synchronous transmission of the Ecomid range.

The contents of this manual are arranged as follows: 9 S 109 transmissions basically consist of:

Part 1:

Adjustment data, tightening torques, spring characteristics and an illustrated list of prescribed ZF special tools.

Part 2:

A step-by-step description of transmission overhaul, divided by Section and steps to be followed.

– a fully synchronized four gear component – an integrated crawler and reverse gear – a rear-mounted range-change group built into the planet

In addition to the above, ZF Friedrichshafen AG offers the following additional equipment as optional attachments: – an engine-dependent ZF power take-off – various clutch-dependent ZF power take-offs – an input for an emergency or dual-circuit steering pump – or a separate heat exchanger for use in extreme conditions.

6

9 S 109

Instructions for carrying out repairs

In any case of doubt always turn to the relevant department within ZF After-Sales Service for advice.

All work on transmissions needs to be done expertly and under clean conditions.

Proper tools are to be used for disassembly and assembly of transmissions.

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 The removed transmission is to be cleaned thoroughly with a suitable agent before opening.

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

Loctite-joined parts are easier to seperate if warmed with a hot-air blower.

Always change shaft seals with rough, ripped or hardened sealing lips. Seal contact surfaces must be absolutely clean and in perfect condition.

REWORKING CLEANING OF PARTS Remove remains of gaskets on all seal faces. Carefully remove burrs or similar patches of roughness using oil-stone.

Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage.

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 grinding or scrolling traces.

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.

Carefully cover opened transmissions to prevent foreign matter from entering.

TRANSMISSION ASSEMBLY RE-USE OF PARTS 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.

Index: 98-10-02

7

Instructions for carrying out repairs

9 S 109

BEARINGS If the bearings are filled while hot, these should be warmed up evenly (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.

d) Duo shaft seals have two sealing lips. The dust-proof sealing lips (X) must face outwards.

X

e) Fill the gap between the sealing lips 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.

SEALING 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.

RETAINING AGENTS 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 repair, fill the transmission with transmission oil.

For the procedure and approved oils, refer to the transmission operating manual and List of Lubricants TEML (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

Index: 98-10-02

9 S 109

Important information

SAFETY NOTICE

GENERAL INFORMATION

Companies repairing 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.

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

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.

! 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.

Index: 98-10-02

9

Tightening torques

9 S 109

Tightening torques for nuts and bolts, extract from ZFN 148 This Standard applies to bolts acc. to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 and for nuts acc. 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: thermaly blackened finish and oiled or galvanized and oiled or galvanized, chrome-plated and oiled.

Tightening of screws is done with calibrated torque wrench.

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

Regular thread Size Bolt Nut

Fine screw Tightening torque MA (Nm) for 8.8 10.9 8 10

Size 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 10

Index: 98-10-02

9 S109

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 fitter.

The values for the tightening torque MA are to be used analogously 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 fitter.

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 MA in Nm 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

Edition: October 1995 Index: 98-10-02

11

Adjustment data

9 S 109

Description

Dimension

Measuring device

Remarks

01. Axial preload of layshaft

0.18 to 0.30 mm

Depth gauge

Turn layshaft and thereby centre bearing rollers.

Adjust zero play.

Then aim to set preload (0.25 mm) using a shim of appropriate thickness.

02. Axial preload of mainshaft and input shaft

0.18 to 0.30 mm

Depth gauge

Turn input shaft and mainshaft and thereby centre bearing rollers. Adjust zero play.

Then aim to set preload (0.25 mm) using a shim of appropriate thickness

03. Axial play of grooved ball bearing situated on output (range-change group)

0 to 0.10 mm

Depth gauge

Up to 0.1 mm play is permitted.

Adjust using shim washer

04. Installation dimension for shaft seal in bearing cover

8 + 0.5 mm

Drift 1X56 126 467 and ring 1X56 137 484

If drift and ring are used, the installation dimension is automatically given

05. Axial play of circlip on sun gear

0 to 0.05 mm

Feeler gauge

Adjust using circlip of appropriate thickness

06. Axial play of snap ring for grooved ball bearing in ring gear carrier

0 to 0.1 mm

Depth gauge

Adjust using circlip of appropriate thickness

07. Axial play of circlip on main shaft and layshaft

0 to 0.1 mm

Feeler gauge

Adjust using circlip of appropriate thickness

08. Axial play of reverse gear

0.40 to 0.75 mm

Depth gauge or feeler gauge

Play is given by correct assembly. Check to confirm

09. Axial play of crawler and first gear

0.20 to 0.45 mm

Depth gauge or feeler gauge

Play is given by correct assembly. Check to confirm

10. Axial play of 2nd speed helical gear

0.20 to 0.40 mm

Depth gauge or feeler gauge

Play is given by correct assembly. Check to confirm

12

9 S 109

Adjustment data

Description

Dimension

Measuring device

Remarks

11. Axial play of 3rd or 4th speed helical gear

0.20 to 0.45 mm

Depth gauge or feeler gauge

Play is given by correct assembly. Check to confirm

12. Axial play of reverse gear situated on the idler shaft

0.20 to 0.60 mm

Feeler gauge

Play is given by correct assembly. Check to confirm

13. Permitted axial play of planetary gears in planet carrier

0.10 to 0.70 mm

Feeler gauge

Dimension data contains permitted level of wear for thrust washer. Minimum thickness per thrust washer = 1.20 mm

14. Limit of wear of synchronizer rings and/or clutch bodies, measured between flat surfaces of ring and body with cones nested firmly together

Main transmission 0.80 mm

Feeler gauge

If gap is smaller, replace synchronizer ring and/or clutch body

Feeler gauge

Upper limit of synchronous play is given by limit of wear of between 0.80 and 1.20 mm

Range-change group 1.20 mm

0.60 mm 15. Information on synchronous play (axial)

16. Information on shifting force of synchronizer’s shift sleeves

Replace all spring packs of the synchronizer. This ensures that the specified shifting force is present.

Shift transmission 270 bis 310 N Range-change group 850 bis 950 N

17. Axial play on speedo pinion shaft

min. 0.10 mm

18. Backlash on pinion shaft

0.10 to 0.20 mm

19. Temperature for shrinkfitting helical gears onto layshaft

Heating up temperature max. 170 °C Temperature difference between joined parts 150 °C

Temperature probe or thermometer

Seating surfaces of gears and shaft must be free of oil and grease during assembly. Do not exceed maximum temperature and only remain at this for 15 min at the most

20. Temperature for “assembly of sun gear”

max. 170 °C

Temperature probe or thermometer

Do not exceed maximum temperature and only remain at this for 15 min at the most

Depth gauge

Check by hand that play can be felt Backlash play is given by correct assembly. Check by hand

13

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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