For information concerning description, installation instructions, operation and maintenance, see respective Operating Instructions, ZF-Ordering-No. 5872 196 002.
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Section : ASTDM
Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous réserve de modifications techniques!
1.Auflage / 1.Edition
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Repair Instruction
PREFACE
Off-Road Transmissions and Axle Systems Division
This documentation has been developed for skilled staff trained by the ZF Passau for the repair and maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting consequential costs, if any, are excluded from this contractual liability. This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
Off-Road Transmissions and Axle Systems Division
Repair Instruction
GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expertlike manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them:
REFERENCE:
CAUTION
For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used!
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. By no means, Molykote is permitted to be used. Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.
Repair Instruction
Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods, information, the use of auxiliaries etc..
CAUTION
DANGER
REFERENCE
Is used, if a deviating and improper working procedure can damage the product
Is used, if lacking care can lead to personal injury or danger to life
Prior to starting the checks and repair works, thoroughly study the present instructions.
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and weight must not be drawn (not even within one representation). The works must be performed according to the description..
REFERENCE:
After the repair works and the checks, the expert staff must convince itself that the product is properly functioning again. .
Repair Instruction
Off-Road Transmissions and Axle Systems Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN
DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m;areal density in t/m2
Nota : Densité lineaire en kg/m;Densité superficielle en t/m2
DrehmomentTNm kpm 1 kpm = 9,81 Nm T (Nm) = Torque(Newtonmeter)F (N) . r (m)
Couple
KraftmomentMNm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force)(Newtonmeter)F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü1,02 atü = 1,02 kp/cm2
Pressure (Overpress)= 1 bar = 750 torr
Pression (Sur-)
Drehzahlnmin -1
Speed
Nombre de Tours
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25,40 mm
1 kg ( Kilogramm )
9,81 Nm ( 1 kpm )
1,356 Nm ( 0,138 kpm )
1 kg / cm
1 bar ( 1,02 kp/cm2 )
0,070 bar ( 0,071 kp/cm2 )
1 Liter
4,456 Liter
1 Liter
3,785 Liter
1609,344 m
0° C ( Celsius )
0 ° C ( Celsius )
Repair Instruction
Off-Road Transmissions and Axle Systems Division
VERGLEICHSTABELLE FÜR MASSEINHEITEN
CONVERSION TABLE TABLEAU DE CONVERSION
1 in ( inch)
2,205 lb ( pounds )
7,233 lbf x ft ( pound force foot) 1 lbf x ft ( pound force foot )
5,560 lb / in ( pound per inch )
14,233 psi (pound force per square inch lbf/in2 ) 1 psi ( lbf/in2 )
0,264 Gallon ( Imp. ) 1 Gallon ( Imp. )
0,220 Gallon ( US ) 1 Gallon ( US )
1 Mile ( Landmeile ) + 32° F ( Fahrenheit )
273,15 Kelvin
Repair Instruction
TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF-STANDARDS 148
Friction value: µ total= 0,12 for screws and nuts without after-treatment as well as phosphatized nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following List:
M
Preface
The present Documentation has been developped for skilled personnel which has been trained by the ZF for the Maintenance and Repair operations on ZF-units. However, because of technical development of the product, the Maintenance and Repair of the unit in your hands may require differing steps as well as also different setting and test data.
This Manual is based on the technical state at the printing. At the preparation, every possible care has been taken to avoid errors. However, we are not liable for possible mistakes concerning the representation and the description.
We are reserving ourselves the right of modifications without previous information.
The responsibility lies with the owner and the user, to pay attention to the safety indications, and to carry out the Maintenance operations according to the prescribed Specifications.
The ZF is not liable for faulty installation, incorrect treatment, insufficient Maintenance, impro-perly and unskilled performed works, and for the subsequential damages resulting from it.
It is imperative to pay attention to the corresponding Specifications and Manuals of the Vehicle Manufacturer.
Important Informations concerning the technical reliability and reliability in service are accen-tuated by the following Symbols:
Valid for Instructions which must be observed at the Maintenance, the Performance or the Operation of the vehicle !
Is inserted at working and operating procedures which have to be exactly respected to avoid a damage or destruction of the unit or to exclude a danger to persons !
Repair Instruction
GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expertlike manner.
The transmission should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again. Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage. All bearings must be treated with operating oil prior to installing them:
REFERENCE:
CAUTION
For heating up parts such as bearings, housings etc., only a heating furnace or an electric drier is permitted to be used!
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data. Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified. In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted. By no means, Molykote is permitted to be used. Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding handling of the respective detergent.
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Repair Instruction
Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff. The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods, information, the use of auxiliaries etc..
CAUTION
DANGER
REFERENCE
Is used, if a deviating and improper working procedure can damage the product
Is used, if lacking care can lead to personal injury or danger to life
Prior to starting the checks and repair works, thoroughly study the present instructions.
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and weight must not be drawn (not even within one representation). The works must be performed according to the description..
REFERENCE:
After the repair works and the checks, the expert staff must convince itself that the product is properly functioning again. .
Repair Instruction
Off-Road Transmissions and Axle Systems Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN
DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m;areal density in t/m2
Nota : Densité lineaire en kg/m;Densité superficielle en t/m2
Tightening torque (Hose pipes) ..................... MA = 35 Nm
Figure 5
Figure 6
Werkstatthandbuch
Geschäftsbereich - A Arbeitsmaschinen-Antriebe und Achssysteme
Repair Manual
1
2
3
4
6.1 Axle disconnection
Loosen cap screws and separate axle disconnection from the housing.
(S) Pry bar set5870 345 036
Loosen hexagon screws and remove output flange.
Remove shaft seal and unsnap retaining ring.
6.2 Assemly
Install shaft seal with sealing lip (arrow) showing to the oil sump.
Exact installation position is obtained by use of the specified driver (S)!
Grease sealing lip!
Depending on the version different shaft seals can be used:
Outer diameter rubber-coated – wet with spirit!
Outer diameter metallic – wet with sealing compound (Loctite, Type No. 574)!
(S) Driver5870 048 237
Install hexagon screws and press on screen sheet (arrow) in alignment.
(S) Pressure bush 5870 506 142
Figure
Figure
Figure
Figure
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Repair Manual
Off-Road Transmissions and Axle Systems Division
Assemble output flange and insert O-ring into gap of output flange and shaft.
Put on washer and fasten it with hexagon screws.
Tightening torque (M10/8.8) .............. MA = 46 Nm
Fix hexagon screws by means of tab washer.
(S) Driver5870 057 009
(S) Handle5870 260 002
Install preassembled axle disconnection and fix it by means of cap screws (2 pcs. M12x80, 7 pcs. M12x75 mm).
Tightening torque (M12/8.8) .................. MA = 79 Nm
Loosen hexagon screws and remove output flange (Figure 32). Following to this press shaft seal out of the housing bore .
Figure 5
Figure 6
Figure 7
6.3 Disassembly shaft seal
Figure 8
Repair Manual
6.4 Assembly Standard version
Off-Road Transmissions and Axle Systems Division
Install shaft seal with sealing lip showing to the oil sump.
Exact installation position is obtained by use of the specified driver (S)!
Grease sealing lip!
Depending on the version different shaft seals can be used: Outer diameter rubber-coated – wet with spirit!
Outer diameter metallic – wet with sealing compound (Loctite, Type No. 574)!
(S) Driver5870 048 237
Insert hexagon screws and press on screen sheet (arrow) in alignment.
(S) Pressure bush
Install output flange until contact.
5870 506 142
Insert O-ring (arrow) into gap of output flange and shaft.
Figure 9
Figure 10
Figure 11
Figure 12
Repair Manual
14
Off-Road Transmissions and Axle Systems Division
Fix output flange by means of washer and hexagon screws.
Tightening torque (M10/8.8) ................ MA = 46 Nm
Then fix hexagon screws by means of tab washer (see opposite Figure).
(S) Driver 5870 057 009 (S) Handle5870 260 002
Swivel transmission housing by 180°.
6.5 Check 4 by 4 switch
Check function of switch by resistance test (Figure 229)
Actuating the axle disconnection by means of compressed air results in a changed resistance if the switch is intact!
(S) Measuring device (Multimeter)5870 221 158
Figure 13
Figure
Werkstatthandbuch
Geschäftsbereich - A Arbeitsmaschinen-Antriebe und Achssysteme
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und Achssysteme
TECHNICAL DATA 4 WG 130/160
Engine power:
Turbine moment:
Engine speed:
Starting torque multiplication:
Engine-dependent Power take-offs: Torque: Speed:
Mass (without oil): Max. KW*
Nm*
min-1*
*= dependent on Vehicle type and application ** = dependent on the Transmission version
Description:
The ZF-Transmissions 4 WG-130/160 are composed of a hydrodynamic torque converter and a rear-mounted multi-speed powershift transmission with integrated transfer case (see
Table- 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via universal shaft) with DIN-, Mechanic- or Spicer-input flange.
The transmission can be shifted manually or fully-automatically by means of the Electronic unit EST-37.
Torque converter:
Unit size W 300 with torque multiplication.
Powershift transmission: 4 Forward speeds and 3 Reverse speeds.
Output:
The powershift transmission has between input and output shaft a center distance of 500 mm, and can be equipped with the following components: -with output flanges to the front and rear axle for different universal shafts -on the rear output (rear-side) with a disk brake as parking brake - on the converter side with axle disconnection.
Power take-off:
For the drive of an external oil pressure pump, an engine-dependent, coaxial power take-off is planned.
Arbeitsmaschinen-Antriebe und Achssysteme
It allows the attachment of pumps with „SAE-B and C“ Connection.
Transmission accessories:
Upon request, the transmissions can be additionally equipped with the following components: -Emergency steering pump with a feed rate of 16 cm 3/rev. or 32 cm 3/rev.
-Electronic speedometer signal, here the Electronic unit EST-37 offers a speedometer signal.
Transmission ratio (mechanical)*
*= According to the Transmission version, other ratios are also possible.
Arbeitsmaschinen-Antriebe und Achssysteme
ANNEX, comprising:
Tables: 4 WG 130/160
1Layout 4 WG-130/160
Installation view 4 WG-130/160 – Direct installation
2AFront view
2BRear view – Standard version
2CRear view – With disc brake
Installation view 4 WG-130/160 – Separate mounting
3AFront view
3BRear view – Standard version
3CRear view – With disc brake
3 Schedule of measuring points and connectins 4 WG-130/160
AEB Automated determination of the filling parameters
TCU Electronic control unit
und Achssysteme
TECHNICAL DATA 6 WG 160
Engine power:
Turbine moment:
Engine speed:
Starting torque multiplication:
Engine-dependent Power take-offs: Torque: Speed:
(without oil):
*= dependent on Vehicle type and application
**= dependent on the Transmission version
Description:
The ZF-Transmissions 6 WG-160 are composed of a hydrodynamic torque converter and a rear-mounted multi-speed powershift transmission with integrated transfer case (see Table 1).
The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situations (necessary input torque).
Input by direct mounting via diaphragm on the engine, or separate installation (input via universal shaft) with DIN-, Mechanic- or Spicer-input flange.
The transmission can be shifted manually or fully-automatically by means of the Electronic unit EST-37.
Torque converter:
Unit size W 300 and 340 with torque multiplication according to the version and a WK.
Powershift transmission: 6 Forward speeds and 3 Reverse speeds.
Output:
The powershift transmission has between input and output shaft a center distance of 500 mm, and can be equipped with the following components: -with output flanges to the front and rear axle for different universal shafts -on the rear output (rear-side) with a disk brake as parking brake - on the converter side with axle disconnection.
Power take-off:
For the drive of an external hydraulic pressure pump,an engine-dependent, coaxial power take-off is existing, upon request also disconnectable. It allows the mounting of pumps with SAE-C connection. Transmission accessories:
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Geschäftsbereich Arbeitsmaschinen-Antriebe und Achssysteme
Upon request, the transmissions can be additionally equipped with the following components:
- Emergency steering pump with a feed rate off 16 cm3/rev. or 32 cm3/rev.
-Electronic speedometer signal for:
-Construction site vehicles here, the Electronic unit EST-37 offers a speedometer signal.
- Road vehicles, the signal required for the speedometer interpretation will be picked-up on the output side by a pulse generator (e.g. is needed for trip recorders).
For this, a frequency divider from the Customer side is necessary.
-Separate mounting of the ZF-Fine filter.
Transmission ratio (mechanical)*
* = According to the Transmission version, other ratios are also possible.
Arbeitsmaschinen-Antriebe und Achssysteme
ANNEX, comprising:
Tables: 6 WG 160
1Design 6 WG-160
Installation survey 6 WG-160 – direct installation
2AFront view
2BRear view
Installation survey 6 WG-160 – separate installation with disc brake
3AFront view
3BRear view
Installation survey 6 WG-160 – separate installation with axle disconnection and torque converter lock-up clutch
4AFront view
4BRear view
4 Measure plan and connections 6 WG-160 with ZF fine filter directly mounted to the transmission
6Oil scheme 6 WG-160 with ZF fine filter directly mounted to the transmission -Forward 1st gear -
7Measure plan and connections 6 WG-160 with externally mounted ZF fine filter
8Oil scheme 6 WG-160 with externally mounted ZF fine filter -Forward 1st gear-
9 Measure plan and connections 6 WG-160 with externally mounted ZF fine filter and lock-up clutch
10 Oil scheme 6 WG-160 with externally mounted ZF fine filter and torque converter lock-up clutch -Forward 1st gear-
11Wheel scheme 6 WG-160
12 Power flow 6 WG-160 -Forward gears-
13Power flow 6 WG-160 -Reverse gears -
14Electro- hydraulic gear shifting with proportional valve
156 WG-160 fully automatic control EST-37 - Standard Circuit diagram - 6029 717 039 –
Arbeitsmaschinen-Antriebe und Achssysteme
16 Speed range selector DW-3
17Speed range selector VTS-3
18Speed range selector SG-6
19 Speed range selector D7
20Type plate
Abbreviations used in the text:
Abbreviation Description
WK Torque converter lock-up clutch
EST-37 Ergocontrol
AEB Automated determination of the filling parameters
TCU Electronic control unit
und Achssysteme
IMPORTANT INSTRUCTIONS
Oil level check (see 4.2):
In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed and the marking on the oil dipstick must then be lying above the cold start mark.
The oil level check in the transmission must be carried out at engine idling speed and operating temperature of the transmission (80° to 90° C).
At stationary engine, the oil level in the transmission is rising essentially, according to the installation conditions !
At every oil change, the ZF-Fine filter must be exchanged. In addition, ZF recommends to start the autonomous calibration of the shifting elements (AEB).
The autonomous calibration of the shifting elements (AEB) must be started after the initial installation of the transmission and the Electronics in the vehicle at the Vehicle Manufacturer and after every replacement of the transmission, the electrohydraulic control or the TCU in case of a failure.
Put the Controller at the starting of the engine always to the Neutral position. At running engine and transmission in Neutral, the parking brake must be engaged or the service brake be actuated, to prevent the vehicle from rolling.
Prior to every start off, loosen the parking brake.
The engagement of the speed out of Neutral is only possible under the programmed transmission input speed (turbine speed).
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.
Reversing (Standard):
The reversing must be performed at standstill, resp. at very low driving speed. Above the programmed reversing limit, the vehicle will be shifted to Neutral by the Electronic unit EST-37, and the vehicle continues rolling in the old driving direction.
The gear of the new driving direction will be only engaged when the programmed reversing speed and the transmission input speed (turbine speed) has fallen below.
The programming is customized and can therefore be different from standard. Therefore, the exact procedure must be taken from the Operating Instructions of the respective Vehicle Manufacturer !
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