ZF Tractor Transmission ECCOM 1.5 Workshop Manual

Order no.: 5871 977 002 ZF - TRACTOR TRANSMISSION ECCOM 1.5 (SDFG SERIES 20) REPAIR LEVEL III ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau

REPAIR MANUAL for ZF – TRACTOR TRANSMISSION ECCOM 1.5 I M P O R T A N T I N F O R M A T I O N : Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit. Continuous technical upgrading of the ZF units and extensions concerning design options may require differing steps, which can be carried out by qualified specialists without greater difficulties by means of the perspective views included in the corresponding spare parts lists. This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of issue of the manual. ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise which edition is the latest one. ACHTUNG: Observe the vehicle manufacturer’s instructions and specifications for the installation and commissioning of the unit! For information on operation, maintenance and for descriptions please refer to the corresponding ZF-Operation Manual. ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau Abt. : ASDM / Division : ASDM Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet! Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted! Copyright ZF Passau GmbH! Toute reproduction, même partielle, est interdite! Technische Änderungen vorbehalten! Subject to technical modifications! Sous réserve de modifications techniques! Konstruktionsstand / Design Level / Niveau Technique 1.Auflage / 1 st Edition / 1ère Édition 2005/01

CONTENT Chapter/page Preface General Conversion table Denomination of standard dimensions Tightening torques for screws 0/1 0/2 … 3 0/4 0/5 0/6 SPECIAL TOOLS W/1 ... WB/15 List of tools (requested special tool) ILLUSTRATED TABLES W/1 ... 9 WB/1 ... 15 DISASSEMBLY 1/1 ... 4/23 1. Disassembly of components 1.1 Disassembly of the clutch control block 1.2 Disassembly of the system control block 1.3 Disassembly of the pump 2. Separation of the transmission halves 3. Disassembly of the intermediate housing 3.1 Disassembly of the front wheel drive 3.2 Disassembly of clutch (KV/KR) and double gear 3.2.1 Disassembly of clutch KV 3.2.2 Disassembly of clutch KR 3.3 Disassembly of the output gear 3.4 Disassembly of the input shaft (hydrostatic unit)) 3.5 Disassembly of the central shaft (clutch KV/KR) 3.6 Disassembly of the intermediate gear 4. Disassembly of the clutch housing 4.1 Disassembly of the multi-disk brake (BG) 4.2 Disassembly of the drum selector gear (planetary transmission) 4.2.1 Disassembly of ring gear P4/BG 4.2.2 Disassembly of clutch K3/K4 4.2.3 Disassembly of planetary drive P4 4.2.4 Disassembly of the central shaft 4.2.5 Disassembly of clutch K1/K2 4.2.6 Disassembly of planetary drive P3 4.2.7 Disassembly of planetary drive P2 4.2.8 Disassembly of planetary drive P1 4.3 Disassembly of the hydrostatic unit 1/1 ... 6 1/1 … 3 1/4 ... 5 1/6 2/1 … 2 3/1 ... 17 3/1 ... 3 3/4 … 10 3/4 ... 7 3/7 ... 10 3/11 … 12 3/13 … 14 3/15 3/16 … 17 4/1 ... 23 4/1 ... 2 4/3 ... 18 4/3 … 4 4/4 … 6 4/7 … 8 4/8 … 9 4/10 … 13 4/13 … 15 4/15 … 17 4/17 … 18 4/19 ... 23

CONTENTS Chapter / Page REASSEMBLY 5/1 ... 8/12 5. Reassembly of the clutch housing 5.1 Reassembly of the hydrostatic unit 5.2 Reassembly of the drum selector gear (planetary transmission) 5.2.1 Reassembly of planetary drive P1 5.2.2 Reassembly of planetary drive P2 5.2.3 Reassembly of planetary drive P3 5.2.4 Reassembly of clutch K1/K2 5.2.5 Reassembly of the central shaft 5.2.6 Reassembly of planetary drive P4 5.2.7 Reassembly of clutch K3/K4 5.3 Reassembly of the multi-disk brake (BG) 6. Reassembly of the intermediate housing 6.1 Reassembly of the input shaft (hydrostatic unit) 6.2 Reassembly of the intermediate gear 6.3 Reassembly of the central shaft (clutch KV/KR) 6.4 Reassembly of the output gear 6.5 Reassembly of the pump 6.6 Reassembly of clutch KV/KR 6.6.1 Reassembly of clutch KV 6.6.2 Reassembly of clutch KR 6.7 Reassembly of the front wheel drive 7. Joining of the preassembled transmission halves 7.1 Setting of the axial play drum selector gear/hollow shaft (KV/KR) 7.2 Setting of the axial play of the KV/KR bearing 7.3 Setting of the axial play of the double gear bearing 7.4 Setting of the axial play of the front wheel drive 8. Reassembly of components 8.1 Reassembly of the system control block 8.2 Reassembly of the clutch control block 8.3 Reassembly of the speed and inductive sensor 5/1 ... 44 5/3 ... 7 5/8 ... 40 5/8 … 11 5/11 … 13 5/14 … 18 5/18 … 25 5/25 … 27 5/27 … 31 5/31 … 40 5/41 ... 44 6/1 ... 34 6/3 6/4 ... 5 6/6 … 7 6/8 ... 11 6/12 ... 13 6/14 … 27 6/15 … 22 6/22 … 27 6/28 … 33 7/1 ... 7 7/1 ... 2 7/2 ... 3 7/4 … 5 7/5 … 6 8/1 ... 12 8/1 … 4 8/5 ... 10 8/11 … 12

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/1 PREFACE This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be made on ZF units. This documentation describes a ZF series product with a design level valid at the date of edition. Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both deviating work steps and differing setting and testing data. We would therefore recommend you to entrust masters and servicemen with the work on your ZF product whose practical and theoretical training is constantly updated in our training school. The Service Stations established by ZF Friedrichshafen all over the world offer you: 1. Permanently trained staff 2. Specified equipment, e.g. special tools 3. State-of-the-art genuine ZF spare parts All work is done there with utmost care and reliability. In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms of the currently applicable contractual conditions. Any damage resulting from work which is done in an improper and unprofessional manner by third parties and any consequential costs incurred shall be excluded from this contractual liability. ZF Passau GmbH Service Department

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/2 GENERAL The Service Manual covers all work required for disassembly and the relating reassembly. When repairing the unit, ensure utmost cleanliness and that the work is done in a professional manner. Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar. Carry out disassembly and reassembly work on a clean working place. Use special tools which have been developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings, thrust washers etc. will be reinstalled. Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with worn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign bodies remain in the housing. Check the lube oil holes and grooves regarding unhindered passage. Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation: NOTE: Only a heating furnace (oil bath) or an electric drier is permitted to be used for heating up parts such as bearings, housings, etc.! Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact. CAUTION: When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual. Tighten screws and nuts according to the enclosed standard table, unless otherwise specified. The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible malfunction. Never wash disks having organic friction linings (e.g. paper disks - adverse effect on lining adhesion). Only dry cleaning is permitted (leather cloth). When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves! DANGER: When using detergents, observe the manufacturer’s instructions regarding their handling.

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/3 Structure of the Service Manual The structure of this repair manual reflects the sequence of the work steps for completely disassembling the dismantled unit. Special tools required for carrying out the repair work are listed in the current text as well as in chapters “W” (List of special tools) and “WB” (illustrated tables). Important information on industrial safety As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully responsible for industrial safety. The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding any damage to persons and products during maintenance and repair work. Repair workshops must familiarize themselves with these regulations prior to starting any work. A suitably trained and skilled staff is required for a proper repair of these ZF products. The repair workshop shall be responsible for the training. The following safety references are used in this manual: CAUTION This symbol serves as a reference to special working procedures, methods, information, use of auxiliaries etc... indicated in this repair manual. DANGER This symbol identifies situations in which lacking care may lead to personal injury or damage to the product. ____________________________________________ NOTE: Thoroughly study this manual before starting any tests or repair work. NOTE: Figures, drawings and parts in this manual do not always represent the original; they show the working procedure. Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on size and weight (not even within one and the same illustration). Carry out work according to the legend. NOTE: After repair work and tests, the expert staff must verify that the product is perfectly functioning again. 

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/4 VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION 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/cm 2 ) 0.070 bar ( 0.071 kp/cm 2 ) 1 liter 4.456 liter 1 liter 3.785 liter 1609.344 m 0° C ( Celsius ) 0 ° C ( Celsius ) = = = = = = = = = = = = = = 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 ) 14.5 psi (pound force per square inch lbf/in 2 ) 1 psi ( lbf/in 2 ) 0.264 Gallon ( Imp. ) 1 Gallon ( Imp. ) 0.220 Gallon ( US ) 1 Gallon ( US ) 1 Mile ( Land mile ) + 32° F ( Fahrenheit ) 273.15 Kelvin

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/5 BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES Hinweis : längenbezogene Masse in kg/m; flächenbezogene Masse in t/m 2 Note : linear density in kg/m; areal density in t/m 2 Nota : Densité linéaire en kg/m; Densité superficielle en t/m 2 Begriff Unit Unité Formelzeichen Formel Sign Symbole Neu Alt New Old Nouveau Vieux Umrechnung Conversion Conversion Bemerkungen Note Nota Masse Mass Masse m kg (Kilogramm) kg Kraft Force Force F N (Newton) kp 1 kp = 9.81 N Arbeit Work Travail A J (Joule) kpm 0.102kpm = 1J = 1Nm Leistung Power Puissance P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW 1 KW = 1.36 PS Drehmoment Torque Couple T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) = F (N) . r (m) Kraftmoment Moment (Force) Moment (Force) M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) = F (N) . r (m) Druck (Über-) Pressure (Overpress) Pression (Sur-) pü bar atü 1.02 atü = 1.02 kp/cm 2 = 1 bar = 750 torr Drehzahl Speed Nombre de Tours n min -1

REPAIR MANUAL Off-Road Driveline Technology and Axle Systems Division 5871 977 002 0/6 TIGHTENING TORQUES FOR SCREWS (IN Nm) ACC. TO ZF-STANDARD 148 Friction coefficient : μ tot.= 0.12 for screws and nuts without rework, as well as phophated nuts. Tighten manually ! Take tightening torques from the chart below, unless otherwise specified: Metric ISO-standard thread DIN 13, page 13 Size 8.8 10.9 12.9 M4 2.8 4.1 4.8 M5 5.5 8.1 9.5 M6 9.5 14 16.5 M7 15 23 28 M8 23 34 40 M10 46 68 79 M12 79 115 135 M14 125 185 215 M16 195 280 330 M18 280 390 460 M20 390 560 650 M22 530 750 880 M24 670 960 1100 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100 Metric ISO-fine thread DIN 13, page 13 Size 8.8 10.9 12.9 M 8 x 1 24 36 43 M 9 x 1 36 53 62 M 10 x 1 52 76 89 M 10 x 1.25 49 72 84 M 12 x 1.25 87 125 150 M 12 x 1.5 83 120 145 M 14 x 1.5 135 200 235 M 16 x 1.5 205 300 360 M 18 x 1.5 310 440 520 M 18 x 2 290 420 490 M 20 x 1.5 430 620 720 M 22 x 1.5 580 820 960 M 24 x 1.5 760 1100 1250 M 24 x 2 730 1050 1200 M 27 x 1.5 1100 1600 1850 M 27 x 2 1050 1500 1800 M 30 x 1.5 1550 2200 2550 M 30 x 2 1500 2100 2500 M33 x 1.5 2050 2900 3400 M 33 x 2 2000 2800 3300 M 36 x 1.5 2700 3800 4450 M 36 x 3 2500 3500 4100 M 39 x 1.5 3450 4900 5700 M 39 x 3 3200 4600 5300

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ZF Tractor Transmission ECCOM 1.5 Workshop Manual

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