ZF TRANSMATIC Transmission Gearbox Workshop Repair Manual

WSK 400 for 16 S 151, 16 S 221 WSK 440 for 16 S 251 4130 751 103a

Subject to alterations in design Copyright by ZF These repair instructions are protected by copyright. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Printed in Germany Edition: 02.00 4130 751 103a

WSK 400/440 Contents Page Preface ....................................................................................................................................................... 4 Important information ................................................................................................................................ 5 Instructions for carrying out repairs ........................................................................................................... 6 Tightening torques ..................................................................................................................................... 8 Consumables .............................................................................................................................................. 10 Adjustment data ......................................................................................................................................... 11 Spring table ................................................................................................................................................ 16 Special tools ............................................................................................................................................... 17 1 Disassembly and assembly of WSK / engine ........................................................................................... 1-1 2 Transmission mounting ........................................................................................................................... 2-1 3 Central wiring harness – WSK 400 /440 ................................................................................................. 3-1 4 Oil reservoir – WSK 400 /440 ................................................................................................................... 4-1 5 Clutch cylinder WSK 400 /440 ................................................................................................................ 5-1 6 WSK / transmission WSK 400 /440 ......................................................................................................... 6-1 7 Selector clutch – WSK 400 /440 ............................................................................................................... 7-1 8 Converter – WSK 400 /440 ....................................................................................................................... 8-1 Converter installation depth “C” ................................................................................................................ 8-2 Axial play of tapered roller bearing “G” .................................................................................................... 8-3 Inductive sensor distance (“n engine”) ....................................................................................................... 8-4 8.1 Dismantling and assembling converter (WSK 440) ................................................................................... 8-5 9 Turbine shaft – WSK 400/440 ................................................................................................................. 9-1 10 Oil filter – WSK 400 /440 ......................................................................................................................... 10-1 11 Control unit – WSK 400 /440 ................................................................................................................... 11-1 12 Retarder – WSK 400 /440 ......................................................................................................................... 12-1 13 Converter housing – WSK 400 /440 ......................................................................................................... 13-1 13.1 Oil feed flange ........................................................................................................................................... 13-1 13.2 Gear pump and wiring harness ................................................................................................................... 13-2 13.3 Converter housing ...................................................................................................................................... 13-4 13.4 Screw connection M10 WSK 400 .............................................................................................................. 13-5 13.5 Screw connection M12 WSK 440 .............................................................................................................. 13-6 14 Pressures and measuring points for WSK 400 and WSK 440 ............................................................... 14-1 15 After-Sales Service function test for WSK system ................................................................................. 15-1

ZF FRIEDRICHSHAFEN AG C.V./Special Transmissions Service Plant 2 Tel.: (0 75 41) 77-0 Fax: (0 75 41) 77-5726 This repair 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 not contained in this manual. We 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 centers. Service points equipped by ZF Friedrichshafen AG all over the world offer you: 1. Continually 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 subject to the contractual conditions prevailing in the individual case. Damage resulting from work performed by non-ZF personnel in an improper and unprofessional manner and any consequential costs are excluded from the contractual liability agreement. Exclusion of liability also applies if genuine ZF spares are not used. Preface 4

SAFETY NOTICE Companies repairing ZF units are responsible for their own work 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 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. GENERAL INFORMATION Read this manual carefully before starting any tests or repair work. CAUTION Pictures, drawings and components do not always repre- sent the original object, but are used to illustrate working procedures. Pictures, drawings and components are not to scale. Conclusions about size and weight should not be drawn (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 by the input shaft NOR by the output flange. ! ! Important information 5

6 In case of doubt always turn to the relevant depart- ment within ZF After-Sales Services for advice. All work on transmissions is to be performed expertly and under clean conditions. Use specified tools to dismantle and assemble transmissions. After removing the transmission from the vehicle, clean thoroughly with a suitable cleaning agent before opening. Pay particular attention to the projections and recesses of housings and covers when cleaning. Parts joined with Loctite are easier to separate if warmed with a fan heater. CLEANING PARTS Remove remains of old gaskets on all seal-faces. Carefully remove burrs or similar patches of roughness using an oil-stone. Lube bores and grooves must be free of anti-corrosion agents and foreign matter; check for perfect passage. Carefully cover opened transmissions to prevent foreign matter from entering. REUSING 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. 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. REWORKING Rework may be carried out on seal contact surfaces using plunge-cut grinding only, never use an emery cloth. Ensure that there are no traces of grinding or riffling. 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. TRANSMISSION ASSEMBLY 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 measure- ment. During assembly, comply with all adjustment data, checking data and tightening torques in the Repair Manual. Instructions for repairs

7 BEARINGS If bearings are mounted in heated condition, they are to be heated evenly (e.g. heating cabinet). Temperature should be at ca. 85 °C and must not exceed 120 °C. Each mounted bearing must be oiled with operating oil. SEALING If a specific sealing agent* is to be used for 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 enters the oil feeds when the surfaces are sealed. 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). d) Dual shaft seals have two sealing lips. The dust-proof sealing lip (X) must face outwards. e) Fill the gap between the sealing lips so it is 60% filled with 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 (makes fitting easier). Press the seal shaft with mounting or faceplate onto the relevant installation depth plan. 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. TRANSMISSION OIL After completing repairs, fill transmissions with transmission oil. For the procedure and approved oils, refer to the transmission operating manual and List of Lubri- cants 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 Instructions for repairs X

Tightening torques 8 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 to nuts acc. to DIN 934. This Standard contains data on tightening torques (M A ) for bolts and nuts in strength categories 8.8, 10.9 and 12.9 and nuts in strength categories 8, 10 and 12. Surface condition of bolts: thermally blackened and oiled or galvanized and oiled or galvanized, chrome-pla- ted and oiled. Tighten screws with a calibrated torque spanner. NOTE Irregular tightening torques are listed separately in the Repair Manual. Edition: August 1991 / checked 1997 Regular screw thread Fine screw thread Size Tightening torque Size Tightening torque M A (Nm) for M A (Nm) for Bolt 8.8 10.9 12.9 Bolt 8.8 10.9 12.9 Nut 8 10 12 Nut 8 10 12 M 4 2.8 4.1 4.8 M 8 x 1 24 36 43 M 5 5.5 8.1 9.5 M 9 x 1 36 53 62 M 6 9.5 14 16.5 M 10 x 1 52 76 89 M 7 15 23 28 M 10 x 1.25 49 72 84 M 8 23 34 40 M 12 x 1.25 87 125 150 M 10 46 68 79 M 12 x 1.5 83 122 145 M 12 79 115 135 M 14 x 1.5 135 200 235 M 14 125 185 215 M 16 x 1.5 205 300 360 M 16 195 280 330 M 18 x 1.5 310 440 520 M 18 280 390 460 M 18 x 2 290 420 490 M 20 390 560 650 M 20 x 1.5 430 620 720 M 22 530 750 880 M 22 x 1.5 580 820 960 M 24 670 960 1100 M 24 x 1.5 760 1100 1250 M 27 1000 1400 1650 M 24 x 2 730 1050 1200 M 30 1350 1900 2250 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

Tightening torques 9 Screw plugs DIN 908, 910 and 7604 The screw plug tightening torques M A were determined according to DIN 7604 for screwing into steel, grey cast and aluminum alloys. The values are based on experience and are intended as reference values for the fitter. The values for the tightening torque M A apply analo- gously 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. Union screws DIN 7643 The tightening torques M A were determined for screwing into steel, grey cast and aluminum 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 condition: as manufactured (without surface protection) and lightly oiled or galvanized, chromated and lightly oiled. Status: October 1995 Screw plugs (DIN 908, 910, 7604) Dimensions Tightening torque screwed into steel/gray cast Al alloy M 8 x 1 20 10 M 10 x 1 25 / 30* 15 / 20* M 12 x 1.5 35 25 M 14 x 1.5 35 25 M 16 x 1.5 40 30 M 18 x 1.5 50 35 M 20 x 1.5 55 45 M 22 x 1.5 60 / 80* 50 / 65* M 24 x 1.5 70 60 M 26 x 1.5 80 / 105* 70 / 90* M 27 x 2 80 70 M 30 x 1.5 100 / 130* 90 / 130* M 30 x 2 95 85 M 33 x 2 120 110 M 36 x 1.5 130 115 M 38 x 1.5 140 120 M 42 x 1.5 150 130 M 42 x 2 145 125 M 45 x 1.5 160 140 M 45 x 2 150 130 M 48 x 1.5 170 145 M 48 x 2 160 135 M 52 x 1.5 180 150 M 60 x 2 195 165 M 64 x 2 205 175 * DIN 7604 Form C Union screws (DIN7643) Pipe Thread Tightening outer torque M A diameter in Nm 4 - 5 M 8 x 1 20 - 25 6 M 10 x 1 25 - 35 8 M 12 x 1.5 30 - 40 10 M 14 x 1.5 35 - 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

10 Consumables WSK 400/440 Description Name Approx. Application Remarks ZF ref. no quantity Jointing compound 0666 690 017 Loctite no. 241 30 mm 3 M3x22 cyl. screw / wiring harness Chapter 13 Sealing compound 0666 790 017 WEVO L 100 20 g Oil feed flange Chapter 13 Gear pump Chapter 13 Grease 0671 190 050 Olista Longtime 3EB 7 g Separating clutch Chapter 7 Grease 0671 195 016 Molycote BR2 plus 4 g Release device Chapter 7 Grease For example: 0750 199 001 Aralub HL2 50 g - Split ring / converter Chapter 8 5 g - Needle sleeve / turbine shaft Chapter 9 2 g - Shaft seal / retarder housing Chapter 12 2 g - Shaft seal / converter housing Chapter 13 Graphite grease Converter centring journal Chapter 1 NOTE: Inquire about the size of bundles that can be delivered before placing any orders !

ZF TRANSMATIC Transmission Gearbox Workshop Repair Manual

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