Zf 6s1000 1200bo Bd Repair Manual

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Repair Manual

6 S 1000 BD
6 S 1000 BO
6 S 1200 BD
6 S 1200 BO

1350 751 101

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Subject to technical changes

Copyright by ZF

The present documentation is protected by copy-

right. Any kind of reproduction or dissemination in
whatever form that does not exclusively correspond
to documentation objectives will be prosecuted if
no prior approval by ZF Friedrichshafen AG was
granted.

Printed in Germany

ZF Friedrichshafen AG, MC-C / 2005-06

Edition: 2005-06

1350 751 101

6 S 1000 BD/BO
6 S 1200 BD/BO Table of Contents

Page

Preface ........................................................................................................................................................... 5
General Comments......................................................................................................................................... 6
Safety Instructions ......................................................................................................................................... 7
Instructions for Repairs ................................................................................................................................. 8
Overview of Amendments ............................................................................................................................ 11
Tightening Torques ........................................................................................................................................ 12
Conversion from DIN to ISO Standards ....................................................................................................... 14
Consumables ................................................................................................................................................. 16
Adjustment Data ............................................................................................................................................ 17
Spring Table ................................................................................................................................................... 21
Special Tools .................................................................................................................................................. 22
Sectional View ............................................................................................................................................... 27

1 Externally-mounted parts, output end ......................................................................................... 1-1

1.1 Removal .......................................................................................................................................... 1-1
1.2 Fitting .............................................................................................................................................. 1-6
1.3 Dismantling cover........................................................................................................................... 1-11
1.4 Assembling cover............................................................................................................................ 1-12

2 Shift mechanism ............................................................................................................................ 2-1

2.1 Removal .......................................................................................................................................... 2-1
2.2 Fitting .............................................................................................................................................. 2-4
2.3 Dismantling..................................................................................................................................... 2-6
2.4 Assembly - Summary of shift mechanism types, driver arrangement and compression
spring arrangement for selector adjustment.................................................................................. 2-16
2.5 Assembling shift mechanism ......................................................................................................... 2-22

3 Externally-mounted parts, input end............................................................................................ 3-1

3.1 Removal .......................................................................................................................................... 3-1
3.2 Fitting .............................................................................................................................................. 3-4

4 Adjusting bearings on input shaft/mainshaft and layshaft ....................................................... 4-1

4.1 Adjusting input shaft and mainshaft ............................................................................................. 4-1
4.2 Adjusting layshaft ........................................................................................................................... 4-3

5 Mainshaft/input shaft and layshaft.............................................................................................. 5-1

5.1 Removal .......................................................................................................................................... 5-1
5.2 Installation ...................................................................................................................................... 5-7

6 Input shaft ...................................................................................................................................... 6-1

6.1 Dismantling..................................................................................................................................... 6-1
6.2 Assembly......................................................................................................................................... 6-1

1350 751 101 - 2005-06 3

6 S 1000 BD/BO
6 S 1200 BD/BO Table of Contents

Page

7 Mainshaft ....................................................................................................................................... 7-1

7.1 Dismantling..................................................................................................................................... 7-1
7.2 Assembly......................................................................................................................................... 7-16

8 Layshaft .......................................................................................................................................... 8-1

8.1 Dismantling..................................................................................................................................... 8-1
8.2 Assembly......................................................................................................................................... 8-4

9 Housing........................................................................................................................................... 9-1
9.1 Dismantling transmission housing................................................................................................. 9-1
9.2 Assembling transmission housing.................................................................................................. 9-4
9.3 Dismantling housing cover............................................................................................................. 9-8
9.4 Assembling housing cover.............................................................................................................. 9-10

1350 751 101 - 2005-06 4

 Preface

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 products

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 up-
dated 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, according to our latest

specifications.

All work performed at these Service Points is car-

ried out conscientiously and with utmost care.

Warranty:
Repair work carried out at ZF Service Points is
subject to the contractual conditions prevailing in
ZF Friedrichshafen AG the individual case.
Nutzfahrzeug- und Sonder-Antriebstechnik
Commercial Vehicle and Damage resulting from work performed by non-ZF
Special Driveline Technology personnel in an improper and unprofessional
Service Werk 2 (Plant 2) manner and any consequential costs are excluded
Phone: +49 (0)7541 77-0 from the contractual liability agreement. Exclusion
Fax: +49 (0)7541 77-908000 of liability also applies if genuine ZF spares are
Internet: www.zf.com not used.

2003-08 5
6 S 1000 BD/BO
6 S 1200 BD/BO General Comments

Transmision description and function

The 6-speed transmission serie is available as a

direct drive or an overdrive transmission with a
separate fitted clutch bell housing. It is of conventio-
nal transmission gearing design. Helical gears are
used for the lock-synchronized forward speeds and
also for the constant-mesh reverse speed.

The 6-speed transmissions may be equipped with the

following auxiliary equipment, depending on the
vehicle configuration:

• ZF secondary retarder

• Engine-dependent power take-offs

•Vehicle-driven power take-off

to drive a pump for an emergency or
dual-circuit steering system

• Clutch-dependent power take-off for con-

nection on output end

• Separate heat exchanger to cool transmission

oil

1350 751 101 - 2005-06 6

 Safety Instructions

Safety Instructions General Information

Companies repairing ZF units are responsible for Read this manual carefully before starting any tests
their own work safety. or repair work.

To avoid injury to personnel and damage to

products, all safety regulations and legal require- CAUTION
ments which apply to repair and maintenance Pictures, drawings, and components do not always
work must be adhered to. represent the original object, but are used to illus-
Before starting work, mechanics must familiarize trate working procedures.
themselves with these regulations. Pictures, drawings, and components are not to scale.
Conclusions about size and weight should not be
Personnel required to carry out repairs on ZF drawn (even within a complete illustration).
products must receive appropriate training in Always follow the working steps as described in the
advance. It is the responsibility of each company to text.
ensure that their repair staff is properly trained.

After completion of repair work and testing, skilled

staff must check whether the product is functioning
The following safety instructions appear in this correctly.
manual:

! THREATS TO THE ENVIRONMENT !

NOTE Lubricants, consumables, and cleaning agents must
Refers to special processes, techniques, data, use of not be allowed to enter the soil, ground water, or
auxiliary equipment, etc. sewage system.
• Ask your local environment agency for safety
information on the relevant products and adhere
CAUTION to their requirements.
This is used when incorrect, unprofessional work- • Collect used oil in a suitably large container.
ing practices could damage the product. • Dispose of used oil, dirty filters, lubricants, and
cleaning agents in accordance with environmental
protection guidelines.
! DANGER • When working with lubricants and cleaning agents
This is used when lack of care could lead to personal always refer to the manufacturer’s instructions.
injury or death.

CAUTION
The transmission must NOT be suspended by the
input shaft NOR by the output flange.

2005-04 7
 Instructions for Repairs

ZF Service Information must be observed. This Gaskets, Locking plates

information is available at all ZF Service Centers
or via the ZF-ServiceLine. Parts which cannot be removed without being
damaged must always be replaced with new parts
In case of doubt always turn to the relevant depart- (e.g. gaskets and locking plates).
ment within ZF After-Sales Services for advice.
All work on transmissions is to be performed by
experts only and under clean conditions.
Use specified tools to dismantle and assemble Shaft Seals
transmissions.
Always change shaft seals with rough, ripped or
hardened sealing lips. Seal contact surfaces must be
After removing the transmission from the vehicle, totally clean and in perfect condition.
clean it thoroughly with a suitable cleaning agent
before opening.
Pay particular attention to the projections and
recesses of housings and covers when cleaning. Reworking

Parts joined with Loctite are easier to separate if Rework may be carried out on seal contact surfaces
warmed with a fan heater. using plunge-cut grinding only, never use an emery
cloth. Ensure that there are no traces of grinding or
scroll.

Cleaning parts If rework is needed on spacer discs, shims etc.

because of clearance adjustment, ensure that the
Remove remains of old gaskets on all sealing sur- reworked areas contain no face runout and have
faces. Carefully remove burrs or similar patches of the same surface quality.
roughness using an oilstone.

Lube bores and grooves must be free of anti-

corrosion agents and foreign matter; check for Transmission Assembly
perfect passage.
Find a clean work area to assemble the trans-
Carefully cover opened transmissions to prevent for- mission. Gaskets are installed without sealing
eign matter from entering. compound or grease. When measuring silicon-
coated gaskets, do not include the silicon layer.
During assembly, comply with all adjustment data
and tightening torques in the Repair Manual.
Reusing parts

Parts such as roller bearings, 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.

2005-04 8
 Instructions for Repairs

Bearings d) Dual shaft seals have two seal-

ing lips. The dust-proof sealing
If bearings are mounted in heated condition, they lip (X) must face outwards.
are to be heated evenly (e.g. heating cabinet). X
Temperature should be at approx. 85 °C and must e) Fill the gap between the sealing
not exceed 120 °C. Each mounted bearing must be lips so it is 60 % filled with grease (e.g. produced
oiled with operating oil. by Aral, such as Aralub HL2 or by DEA, such as
Spectron FO 20).

f) If possible, heat shaft seal bores to between

Sealing 40 and 50 °C (makes fitting easier). Press the
seal shaft with mounting or faceplate onto the
If a specific sealing agent* is to be used for sealing, relevant installation depth plan.
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, Retaining Agents
wipe off the sealing agent on the surfaces to be
sealed near apertures to ensure that no sealing Retaining agents* may only be used in places as
agent enters the oil feeds when the surfaces are specified in the parts list.
sealed. 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 circum-

ference of shaft seals with “steel jacket”. Transmission oil

b) Never apply sealing agent to shaft seals with After completing repairs, fill transmissions with
“rubber jacket”, but apply a thin coat of transmission oil. For the procedure and approved
Vaseline 8420 to the circumference or wet with oils, refer to the transmission operating manual and
a lubricant, e.g. a water-soluble, concentrated TE-ML List of Lubricants (refer to identification
washing-up liquid (e.g. Pril, Coin, Palmolive). plate) which are available from any ZF After-Sales
Service Point and on the Internet under
c) Shaft seals with steel and rubber jackets should www.zf.com.
be treated on the circumference of the rubber After filling the transmission with oil, tighten the
jacket as described above in section b). screw plugs at the oil filling point and the oil over-
flow using the specified torques.

* refer to expendable material

2003-08 9
Zf 6s1000 1200bo Bd Repair Manual
Full download: http://manualplace.com/download/zf-6s1000-1200bo-bd-repair-manual/

1350 751 101 - 2005-06 10

This is the cut pages sample. Download all 144 page(s) at: ManualPlace.com