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GK20 – GK40
Maintenance and Installation Instructions
Edition: 11.07.2006
For possible technical modifications of the product described in this manual ZF Gotha GmbH reserve the
right to change the product documentations, if necessary. Technical modifications are to be considered as
modifications in production, processing and appearance of the product.
Copyright ZF Gotha GmbH 2006
ZF Gotha GmbH • Karl-Liebknecht-Straße 26 • D-99867 Gotha
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Summary of Contents for ZF GK20
- Page 1 Maintenance and Installation Instructions Edition: 11.07.2006 For possible technical modifications of the product described in this manual ZF Gotha GmbH reserve the right to change the product documentations, if necessary. Technical modifications are to be considered as modifications in production, processing and appearance of the product.
- Page 2 40. The herein described work is only allowed to informed by ZF Gotha GmbH and the changed be made by specialists who were trained by ZF pages of this manual will be made available to Gotha GmbH for maintenance and repair work on them.
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Page 3: Table Of Contents
Components and Accessories of a GK Transmission............6 Transmission Identification ....................7 INSTALLATION ......................8 General Instructions ......................8 Torque limits in Nm for screws to ZF Standard 148 ..............8 Condition as supplied ....................... 9 Storage............................9 Transport ..........................9 Removal of the corrosion protection ..................9 Attachment of the Electric Motor.................. - Page 4 Pivoted Connection – Roller Chain Steering..............17 Transmission Attachment to the Mounting Construction in the Vehicle ......22 Drive wheel mounting......................23 INITIAL OPERATION / MAINTENANCE ..............25 Oil grade for transmission types GK 20, GK 25, GK 30............25 Oil grade for transmission type GK 40 ..................
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Page 5: Description
Description Preface This documentation has been developed for the skilled Serviceman, trained by ZF for the Repair and Maintenance operations on ZF-Units. Treated is a ZF-Serial product according to the design stage of the date of 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 other adjustment and testing specifications. -
Page 6: Safety Instructions
• transmission and are not allowed. Only original spare parts from ZF or spare parts approved by ZF are allowed to be used. It is • explicitly pointed out to the fact that spare parts and accessories, which were not supplied by ZF are not checked and approved by us either. -
Page 7: Components And Accessories Of A Gk Transmission
Components and Accessories of a GK Transmission Item 01 one-piece transmission housing Item 02 Venthole for electric motor ventilation Item 03 optional steering: Gear ring with steering pinion (is shown) or steering chain as alternative Item 04 Mounting holes (optional) Item 05 one-piece pivoted bogie bearing (optional) Item 06... -
Page 8: Transmission Identification
Technical data of the transmission is indicated on the model identification plate. Transmission type Serial Number GK 20 200001 4699 801 017 14,50 ZF Parts List No. Total ratio Figure 03 Maintenance and Installation Instructions Edition 11.07.2006 7 of 30... -
Page 9: Installation
Installation General Instructions Torque limits in Nm for screws to ZF Standard 148 Torque limits, if not especially indicated, can be taken from the following list: Metric ISO-Standard thread DIN 13, Metric ISO-Fine thread DIN 13, Sheet 13 Sheet 13 Size 10.9... -
Page 10: Condition As Supplied
(customer-specific agreement possible) • painted with prime coating (ZF Standard 902) and coating varnish (RAL 9005), colour: jet black • The wheel shaft sealing, the centering- and locating face for the drive wheel on the wheel shaft, •... -
Page 11: Attachment Of The Electric Motor
Attachment of the Electric Motor If the unit is supplied with an already attached electric motor this chapter is not applicable. The centering- and locating faces for connection of the electric motor must be perfectly clean and undamaged. Check face run-out of the motor connecting face to the motor shaft. The maximum run-out must not exceed 0.05 mm. - Page 12 Example for the electric motor attachment without centering ring connection directly to the pivoted bogie bearing. Figure 04 Maintenance and Installation Instructions Edition 11.07.2006 11 of 30...
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Page 13: Pivoted Connection-Steering
In order to avoid inadmissible variations among the screw clamping forces, always pretension the • screws carefully crosswise to the specified value. Tightening torque: 34 Nm Cl.3 ZF Standard After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is •... -
Page 14: Mounting Of The Pivoted Bogie Bearing With Holding Ring Gk 40
Mounting of the pivoted bogie bearing with holding ring GK 40 a) Press the pivoted bogie bearing (Item 01) evenly into the transmission top section until contact is obtained. b) Determine the Dim. A and B. Figure 06 Prior to bolting c) Calculate the thickness of the shim rings (Item 02) to be inserted, so that the bearing preload is reached. -
Page 15: Mounting Of The Transmission Top Section Gk 40
Mounting of the transmission top section GK 40 Apply a thin layer of LOCTITE 574 onto the transmission plane face. Place the transmission top section onto the transmission housing that the cyl. pin (Item 01) in the transmission housing is positioned into the fitting bore in the transmission top section. -
Page 16: Mounting Of The Gear Ring Gk 40
Mounting of the gear ring GK 40 1. Place the steering turntable (Item 01) and rotate it so that the boltholes in the steering turntable align with the threaded holes of the transmission top section (Item 02). 2. By means of a plastic tip hammer install the steering turntable until contact and position it with the cyl. -
Page 17: Lubrication And Maintenance Of The Pivoted Connection
Lubrication and maintenance of the pivoted connection First lubrication of the teeth is to be made immediately after mounting. Spray grease is to be sprayed or to be applied evenly onto the teeth. For this purpose and any later relubrication only use acid-free, non- resinous, waterproof and non-ageing greases! Without lubrication and relubrication respectively there will be a direct metallic contact of the teeth resulting in damages. -
Page 18: Pivoted Connection - Roller Chain Steering
Lubricants Description Temperature range Manufacturer Aralup LFZ 1 -25° C to +250°C ARAL Energol WRL 0°C to +80 °C CARDREXA DC 1 -20° C to +120°C SURRET FLUID 4k -20° C to +100°C ESSO CRAFLOSCON CG 901 Manual lubrication -20° C to +150°C Klüber CRAFLOSCON C-SG-0 Plus Spray lubrication Mobiltac A Manual lubrication... - Page 19 Chain guideway Plane face Figure 13 Within an area of approx. 135° around the chain tensioner only riveted connecting elements (chain joints) are allowed to be used. Drive wheel and wheel shaft respectively must be aligned in direction of motion. The chain tensioner should be mounted opposite of the steering...
- Page 20 In order to avoid inadmissible variations among the screw clamping forces, always pretension the • screws carefully crosswise to the specified value. Tightening torque: 34 Nm Cl.3 ZF Standard After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is •...
- Page 21 Calculation formula for steering drive design The steering drive design is to be calculated as follows: Steering torque [Nm]: = Wheel load in kg (see tech. data vehicle) • • • µ b = Wheel width in mm (see tech. data) Steering 4000 µ...
- Page 22 The following chains are currently approved by ZF for GK40 etc.: (see Fig. 16, Page 21) Mounting dimensions (in mm) Single roller chain Ø335.16 DIN 8187-E-10B-1 DIN 8181-E-210B 10B-1 5/8“ x 3/8“ Ø337.07 DIN 8187-E-12B-1 DIN 8181-E-212B 12B-1 ¾“ x 7/16“...
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Page 23: Transmission Attachment To The Mounting Construction In The Vehicle
If this requirement is not fulfilled the service life of the pivoted bogie bearing reduces. Additionally, the reliability in service is put at risk. Shape alternatives of the locating face require a written approval by ZF, which however will only be given after a preceding installation investigation. M 12 0.15... -
Page 24: Drive Wheel Mounting
DIN 74361! Tires with other dimensions or rim offsets require a written approval by ZF! The centering and selection of the corresponding fixing elements for the drive wheel is made as follows: for Vulkollan drive wheels over the centering collar of the wheel shaft with flat collar nut and spring •... - Page 25 Drive wheel Fixing elements Figure 18 After mounting of a wheel it is mandatory to retighten the wheel nuts and wheel bolts respectively with the specified torque after a mileage of approx. 50 km. Maintenance and Installation Instructions Edition 11.07.2006 24 of 30...
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Page 26: Initial Operation / Maintenance
/ Products for / Techn.Information / List of Lubricants The use of alternative oil grades requires the written approval by ZF Gotha GmbH. ZF units are designed up to -30° C. ZF cannot give any warranty for an operation below -30° C. -
Page 27: Maintenance Intervals Transmission
No further transmission oil changes are required when the first oil change was made after 150-300 operating hours. Repaired transmissions are to be treated like new transmissions. Modifications of these specifications require the written approval by ZF. Oil Change Drain the transmission oil at GK 20, GK 25 & GK 30 Do not drain transmission oil into the soil or the sewerage system. - Page 28 Drain the transmission oil at GK 40 Do not drain transmission oil into the soil or the sewerage system. Pay attention to the type and quantity of debris. High oil temperatures are to be expected after continuous operation of the transmission.
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Page 29: Fill In The Transmission Oil At Gk 20, Gk 25 & Gk 30
Fill in the transmission oil at GK 20, GK 25 & GK 30 Clean magnet on the oil drain plug (Item 03) • and always reattach it with a new sealing ring (Item 04). (See Fig. 13) Tightening torque: 22 Nm Fill in the transmission oil. -
Page 30: Fill In The Transmission Oil At Gk 40 (Possibility 2)
Fill in the transmission oil at GK 40 (Possibility 2) Clean magnet on the oil drain plug (Item • 03) and always reattach it with a new sealing ring (Item 04). (See Fig. 14) Tightening torque: 22 Nm Fill in the transmission oil. For oil quantities •... -
Page 31: Maintenance Scheme
Maintenance Scheme Maintenance only once after regularly after after intervals operating 25 h 200 h 300 h 600 h 1500 h hours varying, depending what Mounting 7 days 1 month 3 months 6 months 12 months occurs first intervals Maintenance work Attention: after 50 km it is absolutely necessary to •...
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