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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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Table of Contents
Related Manuals for ZF GK30
Summarization of Contents
Introduction
Manual scope and personnel requirements
Manual covers maintenance and installation for GK transmissions, requiring trained specialists.
DESCRIPTION
Preface
Documentation for skilled serviceman, emphasizes trained personnel and genuine parts.
Components and Accessories of a GK Transmission
Lists and illustrates the various components and optional accessories of the GK transmission.
Transmission Identification
Details how to identify the transmission type and locate the model identification plate.
INSTALLATION
General Instructions
Provides essential guidelines, including torque limits and preparation for installation.
Torque limits in Nm for screws to ZF Standard 148
Lists torque specifications for various metric ISO-standard and fine thread screws.
Condition as supplied
Describes the standard condition of the GK transmission when supplied by ZF.
Storage
Provides guidance on proper storage of GK transmissions to maintain their condition.
Transport
Outlines the correct procedures for transporting the transmission safely.
Removal of the corrosion protection
Instructions on safely removing protective coatings before installation.
Attachment of the Electric Motor
Details the procedure for attaching the electric motor to the transmission unit.
Pivoted Connection-Steering
Covers the mounting of the gear ring with the pivoted bogie bearing for GK 20-30.
Transmission Attachment to the Mounting Construction in the Vehicle
Explains the requirements for mounting the transmission to the vehicle's construction.
Drive wheel mounting
Provides instructions for correctly mounting the drive wheel onto the transmission shaft.
Mounting of the pivoted bogie bearing with holding ring GK 40
Step-by-step guide for mounting the pivoted bogie bearing with a holding ring for GK 40.
Mounting of the transmission top section GK 40
Details the process of mounting the transmission top section onto the GK 40 housing.
Mounting of the gear ring GK 40
Explains how to mount the gear ring onto the steering turntable for the GK 40.
Demounting of the pivoted connection
Describes the process of disassembling the pivoted connection.
Checking of fixing bolts of the pivoted connection
Instructions for regularly checking and tightening fixing bolts on the pivoted connection.
Lubrication and maintenance of the pivoted connection
Covers initial lubrication and maintenance intervals for the pivoted connection teeth.
Pivoted Connection – Roller Chain Steering
Details the components and mounting of the pivoted connection with roller chain steering.
Chain tensioner
Explains the design and mounting of the chain tensioner for roller chains.
Mounting of the pivoted connection
Steps for mounting the pivoted connection, ensuring clean surfaces and correct alignment.
Mounting of the chain tensioner
Detailed steps for installing and tensioning the chain tensioner.
Safety Instructions
Use as directed
Emphasizes strict observance of manufacturer specifications for installation and maintenance.
Personnel qualification
States that all personnel must read, understand instructions, and be trained specialists.
Prohibited working methods
Any method endangering transmission safety or involving unauthorized modifications is prohibited.
Spare parts usage
Only original or ZF-approved spare parts are allowed; liability is excluded otherwise.
Chemical handling
Guidelines for handling aggressive cleaners, including wearing protective gear.
Environmental protection
Prohibits draining oil or cleaners into soil or sewage systems.
Blocking wheels
Wheels must be blocked before working on installed or mounted transmissions.
Disconnecting voltage source
Voltage source for the motor must be disconnected before any work on the transmission.
Local safety regulations
Local regulations for safety and accident prevention must be observed.
INITIAL OPERATION / MAINTENANCE
Oil grade for transmission types GK 20, GK 25, GK 30
Specifies approved oil classifications and standards for GK 20, 25, and 30 transmissions.
Oil grade for transmission type GK 40
Specifies approved oil classifications and standards for the GK 40 transmission.
Oil capacity
Lists the required transmission oil quantities for GK 20, 25, 30, and 40 models.
Maintenance intervals Transmission
Outlines the recommended intervals for transmission maintenance and checks.
Oil Change Procedure for GK 20, 25, 30
Details the procedure for draining and refilling transmission oil for GK 20, 25, 30.
Oil Change Procedure for GK 40
Details the procedure for draining and refilling transmission oil for GK 40.
Refilling Transmission Oil for GK 20, 25, 30
Step-by-step guide for refilling transmission oil into GK 20, 25, and 30 models.
Refilling Transmission Oil for GK 40 (Possibility 1)
Procedure for refilling transmission oil into GK 40, covering possibility 1.
Refilling Transmission Oil for GK 40 (Possibility 2)
Procedure for refilling transmission oil into GK 40, covering possibility 2.
Calculation formula for steering drive design
Steering torque [Nm]
Formula for calculating the steering torque required for the drive design.
Tractive force of the chain [N]
Formula for calculating the tractive force of the chain in the steering drive.
Transmission Attachment to the Mounting Construction in the Vehicle
Requirements for supporting face
Emphasizes the need for a rigid, even, and flat supporting face for the pivoted bogie bearing.
Shape alternatives of the locating face
Requires written approval from ZF for any alternatives to the standard locating face shape.
Drive wheel mounting
Prior to mounting and initial operation
Instructions regarding air volume, carrying capacity, and speed limits for wheels.
Wheel fixing compliance
Ensures wheel nuts and spring washers comply with DIN standards; other dimensions need ZF approval.
Fixing elements selection
Guidance on selecting fixing elements for Vulkollan and pneumatic/CSE-drive wheels.
Preparation before mounting
Key components like wheel shaft and bolts must be clean, grease-free, and undamaged.
Retightening after mileage
Mandates retightening of wheel nuts and bolts after approximately 50 km.
Maintenance Scheme
Maintenance intervals
Defines intervals for maintenance tasks based on operating hours or calendar time.
Maintenance work
Details specific maintenance tasks like bolt retightening, oil changes, and greasing.
Visual inspections
Lists various visual checks for oil leakage, component condition, and transmission status.
Special application conditions
Adjustments to maintenance intervals for stored or extreme operating condition transmissions.
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