German ZF gearboxes on KAMAZ trucks

Model description

The ZF 16S1650 MAZ gearbox is a sixteen-speed manual gearbox, consisting of a main four-stage gearbox, a front two-stage gear divider and a two-stage range amplifier.
Equipped with a backup steering pump driven by the drive wheels, which ensures the operation of the power steering in the event of failure of the main power steering pump. The ZF 16S1650 gearbox is installed on MAZ heavy-duty trucks: 544008, 643008 and others.

Design and principle of operation

Each type of ZF gearbox on KamAZ has its own device. Thus, the 6-speed ZF 6S models are mechanical and have synchronizers in 1st, 2nd, 3rd, 4th, 5th and 6th gears.

The ZF 9S1310 gearbox includes:

• 4-speed gearbox with reduced speed and reverse with dog clutches;
• planetary range multiplier, doubling the number of gears.

As a result, 9 speeds are formed for driving forward and 1 in reverse. The 4-speed part is characterized by mechanical shifting and has a servo shift. The gear shift pattern is “double H” or “cascade H”.

The multiplier has a valve and a double-acting pneumatic cylinder and provides:

• with “double H” - automatic switching when moving from row 3/4 to 5/6 and vice versa;
• with “cascade H” - preselector switching on the gear lever.

In ZF Ecomid gearboxes, the gears are driven by synchronizers, the process is carried out in the following ways:

• without double disengagement of the clutch when setting from low to high speeds;
• without the participation of the accelerator and disengaging the clutch when moving from higher to lower gears.

The ZF 16 gearbox was created for heavy trucks, because the greater the differentiation of the stages, the less load is on the engine, and the vehicle accelerates faster. The design of the ZF 16 s 151 gearbox assumes the presence of a synchronizer, which greatly simplifies the process of gear shifting, extends the life of the engine, clutch and the gearbox itself.

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The 16-speed ZF 16S151 gearbox model consists of:

• gearbox;
• demultiplier;
• front divider.

The gearbox is a synchronized unit with 4 gears, having switching shafts of the rear or front axle, and a Servoshift servo device. Engagement of the reverse speed is ensured by a gear clutch, the gears are installed according to the “double H” or “overlapping H” scheme.

The multiplier switches speeds in 2 modes:

• when transitioning between 3/4 and 5/6 and vice versa, carried out according to the “double H” scheme;
• using the preselector according to the “overlapping H” scheme.

Servoshift is a pneumomechanical control with a master cylinder.

To carry out the switching, pneumatic reinforcement is required. The gearbox can be equipped with a power take-off and a hydrodynamic retarder. With a greater number of speeds, the load is reduced, the movement of vehicles on the road becomes smoother, and fuel consumption is reduced by 15%.

Gearbox control

Shift gears in the gearbox using the gear lever located to the right of the driver's seat. Change gears with the clutch disengaged. Press the clutch pedal all the way. Engage and shift gears at minimum idle speed. Start driving only from first gear (to avoid premature clutch failure). To quickly accelerate the vehicle on good roads and in difficult conditions, it is recommended to use all gears sequentially according to gear shift patterns. In cars with a cable drive to control the gear shift mechanism, a gearbox with a servo shift is used. The servoshift serves to facilitate gear shifting; air is supplied to it from the car's pneumatic system.

Attention! Do not change gears until the operating pressure in the pneumatic drive is reached (from 6.5 to 8.0 kgf/cm2) to avoid cable breakage due to the servoshift not developing the required force.

If there is a divider in the gearbox, a gear divider control switch is mounted in the gear shift lever handle (see Fig. Gear shift lever). The switch can be used to select the highest “B” or lowest “H” gear in the divider. It is recommended to use the entire range of low and high gears. To switch from a higher gear to a lower one, and vice versa (without shifting the lever), you need to move the gear divider control switch to the desired position, and then press and release the clutch pedal after a short (1 second) delay - the gear will engage automatically. To simultaneously shift the lever and engage a higher or lower gear, set the divider control switch to the “B” or “H” position, press the clutch pedal and shift the lever.

Gear shift lever

For gearboxes of models 144, 154, shift gears according to the diagrams (see Fig. Gear shift diagram in a model 144 gearbox and Gear shift diagram in a model 154 gearbox).

Shift diagram for a 144 transmission

Shift diagram for a 154 transmission

For the ZF 9S1310 model gearbox, shift gears according to the diagram (see Fig. Gear shift diagram in the ZF 9S1310 model gearbox):

• 1-2-3-4-lower gears (lowest range of multiplier);
• 5-6-7-8-high gears (highest range of range).

When slowing down, change gears only sequentially: 8-7-6-5-4-3-2-1. Always keep the gear engaged when driving.

Gear shift diagram in the gearbox model ZF 9S1310

Low gear “C” is intended for starting in difficult road conditions and for maneuvering.

Attention! For gearboxes it is strictly prohibited:

• switch from the highest range of the multiplier to the lower range of the multiplier at a speed of more than 30 km/h (for ZF gearboxes);
• move with the gear shift lever in neutral position;
• engage reverse gear (R) when the vehicle is not completely stopped and when the clutch plate is rotating.

Gear shifting in the multiplier occurs automatically: the highest gear is engaged when the gearbox control lever moves from the fourth to the fifth position, the lowest gear is engaged when switching from fifth to fourth. When the lever is moved through the “◊” position, the valve is activated, providing automatic switching of the range multiplier. When the low range is turned on in the range multiplier, a warning lamp lights up on the instrument panel. When the range shifter is switched, the gear shift lever rod of the main box is blocked, and a force is felt on the lever, after which it is recommended to wait 1-1.5 seconds to ensure the gear shift in the range shifter.

ZF company: history and production facilities

Let's start with the fact that ZF is a German manufacturer, and gearboxes and other products of this German concern are well known throughout the world. The units and units of the Polar Division are actively used by both German automakers and others.

Moreover, ZF gearboxes are even installed on Russian cars. Today ZF is one of the three largest manufacturers of automotive components in Germany and the fifteen largest global suppliers of parts, assemblies and components for automobiles in the world.

ZF has a rich history. The full name is Zahnradfabrik GmbH, which literally means “gear factory”. From the very beginning, this company, which was registered back in 1915, specialized in the production of gears and gearboxes for aircraft, cars and ships.

The plant was built in the city of Friedrichshafen (Germany), where the Zeppelin company was based back in 1908. In fact, the capabilities of this enterprise formed the basis of ZF. As of today, the company has produced a large number of gearboxes for both ordinary city cars and racing cars, as well as for trucks, buses and special equipment.

By the way, the ZF concern began to use this name officially only in the early 90s. At the same time, the company has long been producing a fairly wide range of products, not just gears and gearboxes.

Today, the company's facilities are located in different countries of the world, since since 1958 the ZF company began to actively develop, opening factories outside of Germany. For reference, the ZF concern includes more than 120 factories located in 27 different countries.

By the way, a joint venture between ZF and KAMAZ has been successfully operating in the Russian Federation since 2005, known as ZF KAMA from the city of Naberezhnye Chelny. This company produces gearboxes for domestic trucks.

At the same time, the main capacities are traditionally located in Germany, among which there are 3 leading ones in certain areas. First of all, ZF Friedrichshafen is the headquarters and main plant for the production of gearboxes and chassis components for commercial vehicles.

Also worth noting is ZF Saarbruecken, the company specializes in the development and production of gearboxes, as well as chassis for passenger cars. In parallel, ZF Passau also deserves attention, where two enterprises for the production of gearboxes and bridges for buses, as well as road and construction equipment are combined.

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KamAZ gearbox: how to drive correctly

How to use a modern KamAZ gearbox without harm to the car or your own nerves. Any KamAZ gearbox is a complex, technically advanced device. And the ZF 16S151 Ecosplit box is even more so. This reliable, modern unit is widely installed on KamAZ 6520 and 5460. It is always accompanied by detailed instructions, which indicate all the basic operating rules. But life shows that instructions are the last thing a Russian person needs.

Having successfully neglected the rules of use, our driver often causes the box to suffer serious damage. Let's say more: almost every second malfunction in Ecosplits is the result of improper handling. What should you do to ensure that the German KamAZ gearbox serves you for as long as possible? It is enough not to forget about the basic rules of operation. There are only four of them. First, when changing gears, always depress the clutch all the way. If this is not done, the synchronizers inside the gearbox will quickly become unusable.

Secondly, never shift from high gear range (5,6,7,8) to low gear (1,2,3,4) at speeds over 30 km/h. Otherwise, you can say goodbye to range synchronizers. Thirdly, do not “jump” from a high gear to a lower one in one step. By doing this, you expose the synchronizers to excessive loads. But “jumping” from low to high gears is not forbidden.

Fourth, do not coast downhill. This can lead to overheating of the bearings, since the gearbox oil pump will not produce enough pressure to fully lubricate them.

Towing and service

To preserve the German gearbox on KamAZ, do not forget about the rules of proper towing. Thus, starting the engine by towing is allowed only in high gears (5-8), and engaging the PTO or reverse gear is possible only 10 seconds after disengaging the clutch.

As for maintenance, it naturally must be done regularly. If you notice the first signs of a breakdown, immediately go to the workshop. Extraneous knocks, crunching noises, crashes and oil leaks should not go unnoticed! Otherwise, a small malfunction will sooner or later turn into a serious breakdown. It is always better to quickly fix minor problems than to invest a lot of money in major repairs.

In general, units from the ZF concern are rare “guests” in specialized workshops. This is reflected in the legendary German reliability, which was preserved even in the conditions of localization of production in the Russian Federation. But if you do have a breakdown, you can always find the necessary spare parts on our website. In addition, we sell many types of KamAZ gearboxes assembled from Chinese and European manufacturers. We always have what you need!

ZF gearbox

ZF products today include a large list of transmission, chassis, and chassis elements for trucks, passenger cars and special equipment. The ZF company produces manual transmissions for various types of equipment, automatic transmissions for cars and trucks, clutches, drive axles, power steering, gearboxes, etc.

At the same time, many ZF units are produced under its own brand, thanks to which the company is very popular. For example, the durability of the ZF manual transmission and the reliability of gearboxes for trucks and commercial vehicles (Ecolite, Ecosplit, Ecomid line) make this brand very recognizable.

Automatic transmissions are not far behind in popularity (AS Tronic for trucks, eTronic, AS Tronic lite, Ecomat automatic transmissions). ZF products are also actively installed on Volkswagen, Audi, BMW, Renault, Iveco, MAN and DAF models, etc. At the same time, it is customary to associate ZF automatic transmissions with reliability, well-known German quality and a long service life of the units.

Transmission - automatic ZF

The ZF manual gearbox is traditionally considered a reliable solution with a long service life. At the same time, today there is nothing special about this, since besides the Germans, other manufacturers also produce high-quality manual transmissions. Another thing is the automatic transmission.

Compared to competitors, ZF automatic transmissions are not inferior, and in some aspects even superior to automatic transmissions from other manufacturers. By the way, the first to appreciate ZF automatic transmissions was the BMW company, which began to install this manufacturer’s gearboxes en masse on its models, starting with the prestigious BMW 7 Series and ending with the compact BMW 1 Series.

As for modern versions of automatic transmissions, special mention should be made of the popular ZF 8-speed automatic transmission. This eight-speed automatic transmission remains in demand today, even taking into account the emergence of a large number of manual transmissions and CVTs. At the same time, the 8-speed automatic transmission is installed not only on BMWs, it can be found on premium Bentleys and many other cars.

Naturally, with the release of the first version of such a gearbox (6-speed) on the market in 2009, many manufacturers, following the global trend of purchasing units from third-party manufacturers in order to reduce the cost of production, immediately paid attention to the new product from ZF. As a result, the ZF automatic transmission appeared on many cars with automatic transmissions.

The first version was a 6-speed automatic, which gained great popularity, after which a second version of this unit was released, but with 8 steps. The updated ZF transmission was introduced in 2014. Let's look at why the 8-speed automatic transmission has become a bestseller.

• So, it is well known that for quite a long time automatic transmissions had only 3 forward gears. The design is reliable and time-tested. However, there are also disadvantages, the main ones being losses, a decrease in the efficiency of the machine, and an increase in fuel consumption.

Next, engineers began to complicate the automatic, a fourth gear appeared, torque converter locking began to be actively used, etc. But this was not enough to successfully compete with “robots” and CVTs. It is for this reason that there are even more gears in automatic transmissions, which is necessary to increase the efficiency of the transmission, as well as to save fuel and reduce the level of harmful emissions into the atmosphere.

Simply put, the more gears a gearbox has, the more productive and economical such a transmission works in tandem with the engine, allowing the engine to “spun” in the optimal speed range. Naturally, fuel consumption decreases and the amount of harmful emissions decreases. The car also becomes more “elastic” when driving; a stepped gearbox with a large number of gears ensures a very smooth ride.

This approach made it possible to retain all the advantages of a “classic” automatic transmission, while at the same time not being inferior to CVT and preselective dual-clutch robots in a number of indicators and characteristics. In fact, ZF, in the face of fierce competition, developed a truly legendary 8-speed automatic transmission.

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The specified 8-speed ZF automatic transmission can be considered “universal”, since the ZF transmission can be installed on cars with different types of drive (front-wheel drive, rear-wheel drive, all-wheel drive). The unit can be paired with gasoline engines, as well as diesel ones. The ZF gearbox can also be installed on hybrid cars. Also, the 8-speed gearbox received an expanded power output range.

As a result, the ZF automatic transmission can be paired with any type of engine with different power and torque, regardless of the location of the internal combustion engine, longitudinally or transversely, as well as on vehicles with different types of drive.

You can also highlight the unique software of this automatic transmission, which allows the car manufacturer itself to adapt the settings to different models. Naturally, most manufacturers decided to buy a ZF gearbox instead of developing their own automatic transmission. This unit has been actively distributed throughout the world.

For example, such a gearbox can be found on BMW, Alfa-Romeo, Alpina, Aston Martin, Audi, Bentley, Chrysler, Iveco, Jaguar, Jeep, Land Rover, Maserati, Range Rover, Rolls-Royce, Volkswagen, etc.

KamAZ gear shift diagram

The gear shift pattern (from simple to complex) depends on the type of gearbox installed on the KamAZ vehicle.

For example:

• The gearbox switching scheme of model range 14 provides for five forward gears and one reverse (the KamAZ gearbox of this model range is not designed for transporting loads above 10 tons or towing trailers);
• The gearbox switching scheme of the 15 model series, which includes a gearbox (splitter), provides five forward gears and one reverse, and using the divider it is possible to switch on the speed of the lower traction range (there are twice as many gears);
• The gear shift scheme of the KamAZ ZF gearbox provides for gear shifting in several stages: 1B – 2B – ZV – 4N – 4B – 5N – 5B provides fast acceleration under normal operating conditions. 1N -2N-ZN-4N-4V-5N-5V – difficult operating conditions at the beginning of movement, etc.

If we consider the simplest option, the manual transmission of a KamAZ truck operates in two modes: primary (“H”) and secondary (“B”). Dividing gears into two modes significantly reduced the load on the vehicle's internal combustion engine.

Switching modes is carried out using a special lever:

• the lever is lowered—light vehicle driving mode;
• the lever is raised - the vehicle is moving under heavy loads.

By the way, to start moving, you need to spin the crankshaft to several thousand rpm.

KamAZ gearbox with divider: divider control mechanism

To reduce the load on the internal combustion engine of a car, a divider (reducer) is used - a mechanism with a mechanical principle of operation, activated by a switch on the rocker. Its main function is to increase the gearbox ratio.

Components of the design using the example of a gearbox of model series 15:

• divider control valve;
• pressure reducing valve;
• divider activation valve;
• air distribution mechanism;
• air distribution pipe;

Switching the ZF gearbox on KamAZ vehicles

In order to extend the life of the gearbox, as well as reduce fuel consumption, it is necessary to use the highest gear, and also drive at an average crankshaft speed.

KamAZ 6520 is equipped with a ZF16 gearbox. The figure shows the gear shift diagram:

The gearbox has a synchronizer, which makes shifting easier. Rows 3-4 and 5-6 are neutral in the double H pattern. In order to select row 1-2 or 7-8, you need to move the lever in the direction of the desired row.

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The shift order for the overlapping H pattern will be slightly different. Idling is carried out in rows 3-4 and 7-8. Just as in the previous case, switching to rows 1-2 and 5-6 is carried out by pointing the lever towards this row. In the middle position of the row, the handle returns to its original position. Switching to ZF 9 occurs in the same way.

How to switch correctly

The manufacturer of the ZF16 gearbox has prepared operating recommendations. You can find many diagrams with explanations that clearly show how to switch correctly.

The start of movement must be carried out only in 1st gear. You need to engage gears with the clutch disengaged (the pedal is pressed all the way). It is also important to note that shifting should be carried out at minimum idle speed.

Gears are switched using a lever in accordance with the diagram. When slowing down, it is necessary to change gears in a strict sequence from 8 to 1. It is prohibited to switch from the highest range of the multiplier to the lowest at speeds above 30 km/h.

To switch from accelerating to decelerating gear in the divider (and vice versa), you need to raise/lower the divider control switch, hold for 1 second and lower the clutch pedal - the gear will switch automatically.

The ZF 16 gearbox was created for heavy trucks, because the greater the differentiation of the stages, the less load is on the engine, and the vehicle accelerates faster. The design of the ZF 16 s 151 gearbox assumes the presence of a synchronizer, which greatly simplifies the process of gear shifting, extends the life of the engine, clutch and the gearbox itself.

How to change gears on KamAZ

KamAZ gearbox control

Most KamAZ vehicles are equipped with a manual 5-speed gearbox. Gear shifting is carried out by pressing the clutch pedal and selecting the desired gear with the gear lever, but this must be done in stages.

• — Change gears with the clutch disengaged.
• — Press the clutch pedal all the way.
• — Engage and shift gears at minimum idle speed.
• — Start driving only from first gear (to avoid premature failure of the clutch).

The KamAZ 15th series gearbox and ZF gearboxes are equipped with a divider with two modes: increased “B” and decreased “H”. To switch the mode, you need to move the gear divider control switch to the desired position, and then press and after a short delay (1 second) release the clutch pedal - the gear will engage automatically. To simultaneously change gears and engage a higher or lower gear, you must set the divider control switch to the “B” or “H” position, then depress the clutch pedal and shift the lever.

Gear shift diagram

Shift diagram for a 144 transmission

Shift diagram for a 154 transmission

Gear shift diagram in the ZF 9S1310 model gearbox Gear shift in the ZF 9S1310 model gearbox): 1-2-3-4-low gears (lowest range of the multiplier); 5-6-7-8-high gears (highest range of range). When slowing down, change gears only sequentially: 8-7-6-5-4-3-2-1. Always keep the gear engaged when driving. Low gear “C” is intended for starting in difficult road conditions and for maneuvering. On ZF gearboxes, it is prohibited to switch from the highest range to the lowest at a speed of more than 30 km/h and to move with the gear shift lever in neutral.

To get moving, you need to switch gears in several stages; for example, let’s look at the KamAZ start and acceleration scheme on a flat, hard-surfaced road:

• 1st gear, high mode (B);
• 2nd gear, high mode (B);
• 3rd gear, high mode (B);
• Transition to the 2nd low (H) stage and switch to 4th gear;
• Transition to the primary stage (B), the gear remains in 4th;
• Shift to a lower gear (H), engage 5th gear;
• Return to the higher gear (B), stay in 5th gear.

Brief description of the circuit: 1B - 2B - 3B - 4H - 4B - 5H - 5B .

The main feature of starting to move on a KamAZ is a smooth start and acceleration using lower gears.

In case of heavy workload or difficult driving conditions, it is advisable to switch the first four gears in a low mode (H), then switch to the 4th high gear, then the 5th low gear (H) and then to the 5th high gear (B).

The correctly selected mode saves fuel and minimally wears out the power plant.

Features of ZF boxes models 161 and ZF-9S109

Gear shifting in the multiplier occurs automatically: the highest gear is engaged when the gearbox control lever moves from the fourth to the fifth position, the lowest gear is engaged when switching from fifth to fourth. When the lever is moved through the “◊” position, the valve is activated, providing automatic switching of the range multiplier.

When the low range is turned on in the range multiplier, a special indicator lights up on the instrument panel.

The ZF-9S109 model also has an additional “C” gear, intended solely for driving in difficult situations (large amounts of snow on the road, icing, mud) and for maneuvering.

When the range shifter is switched, the gear shift lever rod of the main box is blocked, and a force is felt on the lever, after which it is recommended to wait 1-1.5 seconds to ensure the gear shift in the range shifter.

Driving on inclines

When climbing, you need to switch to the lower “H” mode.

Follow these rules:

• — When switching from 1st to 2nd gear when ascending a KamAZ truck, you must use the method of depressing the clutch pedal twice.
• — In order for the crankshaft to work correctly when changing gears, you need to use the fuel pedal, which also needs to be pressed periodically. At the same time, you can overcome any steepest climb.
• — When climbing, the engine speed should be more than 2000 rpm. Otherwise, the engine may overheat and stop.
• — During the climb, switch to the desired mode, this will facilitate the operation of the engine and all components of the machine.
• — Shift the right gears in a timely manner.

Downhill control

When driving downhill, you cannot turn off the engine, as the power steering stops working and the steering is blocked, which can lead to an emergency.

Problems also arise with brakes, since heavy equipment is equipped with an auxiliary system. Activating the latter eliminates the ability to use the clutch pedal and switch from one mode to another.

Driving on an icy road

Movement on this section of the route is carried out with the greatest range and speed. The stop must be carried out in conjunction with the auxiliary system.

Consider the following: - Keep your distance, leave room for maneuver. — Use the auxiliary braking system. — It is recommended to use chains on the wheels of the machine. — Be sure to consider the risk of skidding during emergency braking due to the trailer wheels locking.

You can only slow down the engine on a descent in exceptional cases, as this leads to engine wear. When braking, the wheels should not slip. To avoid this, you need to turn off the reduced speed, which will help reduce the rotation of the crankshaft.

When skidding , keep your foot on the clutch pedal and turn the steering wheel in the direction of the skid, this will level the car.

When slipping, you need to slow down, lock the differential (using the regulator on the dashboard) and start moving from the second high gear. After completing the difficult section, the differential must be unlocked.

ZF gearbox on KamAZ 6520. Gear placement and shifting.

ZF gearbox on KAMAZ 6520. Location and gear shifting.

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Maintenance and repair

KamAZ trucks with automatic and manual ZF gearboxes must undergo maintenance (MOT) in a car service center, otherwise there may be problems with the warranty. Maintenance consists of changing the oil. The frequency depends on the type of gearbox and operating conditions of the machine. Most often, fuel and lubricants are replaced after 45-90 thousand kilometers, and under particularly difficult operating conditions - at least 1 thousand working hours.

What is needed to extend the life of the gearbox

In order to avoid damage, you must follow the operating recommendations given by the manufacturer.

It is necessary to shift gears correctly, in accordance with the diagrams (double or cascade H).

It is also important to regularly check the transmission oil level and change it every 30 thousand km. Manufacturers always inform you about what oil is needed for a specific gearbox model.

In winter, it is very important to warm up the gearbox, otherwise the thickened oil will not be able to lubricate the parts well enough, which will lead to their premature wear.

You should always start driving in 1st gear; shifting should be done with the clutch disengaged.

Timely maintenance is also important, during which all transmission elements are checked and, if necessary, adjusted.

Level control

Filling volumes are indicated on the nameplate located on the side of the gearbox. Before filling the container, the waste is drained and transmission fluid is poured through the hole. Checking the oil level is carried out as follows: the level is considered correct when it reaches the lower edge of the control hole or when material flows out of it.

Which oil to choose

The ZF 9S1310 TO and ZF 16S151 boxes contain oil that complies with the list of lubricants TE-ML 02. It can be found at all service points of the company. The manufacturer recommends using ZF-Ecofluid M transmission oil.

The oil volume in the ZF 9 box is 9 liters, on KamAZ ZF 16 for standard installation - 11 liters, when replacing - 8 liters.

Malfunctions and their elimination

If shifting gears is difficult, the reason is incomplete disengagement of the clutch. In this case, it is adjusted and the valve to which the divider is connected is checked. The connection valve must always be clean and not closed. If the device is configured incorrectly, the synchronizer may be destroyed.

If rust, condensation and other contaminants enter the valves and cylinders of the receiver from the receiver system, the gearbox automatically switches off. Install in advance the removal of condensate from the pneumatic cleaner with a water separator, if it is missing. Draining is performed once a week, every day in winter.

When the gears switch off spontaneously in the divider, the stroke of the mechanism lever is adjusted.

Typical breakdowns of the ZF gearbox include spontaneous switching off of the range, and extraneous noise when it is turned on. The problem may arise due to improper operation: shifting gears to S at a speed higher than the permissible speed, the synchronizer or its individual parts fail.

ZF automatic transmission error codes

The ZF AS-Tronic automatic transmission can report faults. In order to fix the problem, it is enough to compare the code with the possible cause of the breakdown.

Some SPN error codes:

• 2 – a short circuit has occurred in the front divider (valve Y2)
• 10 – no air pressure on the main valve
• 13 – short circuit in the PTO connection circuit
• 21 – the clutch quickly closed
• 27 – no signal to the CAN bus
• 35 – malfunction of valve output Y3 (front divider)
• 63 – problem when disconnecting the PTO

Change of oil

Only fill in oil that is recommended by the manufacturer (specification ZF TE-ML 01). When initially filling the gearbox, 11 liters are required. oil, at the next change 8 liters. The maximum oil change interval is 90 thousand km. mileage, minimum - annually. If a Kamaz vehicle with a ZF gearbox is operated on construction sites or in severe weather conditions, then it is recommended to change the oil after 45 thousand km. mileage or after 1000 hours of engine operation.

Oil change intervals

• Severe operating conditions: 02A - 1 year or 60,000 km.
• 02B, 02C, 02H - 1 year or 120,000 km.
• 02D, 02E, 02L - 2 years or 240,000 km.

The gearbox oil should be changed when the engine is hot. Unscrew the drain plug and drain the used oil. Clean the drain hole and drain plug from metal shavings with a magnet. Replace the gasket and tighten the plugs with a torque of 60 Nm. Fill the oil through the oil filler hole until the level reaches the bottom edge of the hole or is already pouring out of it.

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Do not allow the gearbox oil level to be low. This may cause serious damage to the box. To check the oil level, place the car on a horizontal platform and let the oil cool to a temperature below 40 C.

Clutch check

In order for the synchronizers in the box to work for a long time, the clutch must also work flawlessly. To check it, do the following:

• At idle, depress the clutch.
• After no later than 20 seconds, slowly and carefully engage reverse gear.

If you hear a grinding noise, the clutch needs to be adjusted or its functionality completely checked.

Transmission ventilation

Because When the car moves, the oil in the gearbox heats up, and increased pressure forms inside. To relieve excess pressure, there is a special breather at the top of the box body. Check its cleanliness periodically.

Nameplate

The nameplate is located on the top of the gearbox housing. Typically, you only need three positions from there:

1. Gearbox number according to specification.
2. Gearbox type.
3. Transmission serial number.

Shifting the ZF gearbox

The ZF Ecosplit gearbox is a synchronized gearbox. Synchronization is carried out by wheel synchronizers. Thanks to this, you can switch speeds faster and more reliably:

• No double pressing of the clutch when upshifting, no pressing the accelerator pedal and no double pressing of the clutch when downshifting, even on slopes and in difficult situations.

Gear layout

Double H. The “double H” switching circuit (Fig. 186) has a spring-loaded neutral position (idle position) on the pass 3/4 (slow range group) and 5/6 (fast range group).

To select gears 1/2 or 7/8, it is necessary to move the gear shift lever in the appropriate direction against the spring force and, when engaged, counteract the spring force. The gearshift lever moves to the corresponding neutral position if it is released in the middle aisle position. The slow group of the multiplier is separated from the fast group by a stronger counteraction spring (“GP-Noskeg”)

The reverse passage is protected by a stop-lock, and therefore more force is required to engage it.

Different spring forces allow good orientation in the switching pattern, i.e. easier finding of passages.

Rice. 186. Gear shift lever with “double H” shift pattern

Gear shift

CAREFULLY! To be more gentle on the transmission, always depress the clutch pedal fully.

To prevent damage to the ZF transmission and engine, shift to the next lower gear only after reaching the maximum permissible speed of the intended gear, achieved as a result of braking.

• Move the shift lever quickly, without using much force. This is especially important when the transmission oil is still cold. It is recommended to move the gear shift lever with an open hand, as shown in Fig. 5.
• When engaging a gear, hold the shift lever against the force of the spring until the synchronization process is completed and the gear is engaged.

Double H. When moving from aisle 3/4 to aisle 5/6 and vice versa, lightly hit the lever with the palm of your hand and quickly, without much force, move the lever to the desired gear position (Fig. 187).

Rice. 187.

NOTICE! When the transmission is cold, greater shifting forces are required to change gears. If, when moving back from aisle 5/6 to aisle 3/4, the range-multiplier does not shift, then slow down the car and set the appropriate gear at a lower speed. CAREFULLY! It is unacceptable to move between aisles 5/6 and 3/4 or vice versa at a vehicle speed of more than 30 km/h.

The transition from one pass to another causes synchronization of the multiplier, which at vehicle speeds of more than 30 km/h leads to premature wear.

Reverse

CAREFULLY! Set the vehicle to reverse only when the vehicle is stationary.

Reverse gear should only be engaged or disabled when the clutch is depressed!

The clutch should only be disengaged at a rotation speed corresponding to the engine idle speed.

Engage reverse gear only after the intermediate shaft has stopped. An intermediate shaft that has not stopped causes a grinding noise when reverse gear is engaged.

NOTICE! Coasting times differ depending on the operating state and can be reduced by short synchronization, preferably 1st gear.

Turn the power take-off on or off. A grinding noise when the power take-off mechanism is turned on is unacceptable. If necessary, increase the waiting time before engaging or check the clutch for complete disengagement. Slowly release the clutch.

Power take-off for KAMAZ with ZF gearbox:

For modernization or repair, it may be necessary to purchase the necessary components. In our catalog you can select a power take-off box for Kamaz or ZF gearboxes installed on KamAZ and components for their installation. We also sell hydraulic equipment for installation on chassis.

Here are the sections of the catalog where you can easily select the components and assemblies necessary for installing additional equipment:

• PTO
• Power take-off
• Hydraulic pump of required performance

Reviews about automatic transmission repairs at ZFMaster

“I’m from Murmansk, my car is a Range Rover Sport 3.6, mileage is 230 thousand km. For the last 60 thousand km I was bothered by strong tremors, I thought for a long time where to turn, and monitored the market. I chose a repairman, and in June I went with my family to the south with a stop in Moscow to have the automatic transmission repaired. I arrived in Moscow at night from June 4 to 5, at 8:30 I was already at the zfmaster. They promised to do it in one day and they did it
.
I’ve already traveled south and returned to Murmansk.” SergeyPublished on yell.ru “While I was waiting for my car at the office, they did everything in just 4 hours. I paid as much as was originally agreed
.
Everything worked out, if my memory serves me right, within 76 thousand. One year warranty, warranty card in hand. I'm planning to come and change the oil. I’m quite happy with everyone, especially their master is super.” Vasily Valentir Published on yell.ru “I used their services, but I couldn’t fully experience it because my car was stolen. I drove for 5 days and had no complaints, it even seemed that it became softer. Many of the club made boxes there, everything was fine. Their recommendations are excellent
. Mad Ed, the Cat in the Barrel, you can ask them. According to my feelings, they are doing everything absolutely normally...”

Valeria Published on audi-club.ru “I had my automatic transmission repaired by Zfmaster, I really liked everything, the guys do the work professionally and quickly, they are located in a very convenient location, 500 meters from the 3rd ring, just
10 minutes from the center
.”
Peter Zimin Published on yell.ru “I spent a long time reading the reviews. I talked a lot with different companies. After a tough casting, I chose Zfmaster, since before that, 11 years ago, I had repaired an automatic transmission on a BMW E32 with them. They made the box for me within a day. For that time it was nonsense. I didn't even believe it at first. But a lot of time has passed and it turns out that the same craftsmen still work in this company. Now I have x6. I did it about a month ago. I was present during the renovation and saw everything with my own eyes
.
Paid 80 thousand rubles. The car has been driving like new for a month. They even eliminated what I initially didn’t like about the operation of the automatic transmission. I recommend it to everyone. They're definitely pros." Viktor Lomtyugov Published on yell.ru “I own a service in Stavropol, I work on boxes only with ZFmaster. Everything is fast, clear, there are no problems
, and most importantly,
a fixed price
, which is convenient for me when I also announce a fixed price to my clients.” IvanovichPublished on yell.ruPreviousNext

What's the result?

Taking into account the above information, we can conclude that auto manufacturers do not always independently develop and manufacture components and assemblies for their cars. The purchase of ready-made gearboxes, chassis elements and other units and components can significantly reduce the cost of production.

We also recommend reading the article about what the automatic transmission manufacturer Jatco is. From this article you will learn about the Jatco company, as well as why the Jatco automatic transmission and variator are considered to be one of the most popular and reliable in the world. The result of this approach is the use of units produced by the world's leading brands specializing in the production of gearboxes, power steering, axles, etc. Moreover, when it comes to gearboxes, among the leaders we can highlight ZF, Aisin, Jatco.

Finally, we note that the example of an 8-speed ZF automatic transmission clearly demonstrates the possibility of widespread distribution of one unit throughout the world and the possibility of its installation on car models of different brands and manufacturers.

Sources

• https://dvigatelkama.ru/korobka-peredach-zf-16s1650-maz/
• https://SpecMahina.ru/kamaz/kpp-zf.html
• https://KrutiMotor.ru/korobki-peredach-zf/
• https://miniteh.com/articles/Informaciya/Nemeckie-KPP-ZF-na-gruzovyh-avtomobilyah-KAMAZ
• https://gearbox-zmt.online/kpp-zf-na-kamaz/
• https://www.zfmaster.ru/

KamAZ control: gearbox and different operating conditions

When lifting the KamaAZ vehicle, it is recommended to use higher gears. Switching from first to second speed involves the “double clutch release” method (for stable operation, do not forget to press the gas pedal and not allow the engine speed to drop).

When descending the KamaAZ, you must not turn off the engine, as the steering wheel of the vehicle may lock. It is also not recommended to depress the clutch pedal and engage gears during descents with the additional braking (auxiliary braking system) turned on.

When driving a KamaAZ on a slippery road surface, it is recommended to brake using the internal combustion engine, using the gears on the KamAZ, since emergency braking leads to blocking of the wheels of the truck trailer.

When skidding, the clutch must be engaged. If the car is driving, it is recommended to turn the steering wheel in the same direction. If the car starts to skid, you need to take your foot off the gas pedal and block the differential.

We also recommend reading the article about what the MAN gear shift circuit is. From this article you will learn what gearboxes are installed on MAN vehicles, the features of the MAN gearbox, and also how to change gears on these trucks.

Please note that improper engine braking can lead to a reduction in the service life of the gearbox and internal combustion engine. At the same time, a timely transition to a lower gear will reduce the crankshaft speed and help avoid wheel slipping.