The largest manufacturer of transmissions for German cars, after creating a joint venture in 2005, began supplying gearboxes (gearboxes) for installation on our domestic trucks.
Thanks to the possibility of optimal selection of the gear ratio in each specific case, at any speed of the vehicle, ZF gearboxes help not only save fuel (up to 16%), but also improve the traction and dynamic characteristics of Kamaz engines, increase their service life and reveal their potential for all 100%.
The following gearbox models from ZF are currently installed on KamAZ:
- ZF 6S700
- ZF EcoMid 9 S1310
- ZF EcoSplit 16 S1650, 16S1820
Design, device and principle of operation
ZF Ecomid
The most common gearbox, 9 stages, is installed on most medium-duty Kamaz trucks (models such as 65155 and 65116), excellent low gear, optimal speed when transporting heavy loads.
The Ecomid gearbox from ZF is a main 4-speed gearbox, which integrates a reverse gear, as well as an additional pair of gears for low gear. At the output of the main gearbox there is a demultiplier (planetary gearbox). As a result, we get: 4 gears on the main gearbox * 2 (gears on the range multiplier) + low gear, a total of 9 gears for forward movement and 1 for reverse.
ZF Ecosplit
16 stages, most often installed on heavy vehicles with Kamaz engines from 320 to 500 hp. power (740.51-320 or 740.50-360). Gearbox weight 290 kg.
The Ecosplit gearbox also consists of a 4-speed main gearbox with a reverse gear and an output range, but in addition to this, a divider has been added to the design (an intermediate shaft at the input with an additional pair of gears). As a result, there are already 16 gears: 4 on the main gearbox*2 on the range multiplier*2 on the divider+2 gears for reverse.
Divider
A divider in the design is needed to increase the number of gears in a certain range of motion. It consists of two pairs of gears with different gear ratios, which are installed on the intermediate shaft drive. This solution makes it possible to select the optimal gear depending on the driving situation and put less load on the engine. The divider is switched using air under pressure (pneumatic drive).
Demultiplier
The multiplier is a planetary type gearbox. Its sun gear is installed on the secondary shaft, and the gearbox output shaft drives it. When driving in a lower gear range, the multiplier increases the torque; in a higher gear range, the torque remains unchanged. The range-multiplier is switched using a pneumatic drive.
Ilya Khlebushkin visited the workshops of the ZF plant in Saarbrücken, Germany
“We are cutting steps - not a step back...” The hoarse voice of Vladimir Vysotsky haunted me during a tour of the workshops of the ZF plant in Saarbrücken, Germany. Eight gears in a compact housing - and that's not the limit!
Refurbishment repairs are possible for any ZF automatic machines, regardless of the year of manufacture. In the latest generations of gearboxes, the torque converter and mechatronics unit most often require replacement. By the way, even “eternal” transmission oil needs to be changed after five years or 100-150 thousand kilometers.
But it all started with three stages, and borrowed ones - in 1965, ZF received a license to produce Borg-Warner automatic transmissions for the BMW 2002 and Peugeot 404. ZF had its first own automatic transmission, that is, automatic transmission, in 1975. In 1982, a second planetary gear was added to the “three-speed” gearbox, receiving the first own four-speed “automatic”; in 1990, the turn of the five-speed gearbox of the 5HP series came (almost simultaneously with the appearance on Mercedes-Benz cars of its own “automatic” with five steps), in 2001 year, the six-speed automatic transmission 6HP debuted on the new BMW “Seven”... It seemed like much more? But in 2002, Mercedes-Benz responded with a gearbox with the self-explanatory name 7G-Tronic, and in 2007, the Japanese eight-speed Aisin unit appeared on the Lexus LS460 sedan. Now Mercedes is working hard on a nine-speed gearbox, and the Koreans from Hyundai and Kia promise to pack as many as ten steps into the box by 2014!
Why did ZF take such a long time with its own “eight-speed” - after all, the 8HP gearbox on the BMW 760 appeared only in 2009? The Japanese added an eighth speed relatively simply, cheaply and quickly, further extending the conventional “longitudinal” automatic transmission with two sequentially installed shafts with the next, fourth planetary gear set. The Germans also needed to somehow attach another set of gears, but they were limited by the dimensional requirements of potential customers BMW and Audi - there was nowhere to extend the box. However, the designers did not sit idly by. As a result, the automatic transmission turned out to be no more than a six-speed gearbox (and fits even on a BMW of the first series), and weighs 70 kg instead of 90 kg! The secret is in a completely new single-shaft, rather than two-shaft, design: the additional planetary gear was “exchanged” for a pair of shaft support bearings. You won’t believe what prevented the Germans from making a single-shaft box faster - just the need to drill an oil hole in a half-meter shaft!
The drilling machine for this operation at the plant in Saarbrücken is shown to the guests with particular pride - beautifully crafted drills with a diameter of 6 mm and a length of 440 mm with a channel for coolant inside, a carefully selected cutting mode with a feed of 20 cm per minute... The workshop, lost in a kilometer-long distance, is filled around the clock working automatic machines: not only are seven thousand boxes of the 6HP and 8HP series made here every day, but also most of their parts - only bearings, gaskets, filters and Bosch electronics are bought externally.
Three stages: the first own “automatic” ZF 3НР22 1975 with one planetary gear
Four stages: ZF automatic transmissions of the 4HP series with a second planetary gear appeared in 1982 (modification 4HP22 in the photo), were produced until 2003 and installed on cars from Peugeot to Porsche 911
“Automatic machines” for cars with a transverse engine appeared at ZF in 1987, and since 1995, similar second-generation gearboxes have been produced in Saarbrücken, already with a torque converter lock, but also four-speed
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The quality system is the famous Toyota TPS, Toyota Production System, with all its attributes: jidoku, kanban, genchi genbutsu and andon, which need to slow down the conveyor in case of errors. Without exception, all assembled boxes are pressurized with helium to check for leaks and tested on stands, at the same time monitoring their noise. 1,400 people work here in each of the three shifts, and they make as many as 1 million 800 thousand boxes a year. I saw a worker swinging a hammer once (he was putting a retaining ring on a shaft) - automation reaches the maximum allowed by German trade union requirements of 80%.
By the way, the number of variations of the same automatic transmission of the 8HP family is more than two hundred and twenty. After all, ZF boxes with the same index, but intended for BMW and Audi, can differ by a third! And not only due to the control programs and the geometry of the connecting flanges (there are only 58 variations of them) - even the torque converters can be different.
Nine steps! In the upcoming automatic transmission of the 9HP series for cars with a transverse power unit, the layout of the planetary gears is developed “in breadth”: one of them is “hidden” inside the other. The same principle is applied to the placement of multi-disc clutches. The axial oil pump is placed sideways and upward and (as with 8HP boxes) is driven by a chain from the input shaft. All this allowed us to make a box less than 40 cm long! Two modifications of the unit are designed for input torque up to 280 Nm (9HP28) and up to 480 Nm (9HP48). Production will begin in 2013... at Chrysler's transmission plant in North Carolina with a capacity of 800 thousand units per year
On a separate branch, transmissions for hybrid BMW and Audi are assembled - in the same eight-speed 8HP gearbox, an electric motor-generator is installed instead of a torque converter. What about preselective units with two clutches? The ZF concern still produces them, but along with conventional “mechanics” at the second “box” plant, in Brandenburg, and only for Porsche. This is the belief of ZF engineers - they believe that the “preselective” is only good for supercars with high-speed engines: ordinary “automatic” cars are unreliable in such conditions due to cavitation, which destroys the torque converter blades at speeds above 7200 rpm. And for other cars, conventional “hydromechanics” is better! ZF claims that it is cheaper than “robots”, is almost equal to them in the ability to save fuel and is not far behind in gear shift time (0.2-0.45 s versus 0.1-0.4 s). Not to mention problems with comfort: no matter what you do with the clutch, it will close harder than the torque converter. It’s not for nothing that “robots” with two clutches have not taken root in America, and even Volkswagen is replacing them with classic “automatic machines” for the American market.
Like the dual planetary gear set (RS1 and RS2), the two brake clutches of the shift system (C, D) are arranged according to the matryoshka principle: one unit inside the other. Another pair of multi-plate clutches are located at opposite ends of the box (B, E). In addition, there are - for the first time in automatic transmissions for passenger cars - two compact dog clutches (A, F). In each of the ten gears (including reverse), three of the six switching elements are simultaneously closed. The operating logic is as follows: the box shifts up sequentially, going through all gears from first to ninth. And down - through gear: for example, “ninth-seventh-fifth” or “eighth-sixth-fourth”. The “input” of torque is through the torque converter (G) with a lock-up clutch, the “output” is from the planetary gear carrier (RS4) through the intermediate gear to the driven gear of the final drive and the cross-axle differential
CVTs? From 2001 to 2005, ZF mass-produced V-belt continuously variable transmissions VT1F for Mini, but they turned out to be expensive and not very durable: the experiment was considered unsuccessful, and the enterprise in Belgium was sold.
But production next door to the main factory workshops is thriving - here they give a second life to faulty gearboxes, of which up to 20 thousand a year are collected in Europe (ZF has the same center in the USA and another one specializing in Land Rovers in England). Here they gathered 90 of the most intelligent mechanics who, in six to seven hours, are able to revive any ZF gearbox - the latest generation under warranty or a three-speed unit from the 70s.
Five stages: the 5НР18 box of the 1990 model worked on BMW third (E36), fifth (E34, E39) and seventh (E32, E38) series
Six stages: ZF 6HP series with three planetary gears - since 2001. Since 2006, the second generation has been produced, with a torque converter locked in all gears and a new mechatronics unit, which has reduced switching time by one and a half to two times. Alas, reliability is not the highest
The seven-speed robotic gearbox with two clutches (their unit is clearly visible in the photo) 7DT for Porsche has been produced since 2009 at the Brandenburg plant. The 7DT-45 is found on the 911 Cayman and Boxster sports cars, the 7DT-70 unit is found on the 911 Turbo, and the 7DT-75 is found on all Panamera hatchbacks.
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A restored box cannot be distinguished from a new one: it has been thoroughly washed inside and out, carefully checked for defects after complete disassembly, and all parts that cause the slightest suspicion have been replaced. The result is an automatic transmission with the same two-year warranty as the new units.
Eight-speed 8HP gearboxes are rare guests here: the gearbox turned out to be more reliable than the previous six-speed gearbox, which had oil pumps leaking and torque converters acting up. And on average, automatic transmissions in Germany require major repairs closer to 300 thousand kilometers.
But here, if an “automatic” lasts 240-250 thousand kilometers, then this is happiness... But there are no boxes from Russia in the Saarbrücken workshops - according to our customs rules, it is expensive to deliver numberless units to Germany for restoration, unlike temporarily exported engines. But - hurray! — ZF has allocated two million euros for a service center in Moscow: 30 people will restore about 2,000 boxes a year. The service will definitely not be idle - a practically new box with a company guarantee in exchange for the old one will cost no more than three to four thousand euros - like a “lottery” repair in a private workshop. We can only hope that the same branded restoration plants will be built here by other automatic transmission manufacturers - Aisin Warner, Jatco, Getrag, GM, Daimler...
Audi A8 3.0TDI, Range Rover Sport 3.0 SDV6, BMW 740 xDrive, Jaguar XF 2.2 Diesel and BMW X6 xDrive 30d... What do they have in common? ZF series 8HP box!
Eight stages: ZF series 8HP automatic transmission, single-shaft design with four planetary gears - serial since 2009. The range of modifications is designed for input torque from 300 Nm to 1000 Nm
The only shaft in the box is 8HP, 542 mm long! The splines on it are produced by cold rolling, the necks are treated with a special abrasive micro-mill, and are hardened with high-frequency currents
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Switching the ZF gearbox on Kamaz vehicles
The switching pattern for the ZF Ecomid and Ecosplit gearboxes on KAMAZ trucks is the so-called “double H”. Those. There is a low (S) and high (L) gear range. Each range has four basic gears, which are expanded by a divider and a multiplier. The return of the lever to “neutral” after switching off the gear occurs automatically due to the fact that the lever is pressed into the neutral position by spring clamps. The multiplier from L range (row 3/4) to S (row 5/6) and back also switches automatically by supplying air under pressure to the working cylinder. You can engage a new gear only after the previous shifting process has been completed. Reverse and low gear (C) are only available in the low (S) range of the multiplier. Engaging these gears requires little effort, because... There is a safety spring installed there, which eliminates the possibility of accidentally selecting one of these gears.
Gear shifting on ZF Ecomid
Gear shifting on ZF Ecosplit
Recommendations for shifting gears
- The gearshift lever should be moved smoothly, without jerking or unnecessary effort, with your hand unclenched.
- When you engage a gear, hold the lever while the synchronizer makes the shift.
- In order to switch from track 3-4 to 5-6 and vice versa, you need to make a short push in the desired direction and then smoothly engage the desired gear.
- If the car is slowing down, it is recommended to change gears in reverse order sequentially or in a maximum of two stages.
- The car should always move with the gear engaged. This is especially true when coasting on a descent.
- When switching from high to low range, the speed should be less than 30 km/h.
- Engage reverse gear only when the car is stationary.
Typical breakdowns
The following malfunctions are typical for ZF gearboxes:
- Difficulty changing gears in the transmission. The causes of the problem may be incomplete deactivation of the clutch. To eliminate the malfunction, you will need to adjust the mechanism. If the clutch system malfunctions, or one of the shafts is worn out, then the device will need to be repaired. To restore the unit, it is recommended to use only original and high-quality spare parts for the ZF gearbox, since when using fakes there is a possibility of rapid wear and failure of the part.
- The gears are switched off independently in the divider. The cause of the malfunction should be sought in violation of the adjustment of the stroke of the lever of this mechanism. To eliminate this, an adjustment must be made.
- The gears on the unit are not switched off or are deactivated on their own while the vehicle is moving. The malfunction may be the result of a maladjustment of the remote drive device or loosening of the clamps of the drive mechanism rod arms. The user needs to make adjustments or tighten the fastenings.
- The speeds in the divider are not activated. The problem should be sought in the violation of the position of the adjusting screw. It is located on the clutch pedal. It is necessary to adjust this element based on the recommendations described by the vehicle manufacturer in the service manual.
Also, when diagnosing, you need to pay attention to the presence of oil smudges and traces of lubricating fluid under the car. When they appear, check the integrity of the gearbox housing, seals and seals.
Specifications
ZF 9S1310 Ecomid
- Number of gears - 9
- Torque – 1300 Nm.
- Gear ratio: 1st – 9.48;
- 2nd – 6.58;
- 3rd – 4.68;
- 4th – 3.48;
- 5th – 2.62;
- 6th – 1.89;
- 7th – 1.35;
- 8th – 1.00;
- 9th – 0.75;
- reverse – 8.97
- New – 380 thousand rubles.
ZF 16S1650 (16S1820) Ecosplit
- Number of gears - 16
- Torque – 1850 Nm.
- Gear ratio: 1st – 16.47;
- 2nd – 13.79;
- 3rd – 11.32;
- 4th – 9.48;
- 5th – 7.79;
- 6th – 6.52;
- 7th – 5.48;
- 8th – 4.58;
- 9th – 3.59;
- 10th – 3.01;
- 11th – 2.47;
- 12th – 2.07;
- 13th – 1.70;
- 14th – 1.42;
- 15th – 1.20;
- 16th – 1.0;
- reverse 1 – 15.42;
- reverse 2 – 12.91;
Operation of the ZF gearbox
To extend transmission life and achieve significant fuel savings, follow these guidelines.
- Try to keep the engine speed always in the middle range for each gear. Use the highest available gear in each speed range.
- Always fully depress the clutch when changing gear, this will prevent increased wear on the gearbox synchronizers.
- ZF gearboxes, which are installed on Kamaz trucks, are equipped with synchronizers; they allow you to change gears quickly, without excessive effort and almost silently. There is no need to double-depress the clutch when moving from lower to higher gears, and vice versa.
Maintenance and repair
Regularly maintain the ZF gearbox on your Kamaz vehicle. This will increase its service life and minimize possible malfunctions during operation.
Repair of ZF gearboxes is recommended to be carried out only in certified service centers or by experienced craftsmen who have disassembled and reassembled more than one such gearbox.
List of certified centers of ZF Friedrichshafen AG
| No. | Name of company | Address | Phone fax |
| 1. | LLC "SIBMAP" | 1 st. Baikalskaya, 277A, Irkutsk, Russia | 8-3952-560730/ 8-3952-142117 |
| 2. | AvtomagistralService LLC | Stroybaza, base 4B, Naberezhnye Chelny, Russia | 8-8552-443050 8-8552-443050 |
| 3. | ZF Service Siberia LLC | Novosibirsk region, village. Krasny Vostok, st. Sovetskaya, 62A, Russia | 8-383-3350505, 8-383-3350506/ 8-383-3350507 |
| 4. | SKIV LLC Master Service" | Chelyabinsk region, Miass, st. 60 years of October, 19, Russia | 8-3513-562522/ 8-3513-561488 |
| 5. | LLC "M 4" | st. Promyshlennaya, 2, Aksai, Rostov region, Russia | 8-863-2292777, 8-863-2268860/ 8-863-2468689 |
| 6. | VolgaScan LLC Center" | st. Pushkina, 67 Volzhsky, Volgograd region, Russia | 8-8443-297184/ 8-8443-298951 |
| 7. | Trading house "Liter - NN" | Orekhovskaya st., 80, 603069, N. Novgorod, Russia | 8-8312-949174/ 8-8312-564341 |
| 8. | Truck Service 36 LLC | st. Vasily Petushkova, 3, 125373, Moscow, Russia | 8-495-5140569/ 8-495-4906208 |
| 9. | CF – Service on Mosgortrans | st. Sailor's Silence, 1517, Moscow, Russia | 8-495-2680045 |
| 10. | OOO "CF Russia" | st. Strelbischenskaya, 1A, St. Petersburg, Russia | 8-812-4499203 |
| 11. | Motorhome Energy GmbH | st. Timiryazeva, 68, Minsk Republic of Belarus | +375-17-2268035/ +375-17-2268024 |
| 12. | SVS-Trans LLP | st. Mailina, 85, Almaty, Kazakhstan | 007-3272-579273 007-3272-505868 |
| 13. | Truck Center Ltd. | st. Chapaeva, 1, Gostomel, Kiev region, Ukraine | +380-44-9795056/ +380-44-9795043 |
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.
- 02A - 1 year or 90,000 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.
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.
What does the transmission repair process include?
Repair of a ZF transmission unit includes the following steps:
- Transmission diagnostics. If necessary, computer equipment or a scanner is connected to the device.
- Dismantling and disassembling the unit to identify defective components and parts.
- Washing and cleaning of gearbox structural elements and internal components.
- Defective transmission parts.
- Selection of spare parts for replacement and repair. Instead of failed ones, new original, contract or functional used parts are installed.
- Flushing the torque converter device from wear products and lubricant deposits.
- Assembly of the transmission unit.
- Filling with high-quality lubricating fluid. For this purpose, it is advisable to use oil recommended by the manufacturer.
- After repair and assembly, the gearbox is tested for leaks.
- The final stage is the final inspection and testing of the unit.
When overhauling an automatic transmission that has traveled more than 200 thousand kilometers, it is recommended to change or restore the torque converter. At the same time, other oil seals, bushings and clutches are taken. The hydraulic block gasket or separator plate should be replaced, even if it is visually intact and unworn. On some models of ZF gearboxes, consumables also include electrical board connectors with seals and tracks that tend to leak at low temperatures. If a vehicle is operated for a long time with a worn torque converter, which emits an extraneous noise while driving, this can cause malfunctions in the operation of the oil pump and pump bearing device.
After the gearbox is repaired, the vehicle is handed over to the car owner with all the necessary documents, including a warranty card and quality certificates for parts and oil.
