How to check the oil level in a ZF Kamaz gearbox?

Changing gearbox oil zf 16

The answer to your request for zf 16 gearbox oil change - come in, we have become even more convenient. Video lessons for car repair and maintenance on your own.

How to repair a car yourself at home. We will help you with repairs and repair the car yourself. We know how to restore a car with minimal investment. I have attached video instructions.

Category: Car repair yourself

Laughter in the topic: The daughter comes home from the club in the morning, the mother warily: - Have you been drinking? The daughter gloomily: - I am the ax!

Published by Admin: at the request of Eberhard

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Video: changing gearbox oil zf 16

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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 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%.

Specifications

Kamaz ZF 9S1310 TO units have the following characteristics:

The maximum input torque is 1300 N*m.
Gear ratios:
reverse - 8.97.
Tachometer type - electronic, z=8.
Weight - 190 kg.
The gearbox tilt angle is up to 3°.
Maximum air pressure is 10 bar.

Operating parameters of the gearbox on KamAZ ZF 16:

Input torque - 1850 N*m.
Gear ratios:
backward movement - 15.36-12.92.
Speedometer type - electronic, z=6.
Structural weight - 289 kg.
Gearbox tilt is 0-3°.
Standardized air pressure is 6.2-10 bar.

Repair of ZF 16S151/16S181/16S221 gearbox (photo report)

Hello everyone, I’ve decided to create an information topic - repairing a ZF gearbox, in this case installed on a KamAZ 6520. The reason for the removal was a spring found in the crankcase cover of the ZF gearbox. It flew off the disk, and at the same time opening the ZF gearbox to replace the 5th-6th gear synchronizer. On a cold one from 4 straight to 6 from a slide, of course, and on a hot one I also tinkered with my brain. After two years of operation, 6 was also affected by such a switch.

In short, it was decided - repair with a photo session, since I did not find any information upon request for repair of the ZF gearbox.

I’ll say right away that you don’t pay attention to mistakes; I don’t write dictation, and at school the Russian language was not fun.

Well, let's start the renovation

We start the analysis from the back, removed the flange with a regular Chinese puller

Yes, I forgot to remove the rocker and turn 10 bolts

and also if the glass seal does not leak and you don’t need an oil pump, you don’t need to turn their bolts

Let's continue to remove the left bracket too, there is a bolt hiding there that holds the clutch cover

bolt hole
broken pin after hitting the bracket with a sledgehammer

Removing the rear gearbox cover zf 16S151

puller mounting holes
hole for directing the oil pipe (during assembly)
the fork mounting bolts are on the same axis, unscrew both (after disassembling the diaphragm)
speedometer sensor
Mark the diaphragm housing when removing it so as not to twist it
coaxial bolts
dutch speed

Sequence

first we tear off the diaphragm nut 3
then coaxial bolts 1-2

I’ll say right away that the removal of the cover was done with the help of assemblies and a sledgehammer, I had to use a sledgehammer to avoid damaging the parts. They pulled the cover up and tapped it on the shaft. If I have to open it again, I’ll make a simple puller, well, I’ll spend an hour at most, but I can easily pull it out. Which is why I advise you to first make a puller!!!

Puller diagram

bolt for fastening to the cover 4 pcs.
puller plate (I think 15mm thick is enough)
good nut
The bolt is even better and longer, with larger threads and a larger diameter. well 30mm at least

remove the zf divider cover

Let's see how the ZF fork stands

pull out the tube and remove the plate

Pulling out the heavy differential

difer
reverse gear shaft zf
rubber ring

pull out the ZF shaft of the differential fork

Removing the back cover

puller mounting holes
hole for directing the oil pipe (during assembly)
the fork mounting bolts are on the same axis, unscrew both (after disassembling the diaphragm)
speedometer sensor
Mark the diaphragm housing when removing it so as not to twist it

Sequence

first we tear off the diaphragm nut 3
then coaxial bolts 1-2

Continuing the repair, unscrew:

shaft lock
retainer plug
holes for fastening the spring crossbar (box fastening)

rubber ring
bushing under the differential (skirt in front of the gearbox)
reverse gear (with the convex part towards the rear of the gearbox)
gear shaft reverse (reverse gearbox tube)

at the bottom there is a cover for installing the reverse gear

zf diaphragm housing can not be disassembled

turn the ZF gearbox with the input shaft to the top, unscrew it and knock it down, do not tighten about bolt 1 near the rocker

Pressing out zf shafts.

I just removed the stopper, took a hammer and beat the gear with an iron rod, it turned out fine, the current took a long time, went under the press there faster and more carefully.

let's continue

remove the casing, unscrew the two stoppers on the divider fork

push the smaller shaft to the right and lock it with a screwdriver or something else

carefully take the primary one along with the crank and plug and pull it out

scatter the sync, collect it carefully, everything is just soldiers and want to fly away, you need to hold each one when installing it in place

Now we pull out the small shaft zf, pay attention to the slot in the end for driving the oil pump, which remains in the casing. combine when assembling

we put the gearbox on its side so that the oil pipe is on top so as not to pull it out along with the shaft

To extend the shaft, you need to press the fork shaft lock

retainer
I pressed the hole with a screwdriver, the lock stroke is about 4-5mm (repeat during assembly)

Well, we got it

transfers signed

removed the stopper and beat the gear 3x ZF

time evening tomorrow Friday in short took the shaft and flew to the edge

ATTENTION !!!

information..

The gearbox was not disassembled for 8 years, only the glass was removed, probably to replace the oil seal.

All bearings (daewoo hungary Daewoo Hungary) are in good condition, gears are all in excellent condition, synchronous 5-6 wear, brake surface was with bronze brakes. whole replacement .

They were installed with iron brakes, that is, friction surfaces. They said that the iron ones are better and the price is lower.

serviceman's response. installed iron 25t rubles for foreign cars with bronze 48t rubles for Kamaz to replace the synchronous one gave the shaft to the ZF repair service in Krasnoyarsk they said 25,000+ replacement 1000 also bought 2 seals for a glass and a flange. 1 boot on the rocker (900 RUR). Seal seal (installed in pairs). Two stones with boots on the clutch fork shaft.

4 small 2 large bronze sliders in the shift forks, a set of gaskets from ZF, they said 3200 they took (3800) during the repair process they called and said that there was no BEARING BUSHING!!! synchronous, that is, the inner race of the bearing + (2200)

The box zf 16S151 was definitely unopened, it was obvious from the bolts that it was interesting how it had been going away for 8 years.

the amount for everything was also announced: 33,000 rubles

in short, a total of 37,000 if I took the box to them - for the repair of ZF boxes (disassembly, defettovka, assembly) 20,000 +37,000 well, plus + how much they charged for installing the shaft, a special puller was designed

rope with two nooses at the ends

we direct the fork shafts and don’t forget about the lock

I tapped the iron with a flange so that the bearing came out of the cover for ease of assembly

This photo report was taken from the forum of the website drom.ru Author of the report: user gazik-oofbr

Author's spelling preserved

dtbm.ru

How and what kind of oil can be poured into the ZF KamAZ gearbox?

30.11.2017

KamAZ special equipment includes a wide range of heavy-duty vehicles, which are equipped with powerful power plants, chassis, and transmission. Driving such a car you feel increased comfort of movement.

Features of the ZF 9 gearbox

The ZF gearbox is found on trucks produced by KamAZ. Decent power with lower fuel consumption is provided by a 9-speed ZF automatic transmission. As a rule, it is installed on cars that have front-wheel drive. The presence of this box guarantees the car owner excellent dynamic performance.

It should be noted that KamAZ uses an additional divider in gearboxes. Changing gears in the divider occurs by moving the control valve switch. Thanks to the divider, there is an increase in the vehicle's traction, and it also makes it easier to control.

To ensure reliable operation of the transmission system, maintenance instructions must be followed.

Oil level control

The danger comes from both an excessive amount of oil in the gearbox and an insufficient amount. This is often the reason why the PF fails prematurely. Checking the oil level in the gearbox can be done using the control holes that are present on the gearbox body. The oil change should be carried out with the engine warm. Since the oil is warm, it has an optimal degree of viscosity, therefore, the fuel will spill out faster.

Selecting gearbox oil

What kind of oil is poured into the ZF KamAZ gearbox? As a lubricant, you can use oil from a domestic manufacturer or well-known foreign brands. Oil options from brands such as Castrol and Mobil are suitable for KamAZ.

What kind of oil should I use? You need to pay attention to liquids that have a high concentration of extreme pressure additives, for example, GL-4 class fuel. If you frequently operate the car at sub-zero temperatures, you should choose 75 W-80 or 75 W-90.

Mobil 75 W-90 Castrol 75 W-80

How much oil should be added to a KamAZ gearbox with a divider? The required volume is about 9 liters. As a rule, this procedure must be carried out every 100,000 km.

In some cases, replacement must be carried out earlier. The need for this arises if heavy vehicles are often used on construction sites.

Thus, KamAZ vehicles have high reliability and good performance. Caring for this automotive system involves timely diagnosis of the vehicle. Helps to extend the working life of the gearbox by selecting high-quality gear oil.

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