Installation Instructions

Power take-offs NS 42/2

Versions b, c
¨

S 5-42

Always read thoroughly

before installation!

CAUTION
Before installing the PTO, check the transmission and PTO type
plates to ensure that the transmission and PTO ratios are compatible
with each other.

Subject to technical changes

Copyright by ZF
This documentation is protected by copyright. Any reproduction and
dissemination in whatever form – also in adapted, paraphrased or extracted
form – in particular as a reprint, photomechanical or electronic reproduction
or as a storage in data-processing equipment or data networks without
approval by the holder of the copyright is prohibited and will be prosecuted
under civil and criminal law.
Printed in Germany

Issue: 07.97

Document number: 6090 754 107

ZF Friedrichshafen AG
D-88038 Friedrichshafen
Service Werk II
Tel. (0 75 41) 77 - 0
Fax (0 75 41) 77 - 57 26
 Important Work Safety Notice

The following safety instructions are included in these installation instructions:

NOTE: Refers to special processes, techniques, data, use

of auxiliary equipment, etc.

CAUTION This is used when incorrect, unprofessional

working practices could damage the product.

! DANGER This is used when lack of care could lead to

personal injury or death.

Take the necessary precautions to ensure that the

transmission unit and PTO are not started up uninten-
tionally.

Never work on a unit or transmission while it is

running. There is a risk of being hit by moving parts
(e.g. propshaft).
This could result in serious accidents or even death.

Always take the necessary precautions to ensure that

moving or raised fixtures, which could present a
danger to yourself or other personnel working on the
vehicle, are secure in order to prevent them falling or
moving.
Unintentionally actuated levers or linkages can cause
reactions in the unit or transmission which may lead
to serious accidents or life-threatening injuries.

2
 Preface Caution!- Installation Notes

Preface

Most PTO units reach the market via sales organizations. Therefore, ZF has no knowledge regarding the use of
these products nor possible dangers for operating personnel. Consequently, ZF cannot exert any influence.
ZF is not responsible for the correct installation of PTO units and auxiliaries, nor decisions regarding safety
devices and warning systems. This is the responsibility of the retrofitters and workshops concerned.
In general, persons installing or retrofitting ZF units are responsible for their own work safety.
ZF will be pleased to provide assistance and advice.

The PTO can be adapted to suit different transmission ratios by installing different gears. This work must always
be carried out by a ZF After-Sales Service centre.
The ratio shown on the PTO data plate must then be altered accordingly.

The illustrations, drawings and parts included in these instructions do not always depict the original. They are
merely used to show work sequences. The illustrations, drawings and parts are not drawn to scale, and no inference
should be made with regard to size and weight (even within any single drawing or illustration).
All work must be carried out as per the instructions contained herein.

PTO start-up

Once installation and inspection work has been completed, the experts must convince themselves that the product
will function perfectly again.
We must point out that, before the PTO can be used and after the propshaft bolts have been secured, the output
flange and propshaft must be checked by hand to ensure free movement and the requisite clearance.
This check must be performed without starting the engine.

Damage resulting from failure to comply with these instructions nullifies any possible warranty claims!

Yours
ZF Friedrichshafen AG
Commercial Vehicle/Special Transmissions Division

3
 Tightening Torques

Tightening torques for bolts and nuts from ZFN 148

Tightening torques for nuts and bolts (see ZFN 148), bolt class 5, tightening torque tolerance ± 15 %.
This standard applies to bolts as per DIN 912, DIN 931, DIN 933, DIN 939, DIN 960, DIN 961, and to nuts as
per DIN 934.
Always use calibrated torque wrenches and torque indicator wrenches when tightening bolts.

4
 Design Options

Design Options:

Version “b’’
with ouput flange Ø 90 mm, 4 bore holes
Ø 8.1 mm (other flange sizes available on request).
Diagram shows compressed air connection (1).

CAUTION
The propshaft working angle must not exceed 5°.
1
00
008059

Version “c’’
for direct pump connection in accordance with BNA
standard NF.R 17-102 or ISO 7653. 2
Drawing shows hydraulics connection (2).
(Ensure clearance between pump and transmission
output flange/propshaft).

008060

5
 Installation Options

Attaching to transmission with attached or

integrated clutch bell housing

Versions “b” and “c”

NS 42/2 b – PTO with output flange
NS 42/2 c – PTO for pump direct connection
(in accordance with ISO 7653). 1
Versions “X” and “Y”
5
“X” – the N 42/2 is attached to the right-hand side of
the transmission
NOTE: Version “b’’: top right (1)
bottom right (2) X
Version “c’’: top right (3)
Y b
bottom right (4)

“Y” – the NS 42/2 is attached to the left-hand side of c

the transmission.
3
NOTE: Version “b’’: bottom left (5)
top left (6) 7
Version “b’’: bottom left (7)
top left (8)
008062
NOTE: Both attachment points can be occupied since
transmission is installed vertically.

Key
- “Y” - left-hand version
- “X” - right-hand version
- “b” - version with flange
- “c” - version in accordance with ISO 7653
2
6

b X
Y
c

8
008061

6
 Preparation Work on Transmission

Preparation work on basic transmission

1 Drain oil from transmission, then retighten oil drain

plug.
Tightening torque = 50 Nm. Do not exceed.
2 Remove parts in sequence shown.
NOTE: The removed parts (1, 2 and 3) are not required for 3
attaching the NS 42/2. 2
1
3 Clean sealing faces.

008063

4 Coat the screw-in thread of the supplied stud bolts (1)

with Loctite 241.
5 Screw stud bolts (1) into the attachment point thread on
the transmission.
1
Tightening torque = 10 Nm.
6 Remove any excess Loctite.

008064

Overdrive version (e.g.: 5.72 - 0.76 and 4.65 - 0.7723)

1 Place 0.5 mm thick gasket (1) on the attachment point.

2 Place intermediate plate (2) on gasket (1).
3 Place 0.5 mm thick gasket (3) on intermediate plate (2).
The thickness of the gasket determines the amount of
backlash. Correction is possible. 3
2
4 Place the NS 42/2 on the attachment point and bolt
using the supplied hex nuts (WAF 15). 1
Tightening torque = 50 Nm.
008066

Direct Drive Version (e.g.: 7.55 - 1.0)

1
1 Place 0.5mm thick gasket (1) on the attachment point.
The thickness of the gasket determines the amount of
backlash. Correction is possible.
2 Place the NS 42/2 on the attachment point and bolt
using the supplied hex nuts (WAF 15).
Tightening torque = 50 Nm.
NOTE: This version is no longer series standard.

008065

7
 Backlash

Adjusting the backlash

6
1 Loosen hex bolts on PTO shift cover and remove 3.1
5
cover.
1
2 Place dial gauge (1) on tooth flank of NS 42/2 input
gear (5). Fig 008067 shows the correct attachment 2
point for the dial gauge.
3 Gently move the PTO input gear (5) back and forth
by hand and note the total play shown on the dial
gauge.
NOTE: The layshaft (6) must not move during this pro-
cedure. 3

4 The play can be adjusted to 0.15 - 0.30 mm using a

different gasket (3) thickness. 4 3
008067
Experience has shown the following:
0.25 mm thick ZF gasket changes play by 0.15 mm.
0.50 mm thick ZF gasket changes play by 0.30 mm. Key
1 Dial gauge
5 Unscrew hex nuts (WAF 15) on PTO and remove 2 NS 42/2 housing
NS 42/2. 3 ZF gasket
6 Correct the gasket thickness(es). 3.1 Intermediate plate
4 Transmission
7 Replace N 42/2 and tighten hex nuts (WAF 15).
5 NS 42/2 input gear
Tightening torque = 50 Nm.
6 Layshaft helical gear
8 Check that backlash is 0.15 - 0.30 mm and readjust
gasket if necessary.
9 Re-attach shift cover with gasket. Coat hex nuts
with Loctite 241 and screw on.
Tightening torque = 20 Nm.

8
 Oil Fill, Leakage Test, Pump Attachment

Oil fill
The oil fill quantity in the tranmission increases by
0.8 liters to 4.0 liters when the NS 42/2 is attached.
NOTE: The exact oil fill quantity is determined by
the overflow edge on the oil fill plug.
Oil fill plug on transmission,
tightening torque = 50 Nm.

Leakage and noise tests

Operate the NS 42/2 for approx. 5 - 10 minutes. Listen
to see if any noise develops. Check for leakages after
operation.
CAUTION
a) Singing noise may mean that the PTO has been
attached with insufficient play. Recheck play setting
and, if necessary, use a thicker gasket
b) Rattling noise may mean that the PTO has been
attached with excessive play. Recheck play setting
and, if necessary, use a thinner gasket.

Pump attachment
The pump must be attached to the PTO in accordance
with the pump manufacturer instructions.
CAUTION
Weight moment (only for NS 42/2 c)
The static load on the flange-mounting face due to the
pump must not exceed 30Nm.
Weight moment = pump weight (including accessories)
x distance between pump centre of gravity and pump
flange-mounting face.

NOTE: If a normally silent PTO suddenly develops

noise after the propshaft is connected, the system must
be checked for forced-out bearings, excessive/uneven
universal shaft angles or wear on the working imple-
ment.

9
 Pneumatic Shift Mechanism

Installation of a pneumatic shift mechanism
Order No.: 0501 207 814
(Fig 008068, Page 11)
1 Install plate with shift valve (7) and instruction
plate (17) in driver cab, if necessary using bracket
(8) and roundhead screw (10).
2 Connect pressure reducer directly to the compressed
air supply unit using hex supports (1).
CAUTION
Observe the arrows marked on the housing when scr-
ewing in the pressure reducer. These arrows correspond
to the pressure reducer through-flow direction, i.e. the
arrows point away from the connection. The pressure
reducer must always be connected directly; no hose
must be used between the connection and the pressure
reducer.
10 Connect cable with safety sleeve (12) to the indica-
tor lamp (9) using flat plug. Use this cable to create
the connection to “+’’ in the vehicle electric circuit.
11 Using a second cable of the same diameter, create a
connection between the second connection on the
indicator lamp (9) and the indicator switch (18) on
the shift cylinder (15).
CAUTION
Route cable so as to avoid shearing, kinks and breaks.
Otherwise there is a risk of short circuit, fire or indica-
tor failure.
NOTE: If the fuse blows, the cause must be determi-
ned and remedied before changing the fuse. Only use a
10 Amp fuse!

3 Screw the adapter (3) into the pressure reducer (2)

and connect the air hose (5) using the adapter (4).
4 Route the air hose (5) to the shift valve (7) attach-
ment point.
CAUTION
Do not wind plastic hose tightly when routing. Care
must be taken to ensure that the hose is not routed near
the exhaust unit or other hot areas!
5 Connect air hose (5) to the upper connection on the
side of the shift valve (7) using adapter (6).
NOTE: The hose nut on the adapter can be reused if
the plastic hose has not been removed from it.
6 Connect the air hose (5) to the lower, vertical
connection on the shift valve (7) using the adapter
(13).
7 Route the air hose (5) from the shift valve (7) to the
shift cylinder (15) of the PTO (16).
8 Connect air hose (5) to the shift cylinder (15) using
the adapter (14).
9 Insert the indicator lamp (9) into the bore provided
in the shift valve (7) and the instruction plate (17).
Tighten using the hex nut (11).

10
 Pneumatic shift mechanism

8 1
13 2
6
7/17 3
4
5
11

10

14

10
18 12
9

15
"+" vehicle
Bordnetzelectric circuit

16

008068

Key
1 Hex supports 10 Roundhead screws
2 Pressure reducer 11 Plastic hex nut
3 Adapter 12 Cable with saftey sleeve and flat plug
4 Adapter 13 Adapter
5 Air hose 14 Adapter
6 Adapter 15 PTO shift cylinder
7 Plate with shift valve 16 PTO
8 Bracket 17 Instruction plate
9 Indicator lamp 18 Indicator switch

11