ZF Gearboxes Scheduled Maintenance Routines

1) A3.1 Routine (1000 Hourly/Annual)

 Visual inspection of the gearbox externally
 Re-tighten all screw/bolt connections accessible from outside
 The chemical cleaning and pressure testing of oil cooler is done
 Safety Devise Checks.

2) A3 Routine (2000 Hourly/2Yearly)

 Carry out visual inspection externally
 Re-tighten all the screw/bolt connections accessible from outside of the gearbox
 Check the control shift position settings and adjust if required
 Lubricate external moving parts
 Oil change
 Clean oil filter and filter housing
 Chemical Cleaning and Pressure testing of oil cooler and check output shaft seal.

3) A4 Routine (6000 Hourly/5Yearly)

 Checking out the oil level
 Carry out visual inspection
 Clean outside of transmission
 Re-tighten all screw/bolt connections accessible from outside
 Check shaft settings, and lubricate external moving parts
 Clean oil filter and filter housing
 Visually check flexible coupling between Gearbox and Engine
 Visually check flexible engine and transmission mounting
 Visually check clutch discs
 Visually check running gears
 Check control unit
 Check actuating unit
 Calibration of Gearbox Monitoring Devices and pressure testing oil cooler.
 Check spray line valves
 Check injection line valves
 Check input shaft seal
 Check output shaft seal
4) A5 Routine (Basic Overhaul)
 Receipt of Gearbox in workshop
 On Receipt make the visual inspection and recorded it
 Dismantle the Gearbox completely
 Clean all the parts and inspect/calibrate all the parts as per the factory recommendation
 Make additional parts list if any required
 Clean Oil Filter and filter housing in case of long life filter or Change oil filter in case of cartridge filter
 Chemical cleaning and pressure testing of Oil coolers
 Assemble back the gearboxes with new/service parts.
 Setting of End play and other allowance
 Do the machining of shim as per the requirement
 Final setting of Endplay/ Clearance
 Calibration of Gearbox Monitoring Devices
 Spin Test as per factory test protocol
 Painting

5) Mandatory basic overhauling Spare Parts offered prior opening of the gearbox is as
below. (Only Parts of wear and tear nature)
 Full set of seals, gaskets, O rings
 Full set of cup springs, small washers etc
 Full set of bearings
 Full set of clutch discs
 Complete Oil Pump
 Bushes, Compression Springs, slotted nuts, piston rings etc
 Oil Filter in case of cartridge filter