GK 20

Maintenance and Installation Instructions GK20 – GK40
Edition: 11.07.2006
For possible technical modifications of the product described in this manual ZF Gotha GmbH reserve the
right to change the product documentations, if necessary. Technical modifications are to be considered as
modifications in production, processing and appearance of the product.
Copyright ZF Gotha GmbH 2006
ZF Gotha GmbH • Karl-Liebknecht-Straße 26 • D-99867 Gotha

Introduction ZF Gotha GmbH reserve further technical
development of their products. It is possible that
procedures can become necessary which differ
This manual describes the maintenance and from those described in the original version of
installation for the transmissions type GK 20, 25, 30 this manual. In this case the customers are
and 40. The herein described work is only allowed to informed by ZF Gotha GmbH and the changed
be made by specialists who were trained by ZF pages of this manual will be made available to
Gotha GmbH for maintenance and repair work on them.
ZF units. It is absolutely required that design and
function of the mentioned transmission types are The customer is responsible to replace the
known. changed pages and thus to keep this manual
updated. The respective version is indicated on
Prior to start work read this manual carefully. Carry the bottom of every page for information. If you
out the single working steps as described and do not are not sure, whether you have the current
change them without permission. Observe the safety version of your manual, please consult the
instructions. If you do not understand a procedure or Technical Service of the ZF Gotha GmbH and
cannot follow it doubtlessly, do not act on your own request the respective current version.
without permission, but consult the Technical Keep this manual in such a way that it can
Service at ZF Gotha GmbH. always be found by persons concerned with the
For the work described in this manual only original product.
spare parts from ZF Gotha GmbH or spare parts A requirement is the availability of corresponding
approved by ZF Gotha GmbH are allowed to be presses and the appropriate bolting technology.
used. If no original parts are used the optimum
function of the transmission can be negatively Contact:
affected and the warranty claim will lapse. ZF GOTHA GMBH
Karl-Liebknecht-Straße 26
D-99867 Gotha
ZF Gotha GmbH do not accept any liability for Tel.: +49 (0)3621 311 - 0
damages and operational failures caused by Fax.: +49 (0)3621 311 - 4419
E-Mail: Aftermarket.zfgotha@zf.com
• imperfect mounting of attached components
• faulty installation
Transmittal of this manual, reproduction and copying –
• modifications on the transmission or the drive even partially –, making use and disclosure of its
unit without permission contents are forbidden without permission of the ZF
Gotha GmbH. Infringements are liable for damages. All
• inadequate use of the transmission or the drive rights reserved for the grant of a patent or registration
unit of a utility model.
• insufficient maintenance
• improperly and incompetently performed work
and the resulting consequential damages
• faulty operation
Maintenance and Installation Instructions Edition 11.07.2006 1 of 30

Table of Contents
TABLE OF CONTENTS ..................................................................................................2
DESCRIPTION ................................................................................................................4
Preface ............................................................................................................................4
SAFETY INSTRUCTIONS...............................................................................................5
Components and Accessories of a GK Transmission......................................................6
Transmission Identification ..............................................................................................7
INSTALLATION ..............................................................................................................8
General Instructions ........................................................................................................8

Torque limits in Nm for screws to ZF Standard 148 ................................................................ 8
Condition as supplied ............................................................................................................... 9
Storage...................................................................................................................................... 9
Transport .................................................................................................................................. 9
Removal of the corrosion protection ........................................................................................ 9
Attachment of the Electric Motor.................................................................................... 10

Attachment of the electric motor to the transmission ............................................................. 10
Pivoted Connection-Steering ......................................................................................... 12

Mounting of the gear ring with pivoted bogie bearing GK 20, GK 25 & GK 30................... 12
Mounting of the pivoted bogie bearing with holding ring GK 40 .......................................... 13
Mounting of the transmission top section GK 40 ................................................................... 14
Mounting of the gear ring GK 40 ........................................................................................... 15
Demounting of the pivoted connection ................................................................................... 15
Checking of fixing bolts of the pivoted connection................................................................. 15
Lubrication and maintenance of the pivoted connection........................................................ 16

Pivoted Connection – Roller Chain Steering.................................................................. 17
Transmission Attachment to the Mounting Construction in the Vehicle ......................... 22

Drive wheel mounting............................................................................................................. 23
INITIAL OPERATION / MAINTENANCE ...................................................................... 25

Oil grade for transmission types GK 20, GK 25, GK 30........................................................ 25
Oil grade for transmission type GK 40 .................................................................................. 25
Oil capacity............................................................................................................................. 25
Maintenance intervals Transmission...................................................................................... 26
Oil Change..................................................................................................................... 26
Drain the transmission oil at GK 20, GK 25 & GK 30 .......................................................... 26
Drain the transmission oil at GK 40 ...................................................................................... 27
Fill in the transmission oil at GK 20, GK 25 & GK 30.......................................................... 28
Fill in the transmission oil at GK 40 (Possibility 1)............................................................... 28
Fill in the transmission oil at GK 40 (Possibility 2)............................................................... 29
Technical Data of the GK – Product Range................................................................... 29
MAINTENANCE SCHEME............................................................................................ 30

Description
Preface
This documentation has been developed for the skilled Serviceman, trained by ZF for the Repair and
Maintenance operations on ZF-Units.
Treated is a ZF-Serial product according to the design stage of the date of Edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and
theoretical training is constantly completed to the actual situation in our Training School.
The Service Stations, established by the ZF Friedrichshafen all over the world, offer you:
1. Constantly trained personnel
2. Prescribed installations, e.g. Special Tools
3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability.
Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the
actual contractual conditions, by the ZF-Warranty.
Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-
expenditures eventually arising from it, are excluded from this contractual responsibility.
This applies also in case of a renouncement of Genuine ZF-Spare Parts.
We did not go into detail for disassembly, reassembly and repair of accessory parts.
Please observe the respective instructions and manuals of the vehicle manufacturer.
Basically all pictures are without any obligation and only serve as illustrative material and for better
understanding purposes.
Important information on industrial safety:
Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
Important information with reference to technical reliability and operational safety are outlined by the
following symbols:
DANGER
This symbol refers to situations where lacking care can lead to personal
injury or damage on the product.
CAUTION
This symbol in these operating instructions serves as a reference to special
working procedures, methods, information, the use of auxiliaries, etc.

Safety Instructions
• The use as directed requires the strict observance with the manufacturer’s specifications for
installation, dis- and reassembly, initial operation and maintenance.
• Every person concerned with installation, disassembly and reassembly, initial operation and
maintenance of the transmission in the user plant must have read and understood the whole
instructions and in particular the safety instructions.
• Any working method which endangers the safety of the transmission is prohibited.
• Modifications and changes without the proper permission are affecting the safety of the
transmission and are not allowed.
• Only original spare parts from ZF or spare parts approved by ZF are allowed to be used. It is
explicitly pointed out to the fact that spare parts and accessories, which were not supplied
by ZF are not checked and approved by us either. We do not accept any liability or admit any
warranty for damages caused by the use of spare parts and accessories which are no
original parts from ZF.
• The described work is only allowed to be made by authorized, skilled and instructed staff.
• The proper repair of these ZF-products requires adequately trained specialists. The repairer
is responsible for the training!
• Keep away aggressive cleaners from your skin, do not drink it or inhale its vapours! Always
wear safety gloves and goggles. If by mistake cleaner was swallowed, call medical aid
immediately! Strictly observe manufacturer instructions.
• Do not drain cleaners or transmission oil into the sewerage system or into the soil.
• Prior to start working on the installed or mounted transmission, the wheels must be blocked.
• Prior to any work on the installed transmission (e.g. oil change) or its mounted-on parts the
voltage source feeding the motor must always be disconnected resp. switched off.
• The local regulations for safety and prevention of accidents must be observed!

Components and Accessories of a GK Transmission
Item 01 one-piece transmission housing
Item 02 Venthole for electric motor ventilation
Item 03 optional steering: Gear ring with steering pinion (is shown) or
steering chain as alternative
Item 04 Mounting holes (optional)
Item 05 one-piece pivoted bogie bearing (optional)
Item 06 Wheel shaft with centering and locating face for drive wheel
Item 07 fully integrated drive pinion with motor connection profile
Item 08 Housing cover
Item 09 Oil filler plug and oil level check
Item 10 Oil drain plug
Other customer-specific accessories are possible!
05 03
03
01
02
09
06
10
07
04
04
08
Figure 01

Transmission Identification
The transmission type is cast in the transmission
housing on the bearing cover side.
Transmission type of
the product range GK
Figure 02
The model identification plate is fixed to the transmission housing side.
Technical data of the transmission is indicated on the model identification plate.
Transmission type Serial Number
GK 20 200001
4699 801 017 14,50
ZF Parts List No. Total ratio
Figure 03

Installation
General Instructions
Torque limits in Nm for screws to ZF Standard 148

Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO-Standard thread DIN 13, Metric ISO-Fine thread DIN 13,
Sheet 13 Sheet 13
Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M 8x1 24 36 43
M5 5.5 8.1 9.5 M 9x1 36 53 62
M6 9.5 14 16.5 M 10x1 52 76 89
M7 15 23 28 M 10x1.25 49 72 84
M8 23 34 40 M 12x1.25 87 125 150
M 10 46 68 79 M 12x1.5 83 120 145
M 12 79 115 135 M 14x1.5 135 200 235
M 14 125 185 215 M 16x1.5 205 300 360
M 16 195 280 330 M 18x1.5 310 440 520
M 18 280 390 460 M 18x2 290 420 490
M 20 390 560 650 M 20x1.5 430 620 720
M 22 530 750 880 M 22x1.5 580 820 960
M 24 670 960 1100 M 24x1.5 760 1100 1250
M 27 1000 1400 1650 M 24x2 730 1050 1200
M 30 1350 1900 2250 M 27x1.5 1100 1600 1850
M 33 1850 2600 3000 M 27x2 1050 1500 1800
M 36 2350 3300 3900 M 30x1.5 1550 2200 2550
M 39 3000 4300 5100 M 30x2 1500 2100 2500
M 33x1.5 2050 2900 3400
M 33x2 2000 2800 3300
M 36x1.5 2700 3800 4450
M 36x3 2500 3500 4100
M 39x1.5 3450 4900 5700
M 39x3 3200 4600 5300
Friction value: µ tot. 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts.
Tightened by hand!

Condition as supplied
The basic transmission is supplied as follows:
• ready assembled
• without oil filling (customer-specific agreement possible)
• painted with prime coating (ZF Standard 902) and coating varnish (RAL 9005), colour: jet black
• The wheel shaft sealing, the centering- and locating face for the drive wheel on the wheel shaft,
the wheel bolt threads, the connecting faces and boreholes for motor and vehicle connection are
provided with a short term corrosion protection.
• Metallic bright sections (like e.g. fits or guides) are also provided with a short term corrosion
protection.
• With internal preservation for short-term storage in a dry ambience.
Storage
The supplied GK-transmissions are provided with an internal preservation, ensuring a corrosion protection
for approx. 1 year at an adequate storage in closed and dry rooms.
If a transmission is to be stored for a longer time, the transmission has to be filled with the specified
transmission oil (see Chapter “Initial Operation / Maintenance” “Oil Grade”).
At an input speed of 1000 to 1500 min-¹ the transmission is to be driven for approx. 2 minutes, so that all
transmission internal parts are wetted with oil.
If this is ensured, the oil can be drained off again.
We recommend repeating this procedure yearly!
Transport
The unit is only allowed to be lifted with soft ropes or belts, never with steel ropes or chains. During
transportation care must be taken to avoid shocks.
Removal of the corrosion protection
Only with a suitable cleaner the corrosion protection is to be removed from the connecting points before
installation into the vehicle. Never use benzene, solvents or other combustible substances for cleaning.
Only use non-toxic, non-combustible and commercially permissible cleaning agents.
Do not drain cleaners into the soil. Overflown cleaner is to be disposed of

adequately. Do not abrade with emery or scrape off! Avoid that cleaners get
in contact with rubber parts, the electrical connections of the accessories or
the motor ventilation!
Keep away cleaning agent from your skin, do not drink it or inhale its
vapours! Wear safety gloves and goggles! In case of skin contact rinse
immediately with a lot of water! If by mistake the cleaning agent was
swallowed, call medical aid immediately! Observe the regulations for the
prevention of accidents!

Attachment of the Electric Motor
If the unit is supplied with an already attached electric motor this chapter is not applicable.
The centering- and locating faces for connection of the electric motor must be perfectly clean and
undamaged. Check face run-out of the motor connecting face to the motor shaft. The maximum run-out
must not exceed 0.05 mm. (see Figure 04)
An excessive face runout will have a negative effect on the noise behaviour
and results in premature wear of the spur gear stage.
Assembly instructions for the splined shaft-hub connection

An assembly paste has to be used as assembling aid and later long-term lubricant for the splined shaft-
hub connection.
Approved special lubrication grease: Klüberplex BEM 34- 132 (KLÜBER LUBRICATION)
Attachment of the electric motor to the transmission

Apply a thin and even coat of the special lubrication grease BEM 34-132 onto the splined shaft-hub
connection. Assemble the electric motor (Item 1) into the centering seat of the pivot bogie bearing (Item 2)
and join it cautiously with the splined hub connection of the drive pinion (Item 3).
Turn the hole pattern of the pivoted bogie bearing to be accurately aligned with that of the electric motor.
Fasten the electric motor by means of six (6) cap screws M8 and locking pieces with the pivoted bogie
bearing. Pay attention to the minimum screw-in depth (see Fig. 04, Item 4).
Please observe the specified mounting dimensions of the corresponding

installation drawing!
For connecting cautiously rotate the wheel shaft of the transmission or the
input shaft of the electric motor (depending on the mounting position) until
the input shaft engages into the splined hub connection of the drive pinion.
When locating the electric motor take care that the splined shaft-hub
connection (Fig. 4; Item 5) of the drive pinion and the electric motor shaft
will not be damaged.
Damages cause louder running noises and premature failure of the splined
shaft-hub connection!

Example for the electric motor attachment without centering ring connection directly to the pivoted bogie
bearing.
01
04
02
03
05
Figure 04

Pivoted Connection-Steering
Mounting of the gear ring with pivoted bogie bearing GK 20, GK 25 & GK 30
1. The centering and supporting face

for the gear ring has to be clean.
2. Pay attention that no foreign 03
substances or cleaning agents get
through the threaded holes (Item
01) of the mounting construction 04
(hole pattern of the housing) inside
the transmission.
3. Place the gear ring (Item 02) and
rotate it, so that the boltholes in the 02
gear ring are aligned with the
threaded holes of the mounting
construction.
4. By means of a plastic tip hammer
install the gear ring.
5. Put on the pivoted bogie bearing
(Item 03) with the correct side and
rotate it so that the boltholes in the
pivoted bogie bearing are aligned
with the hole pattern of the gear
01
ring and the housing.
6. Fasten the pivoted bogie bearing
and the gear ring on the mounting
construction by means hexagon
screws M8x40 (Item 04).
01
Figure 05
Attention
In order to avoid inadmissible leakage problems on the screws, it is mandatory to observe the
following procedure for thread sealing:
• Always seal the screws (Item 01) located in the oil sump of the transmission! For this purpose
these are to be wetted with LOCTITE 243 around the thread contact face and only then to be
attached.
• In order to avoid inadmissible variations among the screw clamping forces, always pretension the
screws carefully crosswise to the specified value. Tightening torque: 34 Nm Cl.3 ZF Standard
148
• After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is
necessary to use new screws.

Mounting of the pivoted bogie bearing with holding ring GK 40
01
a) Press the pivoted bogie bearing (Item 01)

evenly into the transmission top section
until contact is obtained.
b) Determine the Dim. A and B.
Prior to bolting Figure 06
02 03
c) Calculate the thickness of the shim rings

(Item 02) to be inserted, so that the bearing
preload is reached.
d) Dim. A – Dim. B – 0.05 to 0.25 mm =
bearing preload
e) Prepare the required shim ring thickness
and insert it.
Figure 07
In order to obtain the bearing preload a gap of 0.05 – 0.25 mm must exist
before between the holding ring (Item 03) and the inserted shim rings (Item
02) before bolting. Bearing play and an excessive preload have a negative
effect on the service life of the pivoted bogie bearing.
After bolting
02
f) Put on one drop each of LOCTITE 242
onto the threads of the Allen screws M10
(Item 02) and fasten the holding ring (Item
03) with screws.
g) Tighten the screws crosswise.
h) Tightening torque: 46 Nm
Figure 08

Mounting of the transmission top section GK 40
i) Apply a thin layer of LOCTITE 574 onto the

transmission plane face.
j) Place the transmission top section onto the
transmission housing that the cyl. pin (Item
01) in the transmission housing is
positioned into the fitting bore in the
transmission top section.
k) Bolt together the transmission top section 05
and the transmission by means of Allen
screws (Item 02).
l) The transmission top section is additionally 03
bolted with the transmission housing by
means of 2 Allen screws (Item 03) and
hexagon nuts (Item 04).
m) Tightening torque: 46 Nm
n) Put on the centering ring (Item 05) and
fasten it tightly with screws to the pivoted
bogie bearing.
02
01
04
Figure 10
02
Figure 09

Mounting of the gear ring GK 40
1. Place the steering turntable (Item 01) and rotate it so that the boltholes in the steering turntable
align with the threaded holes of the transmission top section (Item 02).
2. By means of a plastic tip hammer install the steering turntable until contact and position it with
the cyl. pins 8m6x20 (Item 03).
3. By means of the cap screws M8x20 (Item 04) fasten the steering turntable onto the transmission
top section.
03 04
02 01
Figure 11
Demounting of the pivoted connection
Demounting of the pivoted connection is basically made in reverse order of the mounting.
Checking of fixing bolts of the pivoted connection
The fixing bolts of the pivoted connection (see Fig.05 Item 04) have to be checked at regular intervals,
especially in case of:
• high breakdown torque load or
• hanging axial load
After the first 100 operating hours the fixing bolts have to be checked and in
case of deviation tightening to the specified value is required! (34 Nm)
Check the fixing bolts always after 600 operating hours, however, half-yearly
at least! In case of special operating conditions or device-dependent
inspection specifications the intervals can be reduced accordingly.
Disregard might cause personal injury or damage on the product!

Lubrication and maintenance of the pivoted connection
First lubrication of the teeth is to be made immediately after mounting. Spray grease is to be sprayed or to
be applied evenly onto the teeth. For this purpose and any later relubrication only use acid-free, non-
resinous, waterproof and non-ageing greases!
Without lubrication and relubrication respectively there will be a direct

metallic contact of the teeth resulting in damages.
Relubrication intervals
The relubrication intervals depend essentially of:
• the existing operating conditions

• the environmental influences like e.g. dirt, water, etc.
• the mounting type of the pivoted connection
Prior to every relubrication procedure it is necessary to clean the teeth, in

particular the tooth root.
Exact relubrication intervals can only be determined by tests under application conditions. If no
comparable results are available, Table 01 serves as orientation.
Operating condition Relubrication interval

dry and clean rooms after 250 h
heavier dirt accumulation, outdoor
after 100 to 150 h
operation
extreme dirt accumulation continuously
Table 01 „Approximate values for the relubrication interval“
The indicated values are based on the following conditions:

• Operating temperature <70°C
• Circumferential speed <0,5m/s
• Low to medium load
If longer relubrication intervals are determined by tests, the relubrication interval can be determined by the
ageing resistance of the lubricant, if necessary.

Lubricants
Description Temperature range Manufacturer
Aralup LFZ 1 -25°C to +250°C ARAL
Energol WRL 0°C to +80 °C BP
CARDREXA DC 1 -20°C to +120°C ELF
SURRET FLUID 4k -20°C to +100°C ESSO
CRAFLOSCON CG 901 Manual lubrication
-20°C to +150°C Klüber
CRAFLOSCON C-SG-0 Plus Spray lubrication
Mobiltac A Manual lubrication
1) -30°C to +120°C Mobil
Mobiltac D Spray lubrication
Cardium Fluid C -30°C to 60 °C SHELL
Crater 2 X Fluid -20°C to +120°C TEXACO
Grippa 33 S -20°C to +80°C Castrol
Table 02 „Lubricants for teeth“
The sequence of the indicated lubricants is no reference to their quality. Lubricant-specific questions have
to be clarified with the respective lubricant manufacturer.
Pivoted Connection – Roller Chain Steering

Components of the pivoted connection
(see Fig.13, Page 18)
Fixing of the roller chain (Item 01) on the chain flange (Item 02) is made by a chain tensioner (Item 03)
with an adjustable element (Item 04).
Sixteen (16) holes (Item 05) on the plane face of the chain guideway allow fixing of the chain tensioner at
the most suitable mounting position, which is opposite to the chain pinion.
Chain tensioner
The chain tensioner is designed for mounting of the following DIN – Simplex-Roller Chains:
• Single roller chain 5/8“ x 3/8“ DIN 8187 (European Design),

• Single roller chain 3/4“ x 7/16“ DIN 8187 (European Design)
Tensioning of the roller chain is made via the tensioning bolt and the adjustable element of the chain
tensioner.
With the chain tensioner an overall length of the chain of approx. 25 mm can be adjusted.
Approx. 12 mm of it can be compensated via the adjustable element and the tensioning bolt, the rest by
means of the two holes in the chain tensioner.
We recommend that the roller chain in new condition is attached on the first bore of the chain tensioner
and to use connecting elements (chain joints, Item 06 and Item 07) in accordance with DIN 8187 / 8181.
(Fig. 07)

Chain guideway 01 06
Plane face 07
05
04
03
02
Figure 13
Within an area of approx. 135° around the chain tensioner only riveted
connecting elements (chain joints) are allowed to be used.
Drive wheel and wheel

shaft respectively must
be aligned in direction of
motion.
The chain tensioner
should be mounted
opposite of the steering
pinion. This ensures that
there is an equal steering
angle towards both sides.
Figure 14
Mounting of the pivoted connection

(see Fig.05, Page 12)
1. The centering and supporting face for the chain flange has to be clean.
2. Pay attention that no foreign substances or cleaning agents get through the threaded holes (Item
01) of the mounting construction (hole pattern of the housing) inside the transmission.
3. Place the chain flange (Item 02) and rotate it, so that the boltholes in the chain flange are aligned
with the threaded holes of the mounting construction.
4. By means of a plastic tip hammer install the chain flange until contact is obtained.
5. Put on the pivoted bogie bearing (Item 03) with the correct side and rotate it so that the boltholes
in the pivoted bogie bearing are aligned with the hole pattern of the flange and the housing.
6. Fasten the pivoted bogie bearing and the chain flange on the mounting construction by means
hexagon screws M8x40 (Item 04).

Attention
In order to avoid inadmissible leakage problems on the screws, it is mandatory to observe the
following procedure for thread sealing:
• Always seal the screws (Item 01) located in the oil sump of the transmission! For this purpose
these are to be wetted with LOCTITE 243 around the thread contact face and only then to be
attached.
• In order to avoid inadmissible variations among the screw clamping forces, always pretension the
screws carefully crosswise to the specified value. Tightening torque: 34 Nm Cl.3 ZF Standard
148
• After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is
necessary to use new screws.
Mounting of the chain tensioner
1. Hang the chain tensioner (Item 03) into the requested position on the chain guideway and swivel it so
that the tensional pin (Item 09) can be hit in.
2. Fasten the tensioning bolt (Item 10) with the hexagon nut (Item 11) on the chain tensioner.
3. Attach the adjustable element (Item 04) into the tensioning bolt.
4. With the connecting elements (Item 06 and Item 07) hang in the roller chain (Item 01) and lock it. Pay
attention that the roller chain is mounted on the adjustable element (Item 04) in the correct position
and in accordance with the mounting dimensions.
+1
5. Tension the roller chain by tightening the tensioning bolt. At a tightening torque of: 6 Nm the roller
chain is tensioned correctly and the adjustment of the chain drive is correct.
6. Then fix the hexagon nut to the adjustable element and lock it respectively.
03 09
07
10
11
06
04 01
Figure 15

Calculation formula for steering drive design
The steering drive design is to be calculated as follows:
Steering torque [Nm]:
FR • 9.81 • b • µ FR = Wheel load in kg (see tech. data vehicle)

TSteering = b = Wheel width in mm (see tech. data)
4000 µ = Frictional value (depending on ground
conditions and wheel material)
Tractive force of the chain [N]:
TSteering • 2 • k 1
Fz = k1 = Thrust factor (empirical values required)
D
Depending on the damping at the steering stop it is required to consider thrust factors up to 2.5. Pay
attention to dampened final stops enabling to obtain as low as possible tractive forces of the chain so that
small chain sizes can be used.
Chain tensioners are not allowed to be used as steering stop and are
designed for the maximum wheel load and maximum wheel width (See
Technical Data of the Transmission). In case of an excessive steering torque
on the input side this will result in a too high tractive force of the chain.
In this case it is unavoidable that the steering mechanism gets damages!

The following chains are currently approved by ZF for GK40 etc.:
(see Fig. 16, Page 21)
Mounting dimensions (in mm)

Single roller chain D E F
10B-1 5/8“ x 3/8“ Ø335.16 DIN 8187-E-10B-1 DIN 8181-E-210B
12B-1 ¾“ x 7/16“ Ø337.07 DIN 8187-E-12B-1 DIN 8181-E-212B
Ø 383 E
3,3
18,2
Center Chain track

F
Figure 16

Transmission Attachment to the Mounting Construction in the Vehicle
For economy reasons the cross sections of the pivoted bogie bearings are kept very small in comparison
with the diameter. This requires a rigid and torsion-resistant mounting construction for these bearings.
Additionally the supporting face for the pivoted bogie bearings and mounting of the same must also
provide the maximum evenness or flatness. (see Fig. 17)
The supporting face in the vehicle requires a mechanical machining. Inadmissible distortions or
deformations during fastening of the screws occur due to uneven locating on the frame plate or
unevenness in the locating area of the pivoted bogie bearing.
The pivoted bogie bearing must support evenly on the whole surface of the
mounting construction. If this requirement is not fulfilled the service life of
the pivoted bogie bearing reduces. Additionally, the reliability in service is
put at risk.
Shape alternatives of the locating face require a written approval by ZF,

which however will only be given after a preceding installation investigation.
M 12
0.15
Screw-in depth
min 15 mm
Figure 17
Please observe the specified vehicle mounting dimensions indicated in the

corresponding installation drawing of the unit!

Drive wheel mounting
If the unit is supplied with the drive wheel already mounted this chapter is not applicable.
For the reliable attachment of the drive wheel to the wheel shaft of the transmission during operation, the
dimensional conformity of wheel shaft and drive wheel connection as well as the use of the correct fixing
parts at the specified tightening torque is decisive.
Prior to mounting and initial operation of inflated wheels the required air
volume is to be filled into the wheel! (See information of the wheel
manufacturer)
Carrying capacity and air pressure acting on the wheel are not allowed to
exceed the recommendations of the wheel manufacturer.
It is mandatory to observe the instructions as to limited carrying capacities
and maximum speeds! Damaged, worn or deformed drive wheels are not
allowed to be repaired or mounted!
Pay attention that mounting of the drive wheel and the appropriate wheel
nuts as well as spring washers are in compliance with DIN 74361! Tires with
other dimensions or rim offsets require a written approval by ZF!
The centering and selection of the corresponding fixing elements for the drive wheel is made as follows:
• for Vulkollan drive wheels over the centering collar of the wheel shaft with flat collar nut and spring
washer.
• for pneumatic/CSE-drive wheels with spherical collar nut.
• The drive wheel of the respective design and the appropriate fixing elements have to be fastened
with screws.
Prior to drive wheel mounting pay attention that the wheel shaft, the rim
mounting face, the wheel bolts, the spring washers and the wheel nuts are
clean, free from grease and undamaged.
Tightening torque for all fixing elements of the thread size M14x1.5 is 140 Nm.

Drive wheel
Fixing elements
Figure 18
After mounting of a wheel it is mandatory to retighten the wheel nuts and

wheel bolts respectively with the specified torque after a mileage of approx.
50 km.

Initial Operation / Maintenance
If the units are not delivered with filled oil, fill in the transmission oil before
the initial operation!
Oil grade for transmission types GK 20, GK 25, GK 30
Approved are only oils which fulfill the below specifications:

• Classification to API-GL5
• Classification to MIL-L-2105C/D, test method A (score test), test method C (endurance wear test)
• ZF List of Lubricants TE-ML 17, Lubricant class 17B
Oil grade for transmission type GK 40
Approved are only oils which fulfill the below specifications:

• Classification to API-GL4 or API-GL5
• Classification to MIL-L-2105 or MIL-L-2105 C/D
• ZF List of Lubricants TE-ML 17, Lubricant class 17A and 17B
Detailed data to the oils grades is found in the Internet under the below mentioned address:
www.zf.com / Products for / Techn.Information / List of Lubricants
The use of alternative oil grades requires the written approval by ZF Gotha GmbH.
ZF units are designed up to -30°C. ZF cannot give any warranty for an operation
below -30°C.
In general the components are not damaged in cold store operation at temperatures
to -40°C as these mostly only occur for a short time after vehicle start-up. For critical
single cases independent tests by the vehicle manufacturer are recommended!
Oil capacity
Total transmission oil quantity GK 20 2.2 liters

The oil quantities are approximate values and serve as guide only.

Maintenance intervals Transmission
After approx. 25 operating hours:

• Visual inspection for possible oil leakage on the transmission; oil level check
After 150 – 300 operating hours:

• First oil change
After 1500 operating hours or at yearly intervals:

(whatever occurs first)
• Visual inspection for damages, leakages and possible oil loss on the transmission – oil level check
No further transmission oil changes are required when the first oil change
was made after 150-300 operating hours. Repaired transmissions are to be
treated like new transmissions.
Modifications of these specifications require the written approval by ZF.
Oil Change
Drain the transmission oil at GK 20, GK 25 & GK 30
Do not drain transmission oil into the soil or the sewerage system.
Pay attention to the type and quantity of debris.
High oil temperatures are to be expected after continuous operation of the

transmission. Wear temperature-resistant gloves!
• Position the vehicle on even ground and

lock the wheels for safety purposes.
• Carefully clean the area around the oil
filler and oil drain plug.
• Place a suitable big oil collecting vessel
under the oil drain plug.
02
• Loosen the oil filler plug (Item 01) with a
6mm Allen wrench. Remove the oil filler
plug and the sealing ring (Item 02).
• Loosen the oil drain plug (Item 03) with a 01
6mm Allen wrench. Remove the oil drain
02
• Have the transmission oil drained into the
vessel completely.
03
Figure 19

Drain the transmission oil at GK 40
Do not drain transmission oil into the soil or the sewerage system.
Pay attention to the type and quantity of debris.
High oil temperatures are to be expected after continuous operation of the

transmission. Wear temperature-resistant gloves!
• Position the vehicle on even ground and

lock the wheels for safety purposes.
• Carefully clean the area around the oil
filler and oil drain plug.
• Place a suitable big oil collecting vessel
under the oil drain plug.
• Loosen the oil filler plug (Item 01) with a 02
6mm Allen wrench. Remove the oil filler
• Loosen the oil drain plug (Item 03) with a 01
6mm Allen wrench. Remove the oil drain
• Have the transmission oil drained into the 02
vessel completely.
03
Figure 20
For all transmissions an oil drain time of approx. 5 min. must not be
exceeded.

Fill in the transmission oil at GK 20, GK 25 & GK 30
• Clean magnet on the oil drain plug (Item 03)
and always reattach it with a new sealing ring
(Item 04). (See Fig. 13)
Tightening torque: 22 Nm
• Fill in the transmission oil. For oil quantities and
viscosity classes see Chapter „Initial Operation 05
/ Maintenance“ Paragraph „Oil Grade“ & „Oil
Capacity“
• For filling use a suction and pressure injector
(Item 05). This allows an easy and rapid filling
of the transmission with oil.
• The correct oil level and the correct oil quantity
is achieved when the oil level is at the lower
edge of the oil filler plug, at least when oil
penetrates at the oil filler plug.
• Attach the oil filler plug (Item 01) with a new
sealing ring (Item 02).
• Tightening torque: 22 Nm
Figure 21
Fill in the transmission oil at GK 40 (Possibility 1)
• Clean magnet on the oil drain plug (Item 03)
and always reattach it with a new sealing ring
(Item 04). (See Fig. 14)
• Fill in the transmission oil. For oil quantities and
viscosity classes see Chapter „Initial Operation
/ Maintenance“ Paragraph „Oil Grade“ & „Oil
Capacity“
• For filling use a funnel with hose. Maximum
outer diameter of the hose is 13 mm. 02
• The correct oil level and the correct oil quantity
is achieved when the oil level is at the lower
edge of the oil filler plug, at least when oil 01
penetrates at the oil filler plug.
• Attach the oil filler plug (Item 01) with a new
sealing ring (Item 02).
Figure 22

Fill in the transmission oil at GK 40 (Possibility 2)
• Clean magnet on the oil drain plug (Item
03) and always reattach it with a new
sealing ring (Item 04). (See Fig. 14)
• Fill in the transmission oil. For oil quantities
and viscosity classes see Chapter „Initial
Operation / Maintenance“ Paragraph „Oil
Grade“ & „Oil Capacity“
• For filling use a funnel with hose.
Maximum outer diameter of the hose is
13 mm. 02 01
• After filling in of the specified oil quantity
leave the transmission standing for 2
minutes.
• The correct oil level and the correct oil
quantity is achieved when the oil level is at
the lower edge of the oil filler plug, at least
when oil penetrates at the oil filler plug.
• Attach the oil filler plug (Item 01) with a
new sealing ring (Item 02).
Figure 23
Remove spilled oil with a suitable oil binder.
After 25 operating hours check the oil level once again. Refill oil, if
necessary!
Technical Data of the GK – Product Range

GK – product range GK 20 GK 25 GK 30 GK 40
Max. wheel load kg 2000 2600 3400 4200
Max. wheel size Ø mm 310 350 406 406
Max. wheel size mm 125 140 160 178
Max. wheel torque Nm 980 1400 1700 2600
-1
Max. speed min 4500 4500 4500 4500
Ratio 10,2 – 25,4 10,0 – 24,3 11,5 – 25,1 15,5 – 19,9
Envelope mm 168 182 208 230
Temperature
°C - 30 to + 40 - 30 to + 40 - 30 to + 40 - 30 to + 40
range
Weight, without oil,
E-motor, drive kg 46 57 60 70
wheel
Subject to technical modifications.

Maintenance Scheme
Maintenance after
only once after regularly after
intervals operating 0h 25 h 200 h 300 h 600 h 1500 h

hours
varying, depending what at
Mounting 7 days 1 month 3 months 6 months 12 months
occurs first intervals
Maintenance work
Attention:
after 50 km it is absolutely necessary to
retighten the wheel nuts of the installed
drive wheel with the specified tightening
torque of 140 Nm!
•
Retighten the fixing bolts of the pivoted
connection with the specified tightening
torque 34 Nm! •
Oilchange
•
Greasing of the teeth on the pivoted
connection •
Visual inspections
Visual inspection for oil leakage
General condition of the pivoted

• • •
connection (for extreme conditions, see
Chapter „Lubrication and maintenance
intervals of the pivoted connection“
•
General condition of the transmission
(e.g. damages; cracks in the housing,
noises, etc.) •
General condition of the drive wheel
(e.g. deformation, damage, etc.) •
General condition of the motor (e.g.
grease in the motor, tempering colours,
fan inspection, etc.) •
Special application conditions
stored transmissions Conservation to be renewed every 6 months
Transmissions with less operating hours acc. to maintenance scheme
Transmissions with extreme operating
Intervals to be reduced by half
conditions

GK 20

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Maintenance and Installation Instructions GK20 – GK40

Copyright ZF Gotha GmbH 2006

ZF Gotha GmbH • Karl-Liebknecht-Straße 26 • D-99867 Gotha

Maintenance and Installation Instructions Edition 11.07.2006 1 of 30

TABLE OF CONTENTS ..................................................................................................2

Components and Accessories of a GK Transmission......................................................6

Transmission Identification ..............................................................................................7

General Instructions ........................................................................................................8

Condition as supplied ............................................................................................................... 9

Removal of the corrosion protection ........................................................................................ 9

Attachment of the Electric Motor.................................................................................... 10

Pivoted Connection-Steering ......................................................................................... 12

Mounting of the pivoted bogie bearing with holding ring GK 40 .......................................... 13

Mounting of the transmission top section GK 40 ................................................................... 14

Mounting of the gear ring GK 40 ........................................................................................... 15

Demounting of the pivoted connection ................................................................................... 15

Checking of fixing bolts of the pivoted connection................................................................. 15

Lubrication and maintenance of the pivoted connection........................................................ 16

Maintenance and Installation Instructions Edition 11.07.2006 2 of 30

Transmission Attachment to the Mounting Construction in the Vehicle ......................... 22

INITIAL OPERATION / MAINTENANCE ...................................................................... 25

Oil grade for transmission type GK 40 .................................................................................. 25

Maintenance intervals Transmission...................................................................................... 26

Drain the transmission oil at GK 40 ...................................................................................... 27

Fill in the transmission oil at GK 20, GK 25 & GK 30.......................................................... 28

Fill in the transmission oil at GK 40 (Possibility 1)............................................................... 28

Fill in the transmission oil at GK 40 (Possibility 2)............................................................... 29

Technical Data of the GK – Product Range................................................................... 29

Maintenance and Installation Instructions Edition 11.07.2006 3 of 30

Important information on industrial safety:

Maintenance and Installation Instructions Edition 11.07.2006 4 of 30

Maintenance and Installation Instructions Edition 11.07.2006 5 of 30

Maintenance and Installation Instructions Edition 11.07.2006 6 of 30

Transmission type Serial Number

ZF Parts List No. Total ratio

Maintenance and Installation Instructions Edition 11.07.2006 7 of 30

Torque limits in Nm for screws to ZF Standard 148

Maintenance and Installation Instructions Edition 11.07.2006 8 of 30

The basic transmission is supplied as follows:

Removal of the corrosion protection

Do not drain cleaners into the soil. Overflown cleaner is to be disposed of

Maintenance and Installation Instructions Edition 11.07.2006 9 of 30

Assembly instructions for the splined shaft-hub connection

Attachment of the electric motor to the transmission

Please observe the specified mounting dimensions of the corresponding

Maintenance and Installation Instructions Edition 11.07.2006 10 of 30

Maintenance and Installation Instructions Edition 11.07.2006 11 of 30

1. The centering and supporting face

Maintenance and Installation Instructions Edition 11.07.2006 12 of 30

a) Press the pivoted bogie bearing (Item 01)

Prior to bolting Figure 06

c) Calculate the thickness of the shim rings

Maintenance and Installation Instructions Edition 11.07.2006 13 of 30

i) Apply a thin layer of LOCTITE 574 onto the

Maintenance and Installation Instructions Edition 11.07.2006 14 of 30

Maintenance and Installation Instructions Edition 11.07.2006 15 of 30

Without lubrication and relubrication respectively there will be a direct

• the existing operating conditions

Prior to every relubrication procedure it is necessary to clean the teeth, in

Operating condition Relubrication interval

The indicated values are based on the following conditions:

Maintenance and Installation Instructions Edition 11.07.2006 16 of 30

Pivoted Connection – Roller Chain Steering