Operating
Instructions
Repair
2K800/2K801/2K802
26
EN 4161.758.103m – 2015-10
6
Repair
In the event of gearbox malfunctions, first check
the connected components and their ports and
connections.
Carefully document the type of fault so as to assist
manufacturer diagnosis (see chap. 6.1).
Repairs on the gearbox itself may only be carried
out by ZF Friedrichshafen AG or by authorized ZF
after-sales points.
6.1
Gearbox fault checklist
If you encounter drive unit faults, please refer to
the remedies in chapter 7 first of all for help.
If this does not solve the problem, you will need to
provide the following information for diagnosis at
ZF Friedrichshafen AG or an authorized ZF after-
sales point:
Gearbox data on the model plate:
Typ:
. . .
(Type)
Stückliste:
. . . . . . . . . .
(Parts list no.)
Serien-Nr.:
. . . . . .
(Serial no.)
Motor data on the model plate
Manufacturer:
. . .
Type/size:
. . .
Questions for fault diagnosis:
Is gearbox oil sight glass dark/discolored
black?
Smell of burning oil at oil breather?
Gearbox running noise in 1:1 or 4:1 gear ratio,
or only in one rotation direction or in both
rotation directions?
Before the running noise occurred, was the
machine operated in only one gear ratio (1:1)
for an extended period of time?
Did the running noise occur after changing the
machine's cycle or was the machine cycle
unchanged?
Was any maintenance carried out on the
machine before the fault occurred and, if yes,
what did this maintenance work involve?
No gear change or gear loss in the event of
a shift problem?
Does shift logic conform to ZF specifications
(see page 20)?
What is the shift unit voltage during the shift
sequence?
