ZF Transmission Service Manual - Rvd.center

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ZF Transmission Service Manual

ZF Transmission Service ManualPrefaceThe Service Manual introduces the ZF 4WG200(4WG158、6WG200 also applied)transmissionremoval and assembling process and offers the transmission service process technology andstandard requirements, which can help the service personnel understand the transmission removaland assembling methods more profoundly as well as lay a solid technical foundation for the servicepersonnel to correctly judge the malfunction and do troubleshooting.The Service Manual mainly includes following content:Chapter I. IntroductionThe chapter mainly introduces the transmission service precautions as well as symbol meaningsand common thread tightening torque value in the text.Chapter II. Transmission SystemThe chapter mainly introduces the mechanical principles of different gears of the transmissionas well as the transmission operation and maintenance.Chapter III. Transmission RemovalThe chapter introduces the correct parts removal steps as well as precautions during removal.Chapter IV. Transmission AssemblingThe chapter introduces the correct parts assembling steps as well as precautions duringassembling.Chapter V. Malfunction Diagnosis and TroubleshootingThe chapter introduces the malfunction diagnosis and troubleshooting of the transmissionsystem and ZF transmission.AttentionDue to product improvements, relevant parts in the Service Manual will be subject to change withoutfurther notice. For the newest data and information, please consult with or get them from ShandongLingong Construction Machinery Co., Ltd.

ZF Transmission Service ManualTable of Contents1 Introduction . 11.1 Safety Precautions . 11.2 Instructions of Marks and Symbols . 31.3 Common Bolt Tightening Torque Table . 32 Transmission System . 52.1 Transmission Introduction . 52.1.1 General Overview of the Transmission . 52.1.2 Basic Parameters of the Transmission-torque Converter Assembly . 72.1.3 Mechanical Principles of the Gears of the Transmission (4WG158/200) . 72.1.4 Introduction to KD Key Functions (4WG158/200) . 122.1.5 Operation and Maintenance of ZF Power Gearshift Transmission. 143 Transmission Removal . 203.1 Transmission Assembly Removal . 203.1.1 Torque Converter Removal . 203.1.2 Transmission Control Valve Removal . 213.1.3 Oil Filter Removal . 243.1.4 Removal of the Auxiliary PTO Wheel Hub . 253.1.5 Input Device Removal . 253.1.6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO . 283.1.7 KVK1 Clutch Assembly Removal. 293.1.8 KRK2 Clutch Assembly Removal . 303.1.9 K3K4 Clutch Assembly Removal . 323.1.10 Removal of the Parking Brake and the Output Device. 333.1.21 Intermediate Shaft Assembly Removal . 393.1.22 Removal of the Output Shaft Rotation Speed Sensor. 413.1.23 Removal of the Seal Cover of the Transmission Body . 413.1.24 Removal of the Torque Converter Pressure Regulating Valve . 413.2 Transmission Assembly Component Removal . 423.2.1 Main PTO Removal . 42I

ZF Transmission Service Manual3.2.2 Input Component Removal . 443.2.3 KVK1 Clutch Removal . 483.2.4 KRK2 Clutch Removal . 593.2.5 K3K4 Clutch Removal . 684 Transmission Assembly . 774.1 Assembling of the Transmission Assembly. 774.1.1 K3K4 Clutch Assembly. 774.1.2 Main PTO Assembly . 894.1.3 Input Part Assembly . 914.2 Transmission Assembly. 964.2.1 Output Part Assembly . 964.2.2 Intermediate Shaft Component Assembly . 1024.2.3 Torque Converter Pressure Control Valve Assembly . 1034.2.4 Assembling of the K3K4 Clutch Assembly. 1044.2.5 Rotation Speed Sensor Assembly. 1064.2.6 KRK2 Clutch Assembly . 1074.2.7 KVK1 Clutch Assembly. 1094.2.8 Auxiliary PTO Assembly . 1114.2.9 Input Component Assembly . 1124.2.10 Main PTO Component Assembly . 1144.2.11 Oil Filter Assembly . 1144.2.12 Transmission Control Valve Assembly. 1154.2.13 Torque Converter Assembly . 1185 Malfunction Diagnosis and Troubleshooting . 1195.1 Malfunction Diagnosis and Troubleshooting of the Transmission System . 1195.2 Malfunction Diagnosis and Troubleshooting of Transmission. 122II

ZF Transmission Service Manual1 Introduction1.1 Safety PrecautionsImportant Safety PrecautionsThe maintenance and repair is very important for a safe vehicle operation. The Manualmainly describes the correct removal and assembling technology of the transmissionassembly.To avoid personal injuries,will be made as the safety mark in the Manual. Theprecautions with shall be paid high attention to. In case of potential dangers, it isrecommended to consider the own safety first of all, and then consider taking necessarysafety measures.Safety TipsDuring assembling and removal, wrong operation method will lead to parts damages, servicelife shortening, service performance deterioration, and other unsafe factors. Accordingly, whenassembling and removing the parts, it is recommended to carefully read the Manual.1. All parameters, figures and relevant content in the Manual are applicable for the standardequipped product. For derivative product, please consult with us or refer to relevant materials.2. In the repair workshop, the places special for assembling and removal operation and storingremoved parts shall be prepared, and the corresponding tools and parts shall be placed in aproper site. In addition, the working area shall be kept clean, which shall be free from oil dirtand pollutants. Smoking is only allowed in the specified place; smoking is not allowed duringoperation, and corresponding fire extinguishers shall be prepared.3. The welding operation can only be conducted by the trained personnel with weldingexperience. During welding, welding gloves, retainer, goggles, work cap and other workclothes applicable for welding operation.4. Before removing the transmission-torque converter assembly, it is necessary to cleanpollutants on the surface of the transmission-torque converter assembly, so as to avoid pollutingthe parts during removal.5. During operation, it is necessary to wear safety boots and safety helmet. It is not allowed towear unqualified work clothes; it is necessary to fasten buttons of the work clothes. Whenknocking the parts with the copper rod, it is necessary to wear goggles.6. The gasoline, kerosene and water-based oil stain cleaning agent can be used to clean theremoved parts.7. When applying the traveling crane or other hoisting equipment, check relevant spreader fordamages first of all, and such hoisting equipment with sufficient hoisting capacity shall be used.During hoisting, the appointed hoisting position shall be used for slow hoisting, so as to avoidparts collision. It is not allowed to work in the area under the hoisted parts.1

ZF Transmission Service ManualAttentionAs the torque converter has no axial positioning, it is necessary to prevent its slipping in case ofremoval and assembling of the transmission, as shown in Figure 1-1Figure 1-18. In case of simultaneous operation with two or more persons, they shall reach an agreement inthe operation procedures before operation, so as to avoid accidents due to incompatible pace.9. It is necessary to properly keep all tools and be familiar with their application methods.10. In case of alignment of two holes, it is forbidden to insert hands and fingers. For parts to bedirectly assembled by hand, it is necessary to pay attention that the gripping position is freefrom squeezing danger.11. It is necessary to test the removed parts; the parts whose application performance is affectedshall be replaced with a new one.12. After assembling, the parts shall be free from interference.13. When assembling the oil seal and seal ring through the keyway, screw hole and step, it isnecessary to apply relevant protection measures to avoid damages.14. When assembling the parts, the applied tools shall match with the thread fastener, so as toavoid damages.15. When screwing down the connector body and screw plug, it is not allowed to use pneumaticwrench and other similar tightening tools. It is necessary to screw them down by hand and thenwith the torque wrench with corresponding capacity, so as to reach the corresponding torquevalue.16. When draining out fluid in the transmission, it is necessary to slowly screw off the oil drainplug, so as to avoid fluid spraying.2

ZF Transmission Service Manual1.2 Instructions of Marks and SymbolsTo ensure that the Manual can play a role, it is necessary to use marks specified in Table 1-1for aspects of the important safety and quality requirements.Table 1-1MarkRemarksSpecial attention shall be given to the safety in case ofoperation.SafetySpecial attention shall be given to the safety in case ofoperation as there is pressure inside.Special attention shall be given to the technical requirementsin case of operation to ensure that the operation is qualified.AttentionPart or device weight or removal and assembling method.WeightAttention shall be given to selection of the spreader and itsoperation posture.TighteningtorqueSpecial attention shall be given to the tightening torque ofthe component in case of assembling.CoatingThe place which needs adhesive and lubricating greasecoating.Oil and waterFill the engine oil, water and fuel with certain capacity.DrainingThe place needing oil or water draining and drainingcapacity.1.3 Common Bolt Tightening Torque TableTable 1-2Nominal diameter of bolt mmYieldstrengthN/mm268.86409 1222 3010.990013 1612.9108016 21Bolt strengthgradeYieldstrengthN/mm2168.8640193 257264 35410.9900280 33012.91080326 434Bolt strengthgrade810121445 5978 104124 16530 3665 78110 130180 21038 5175 100131 175209 278Tightening torque NmNominal diameter of bolt mm18202224376 502521 683651 868380 450540 650740 880940 1120448 597635 847864 11521098 1464Tightening torque Nm3

ZF Transmission Service ManualNominal diameter of bolt mmYieldstrengthN/mm2278.8640952 12691293 172310.99001400 165012.910801606 2142Bolt strengthgrade303336391759 23452259 30122923 38981700 20002473 32982800 33504111 54812181 29082968 39583812 50824933 6577Tightening torque Nm4

ZF Transmission Service Manual2 Transmission System2.1 Transmission Introduction2.1.1 General Overview of the TransmissionThe ZF power gearshift transmission is composed of the hydraulic torque converter andrear-mounted countershaft transmission with multi-sheet friction clutch. The SDLG 938L、948L wheel loader adopts the 4WG158 gearbox assembly ,the SDLG 958L、959、968 wheelloader adopts the 4WG200 gearbox assembly which can realize speed switching between 4forward gears and 3 reverse gears. The SDLG G9190 grader adopts the 6WG200 gearboxassembly which can realize speed switching between 6 forward gears and 3 reverse gears1234561. Connecting socket2. Torque converter shell3. Transmission control valve4. Transmission pressure measuringport5. Torque converter oil temperaturemeasuring port6. Transmission oil outlet7. Oil suction pipe8. Transmission housing9. Nameplate789Figure 2-110111213141516171819202110. Lifting ring screw11. Oil filter12. Auxiliary PTO13. Main PTO14. KV15. KR16. K217. K118. K319. K420. Rotation speed sensor21. Parking brakeFigure 2-25

ZF Transmission Service Manual1234567Figure 2-31. Auxiliary PTO2. Variable speed pump3. KVK1 clutch assembly4. Intermediate shaft component5. KRK2 clutch assembly6. K3K4 clutch assembly7. Output shaft assembly12345Figure 2-41. M42. M33. M564. M25. M1

ZF Transmission Service Manual2.1.2 Basic Parameters of the Transmission-torque Converter AssemblyTable 2-1TypeItem4WG1584WG2006WG200Six forward gears andTransmission gearFour forward gears and three reverse gearsthree reverse gearsTorque converter inlet8.5oil pressure (bar)Torque converter5outlet oil pressure (bar)Transmission working16&18pressure (bar)Gearbox oil draining35capacity(L)2.1.3 Mechanical Principles of the Gears of the Transmission (4WG158/200)1. First forward gearZ0 ZV ZV1 Z1 Z2 Z3 Z outputThe solenoid valves M2, M3, M4 act and the transmission pressure oil flows into KVK1 clutch,thus respectively pushing the piston to move; pressing the interior friction lining out of the clutchesand forming the transmission subassembly.The power transmission route: Driving gear Z0 forward gear input gear ZV forward gear clutchKV KV1 ring gear assembly ZV1 first gear clutch K1 gear Z1 of the first gear second gearcombination gear Z2 gear Z3 of the third gear output shaft gear Z output output shaft, as shownin Figure 2-57

ZF Transmission Service ManualTurbineEngineZ outputRear outputFront outputFigure 2-52. Second forward gearThe solenoid valves M3 and M4 act and the transmission pressure oil flows into KVK2 clutch, thusrespectively pushing the piston to move; pressing the interior friction lining out of the clutches andforming the transmission subassembly.The power transmission route: Driving gear Z0 forward gear input gear ZV forward gear clutchKV KV1 ring gear assembly ZV1 KR2 ring gear assembly ZR2 second gear clutch K2 second gear combination gear Z2 gear Z3 of the third gear output shaft gear Z output outputshaft, as shown in Figure 2-6Z0 ZV ZV1 ZR2 Z2 Z3 Z outputZ outputFigure 2-68

ZF Transmission Service Manual3. Third forward gearThe solenoid valve M3 acts and the transmission pressure oil flows into KVK3 clutch, thusrespectively pushing the piston to move; pressing the interior friction lining out of the clutches andforming the transmission subassembly.The power transmission route: Driving gear Z0 forward gear input gear ZV forward gear clutchKV KV1 ring gear assembly ZV1 KV2 ring gear assembly ZR2 K34 ring gear assembly Z34 third gear clutch K3 gear Z3 of the third gear output shaft gear Z output output shaft, as shownin Figure 2-7Z0 ZV ZV1 ZR2 Z34 Z3 Z outputZ outputFigure 2-7Z intermediateZ outputFigure 2-89

ZF Transmission Service Manual4. Fourth forward gearThe solenoid valve M5 acts and the transmission pressure oil flows into K3K4 clutch, thusrespectively pushing the piston to move; pressing the interior friction lining out of the clutches andforming the transmission subassembly.The power transmission route: Driving gear Z0 forward gear input gear ZV intermediate gear Zintermediate gear Z4 of the fourth gear fourth gear clutch K4 K34 ring gear assembly Z34 thirdgear clutch K3 gear Z3 of the third gear output shaft gear Z output output shaft, as shown inFigure 2-8Z0 ZV Z intermediate Z4 Z34 Z3 Z output5. First reverse gearThe solenoid valves M1, M2, M4 act and the transmission pressure oil flows into KRK1 clutch,thus respectively pushing the piston to move; pressing the interior friction lining out of the clutchesand forming the trans

ZF Transmission Service Manual 5 2 Transmission System 2.1 Transmission Introduction 2.1.1 General Overview of the Transmission The ZF power gearshift transmission is composed of the hydraulic torque converter and rear-mounted countershaft transmission with multi-sheet friction clutch. The SDLG 938L、

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