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4.2 Transmission Assembly

1. Figure 4 21 83 A LU ZR IS I ZF Transmission Service Manual SDLG 21 Install the retainer ring into the cylinder clip groove of K4 clutch with the snap ring pliers Figure 4 22 1 Retainer ring 2 Snap ring pliers 22 Take down the clutch spring removal and assembling tooling Figure 4 23 23 Firstly place the external friction lining into the K4 clutch Attention During use if the external friction lining of the clutch is worn out and more than 2 3 parts of the pattern groove of the friction lining are worn out timely replacement shall be done 1 Figure 4 24 1 External friction lining 84 A WR IS I ZF Transmission Service Manual SDLG 24 Install the internal friction lining into the K4 clutch Attention Firstly place the external friction lining into the clutch and then place the external and internal friction linings in turn including 9 external friction linings and 8 internal friction linings 1 Figure 4 25 1 Internal friction lining 25 Place the bearing plate into the K4 clutch Figure 4 26 1 Bearing plate 26 Install the elastic retainer ring into the K4 clutch Figure 4 27 1 Elastic retainer ring 85 A LU ZR IS I ZF Transmission Service Manual SDLG 27 Slightly push the K4 clutch friction lining upwards with the screwdriver and record the clutch piston stroke which is measured by the dial indicator Attention Press th
2. Figure 4 36 1 K3K4 clutch assembly ZF Transmission Service Manual 33 Install the needle bearing into the K4 clutch gear 34 Install the K4 clutch gear Attention Before installing the gear it is necessary to perform alignment to the internal friction lining splines of the clutch 35 The K3K4 clutch assembling is completed Attention The KVK1 and KRK2 clutch assembling process can follow the K3K4_ clutch assembling process which is omitted here 88 A WR IS I ZF Transmission Service Manual SDLG 36 The KVKI1 clutch assembling is completed Figure 4 37 1 KVKI1 clutch assembly 37 The KRK2 clutch assembling is completed Figure 4 38 1 KRK2 clutch assembly 4 1 2 Main PTO Assembly 1 Install the needle bearing into the wheel hub of the output transmission body and then install the retainer ring Figure 4 39 1 Retainer ringx2 2 Needle bearing 89 A LU ZR IS I ZF Transmission Service Manual SDLG ain 2 Install the retainer ring into the transmission gear hole and then install the gear into the wheel hub of the output transmission body Figure 4 40 1 Transmission gear 2 Retainer ring 3 Insert the PTO shaft into the gear hole knock in the ball bearing and insert 2 elastic retainer rings and retainer ring Figure 4 41 1 Ball bearing 2 Elastic retainer ringx2 4 The PTO assembling is completed Figure 4 42 1 Retainer ring 45x1
3. compensation washer the transmission shall SS i be placed flatly to prevent the washer falling down to the bottom of the transmission body Pore A Figure 3 38 1 Thrust washer 2 Thrust washer 3 Compensation washer 32 SDLG Figure 3 39 1 K3K4 clutch assembly 2 Clutch shaft positioning tooling 29380017611 Figure 3 40 1 K3K4 clutch assembly l 2 3 Figure 3 41 1 Hexagon head screw M10 25 x6 2 butterfly pressure plates 3 Nut M10 x2 A WRIS I ZF Transmission Service Manual 4 Take out the K3K4 clutch assembly from the transmission body oe A Attention When taking out the clutch assembly hold the clutch assembly with the clutch shaft positioning tooling and the operation shall be slow to avoid slipping 5 The K3K4 clutch assembly removal is completed Attention Mark the K3K4 clutch with the marker for convenient distinguishing 3 1 10 Removal of the Parking Brake and the Output Device 1 Remove the bolt and washer between the brake wheel hub and the brake flange Attention After taking down the wheel hub connect 2 bolts M10 25 between the butterfly pressure plate and the brake wheel hub 33 A WRIS I ZF Transmission Service Manual SDLG 2 Take down the brake wheel hub and remove the lock washer Figure 3 42 1 Brake wheel hub 2 Lock washer 3 Remove the bolt between the pressure plate and the output flange Figure 3 43 1 Lock washer
4. l Figure 4 79 1 Sealing washer 4 2 3 Torque Converter Pressure Control Valve Assembly 1 Install the pressure spring and the valve core into the valve sleeve hole Figure 4 80 1 Pressure spring 2 Valve core 3 Valve sleeve 2 Firstly install the O ring onto the screw plug and then install the valve sleeve component into the pressure maintaining valve hole of the torque converter of the transmission body and screw down the screw plug after that the assembling is completed Figure 4 81 1 O ring 2 Screw plug CM30 1 5 103 A LU ZR IS I ZF Transmission Service Manual SDLG 4 2 4 Assembling of the K3K4 Clutch Assembly 1 Install the O ring and piston ring on the K3K4 clutch shaft Figure 4 82 1 K3K4 clutch assembly Figure 4 83 1 Piston ringx3 2 O ring 49 3 2 Coat the thrust washer with grease and fix it onto the inner wall of the transmission body Figure 4 84 1 Thrust washer 2 Thrust washer 104 A WR IS I ZF Transmission Service Manual SDLG 3 Place the clutch assembly into the transmission body A Attention When placing the clutch use the tooling and jack up the bottom of the clutch to avoid its falling 1 2 Figure 4 85 1 K3K4 clutch assembly 2 Clutch assembling tooling 29380017611 4 Overturn the transmission to make it be in a horizontal position and then install the clutch assembling tooling Figure 4 86 5 Take out the to
5. 1 Bearing plate 9 Take out the external friction lining from the KR clutch 1 Figure 3 127 1 External friction lining 10 Take out the internal friction lining from the KR clutch 1 Figure 3 128 1 Internal friction lining 62 A LU ZR IS I ZF Transmission Service Manual SDLG 11 Take out the external and internal friction linings and place them aside 12 Install the clutch spring removal tooling and press down the KR clutch pressure spring I 2 Figure 3 130 1 Clutch spring removal tooling 2 Pressure spring 13 Take down the retainer ring of the KR clutch pressure spring with the snap ring pliers Figure 3 131 1 Retainer ring 63 A LU ZR IS I ZF Transmission Service Manual SDLG 14 Take out the retainer ring and guide ring of the KR clutch _ Figure 3 132 1 Guide ring 2 Retainer ring 15 Take out the guide ring and pressure spring of the KR clutch Figure 3 133 1 Lower guide ring 2 Pressure spring 3 Upper guide ring 16 Take out the KR clutch piston Figure 3 134 1 KR clutch piston 64 A WR IS I ZF Transmission Service Manual SDLG 17 Remove the needle bearing on the KR clutch P Figure 3 135 1 Needle bearing 2 Check valve i 18 Take out the roller bearing of the K2 clutch gear Figure 3 136 1 Roller bearingx2 19 Take down the gear and thrust washer of the K2 clutch Figure 3 137 1 K2 clutch gear 2
6. 2 Hexagon head screw M10 30 x2 4 Take down the pressure plate distance washer and O ring Figure 3 44 1 Pressure plate 2 O ring 3 Distance washer 34 AX wis SDLG Figure 3 45 1 Brake flange 2 Fixing plate Wert ete Figure 3 46 1 Brake drum wheel 2 Drum wheel tension spring Figure 3 47 1 Oil seal ZF Transmission Service Manual 5 Remove the brake flange and the fixing plate 6 Remove the brake drum wheel A Attention When removing the drum wheel the force shall be slow and sufficient and protection measures shall be taken to avoid spring detachment 7 Take out the oil seal from the output device Attention When taking out the oil seal the force shall be uniform and sufficient to avoid damages And the special removal tooling can also be used 39 A WR IS I ZF Transmission Service Manual SDLG 8 Take down the lock washer and remove the bolt between the pressure plate and the output flange Figure 3 48 1 Lock washer 2 Hexagon head screw M10 30 x2 9 Take down the pressure plate distance washer and O ring in turn gt Lu re E g BA Figure 3 49 1 Pressure plate 2 Distance washer 3 O ring i 10 Take down the output flange Figure 3 50 1 Output flange 36 A LU ZR IS I ZF Transmission Service Manual SDLG 11 Take down the oil seal Attention When taking out the oil seal the force shall be uniform and sufficient
7. SDLG 2 1 2 Basic Parameters of the Transmission torque Converter Assembly Table 2 1 Six forward gears and Transmission gear Four forward gears and three reverse gears three reverse gears Torque converter inlet oil pressure bar Torque converter outlet oil pressure bar Transmission working pressure bar Gearbox oil draining capacity L 2 1 3 Mechanical Principles of the Gears of the Transmission 4WG158 200 1 First forward gear Ly Ly Lyi L 7 L127 L3Z output The solenoid valves M2 M3 M4 act and the transmission pressure oil flows into KVKI1 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches and forming the transmission subassembly The power transmission route Driving gear Zo forward gear input gear Zy forward gear clutch KV KVI1 ring gear assembly Zy first gear clutch K1 gear Z of the first gear second gear combination gear Z gear Z3 of the third gear output shaft gear Z output output shaft as shown in Figure 2 5 A WR ISI ZF Transmission Service Manual SDLG Turbine Engine Ji K4 K3 Z output Rear output Front output Figure 2 5 2 Second forward gear The solenoid valves M3 and M4 act and the transmission pressure oil flows into KVK2 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches and forming the transmission subassembly
8. daie s CALTEX ESSO SHELL 5 7 3 Oil filter replacement Coat the seal ring with a thin layer of oil Press down the filter till it contacts with the sealing surface of the transmission after that screw it down for 1 3 to 1 2 circles by hand Fill oil Start the engine When the engine idly runs about 1000rpm and the transmission oil has a working temperature check the transmission oil level When the oil temperature is 40 C it shall be within the cold oil level range When the oil temperature is 80 C it shall be within the hot oil level range Check if it is screwed down If necessary screw it down by hand again A LU ZR IS I ZF Transmission Service Manual SDLG 3 Transmission Removal 3 1 Transmission Assembly Removal 3 1 1 Torque Converter Removal 1 Pull out the intermediate ring and the torque converter from the transmission completely drain out residual oil in the torque converter and place it aside Figure 3 1 1 Torque converter 2 Intermediate ring 2 Remove the bolt connecting with the shell and Gn seals the transmission AN i yy A ZF a 7 j y I Ty A meg A n pe 1 2 Figure 3 2 1 Hexagon screw M10 50 x14 2 Tension pin 20 AX wis SDLG 1 Figure 3 3 1 Connecting shell Figure 3 4 1 Head cap screwx1 2 Head cap screwx5 Figure 3 5 1 Head cap screwx1 1 ZF Transmission Service Manual 3 Ad
9. Turn the transmission control handle to the neutral gear N Fill oil till reaching the upper scale in the cold oil area Turn the parking brake to the safe position Select all gears once Check the oil level again Ilf necessary fill oil again At 40 C the oil level shall be between the lower scale cold and the middle scale At 80 C the oil level shall be between the upper scale hot and the middle scale amp Attention When you drain the oil out the oil in the torque converter cooler should be drained out too A WRIS I ZEF Transmission Service Manual SDLG Oil Replacement Period Table Table 2 3 First oil Normal oil Oil level replacement replacement Upon every 1000 SAEISW40 Mobil Delvac Upon 100 working hours not Super 1300 or TITAN Part name Oil product standard check working hours longer than one universal engine oil Before daily the filter shall year and the filter HD15W 40 produced by use also be replaced shall also be Shanghai Desi Oil Product replaced Company Transmission Other optional oil product Table 2 4 Kinematic Domestic oil grade viscosity Similar foreign oil product grade 100 C mm 7 s transmission oil Q SHO18 44 03 1994 Torque fluid 175 RPM Torque fluid NO 5 Torque Fluid 47 Rotella 10 w In case of each oil replacement ZF coarse filter shall also be replaced The replacement requirements are as follows
10. i Figure 3 32 1 Hexagon nut M8 2 Clutch shaft removal tooling 30 A WR SS ZF Transmission Service Manual SDLG Figure 3 33 1 Compensation washer 2 Thrust washer 3 Thrust washer 1 Figure 3 34 1 KRK2 clutch assembly Figure 3 35 1 KRK2 clutch assembly 2 Take down the thrust washer and the compensation washer from the KRK2 clutch shaft Attention When taking down the thrust washer and the compensation washer the transmission shall be placed flatly to prevent the washer falling down to the bottom of the transmission body 3 Take out the KRK2 clutch assembly from the transmission body Attention When taking out the clutch assembly place the transmission in a proper position and the operation shall be slow to avoid slipping 4 The KRK2 clutch assembly removal is completed Attention Mark the KRK2 clutch with the marker for convenient distinguishing l A WRIS I ZF Transmission Service Manual SDLG 3 1 9 K3K4 Clutch Assembly Removal 1 Remove two hexagon nuts from the K3K4 clutch shaft Figure 3 36 1 Hexagonal nut M8 x2 2 Pull out the clutch shaft with the tooling e aN fies J or w l a p g i l Figure 3 37 1 Clutch shaft removal tooling 3 Take down the thrust washer and the compensation washer from the K3K4 clutch 7 LN shaft W A Attention t Si When taking down the thrust washer and the
11. 75 90 A WR IS I ZF Transmission Service Manual SDLG 4 1 3 Input Part Assembly 1 Knock the ball bearing onto the auxiliary driving shaft a ba Figure 4 43 1 Ball bearing 2 Auxiliary driving shaft 2 Install the flat key of the internal gear of the gear pump on the shaft and cover it with the oil pump Figure 4 44 1 Internal gear of the gear pump 3 Knock another ball bearing into the oil pump bearing hole Attention Ensure that the auxiliary driving shaft can flexibly rotate Figure 4 45 1 Ball bearing 91 A LU ZR IS I ZF Transmission Service Manual SDLG 4 Install the clip for shaft and buckle seal ring Figure 4 46 1 Clip 30x1 5 2 Seal ring 5 Knock the needle bearing into the bearing hole of the pump impeller bearing seat and then install the oil seal Attention Replace the old oil seal with a new one Figure 4 47 1 Oil seal O75 2 Needle bearing 6 Install the roller bearing into the bearing hole of the oil feed flange Attention Before assembling it is necessary to clean the oil feed flange Figure 4 48 1 Roller bearing 2 Oil feed flange OZ A WR IS I ZF Transmission Service Manual SDLG 7 Install the input gear into the oil feed flange and adjust the gear clearance Figure 4 49 1 Input gear 8 Install the seal ring onto the drive shaft Figure 4 50 1 Drive shaft 2 Seal ring 9 Insert the driv
12. Figure 4 117 1 Head cap screwx8 he JA Q 4 2 12 Transmission Control Valve Assembly 1 Respectively place the paper pad lower partition plate paper pad and oil passage plate onto the transmission body valve plate plane Attention Replace the removed paper pad with a new one Before assembling clean the valve plate oil passage plate and baffle plate of the transmission body 2 Fix 3 bolts between the oil passage plate and the transmission body a Nm 20N m 3 Fix 8 bolts between the oil passage plate and the transmission body Nn 20N m Attention Repeatedly screw down the bolt in accordance with the diagonal sequence 115 A LU ZR IS I ZF Transmission Service Manual SDLG a Se b Pia yw S APAN WA 5 E A iii LT a 43 d w 7 ri E 1 2 3 4 Figure 4 118 Paper pad 2 Transmission control valve Figure 4 119 1 Head cap screwx11 Figure 4 120 1Head cap screwx5 4 Place the paper pad upper partition plate paper pad and control valve onto the oil passage plate Attention Replace the removed paper pad with a new one Before assembling clean the baffle plate and the variable speed valve 5 Screw down 11 bolts between the variable speed valve and the transmission body 20N m Attention Repeatedly screw down the bolt in accordance with the diagonal sequence 6 Screw down 5 bolts between the
13. The power transmission route Driving gear Zo forward gear input gear Zy forward gear clutch KV KVI ring gear assembly Zy KR2 ring gear assembly Z 2 second gear clutch K2 second gear combination gear Z gear Z3 of the third gear output shaft gear Z outpu output shaft as shown in Figure 2 6 Lo Ly Ly 1 LZR Ln L 3L output KV K1 Zy He Zo d A a Z output Figure 2 6 A WR GS ZEF Transmission Service Manual SDLG 3 Third forward gear The solenoid valve M3 acts and the transmission pressure oil flows into KVK3 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches and forming the transmission subassembly The power transmission route Driving gear Zo forward gear input gear Zy forward gear clutch KV KV I ring gear assembly Zy K V2 ring gear assembly Z r2 K34 ring gear assembly Z34 third gear clutch K3 gear Z of the third gear output shaft gear Z oupu output shaft as shown in Figure 2 7 Ly Ly Ly 1 LR2 347 3 output KV K1 Zy 4 i ce J n Z3 Z output Figure 2 7 KV K1 Zy Pa bil OS sA b bh gt KR K2 L c e a Z intermediate I Z3 rs Z K4 K3 Z34 Z output f Figure 2 8 A W RISI ZF Transmission Service Manual 4 Fourth forward gear The solenoid valve M5 acts and the transmiss
14. Thrust washer 65 A WR IS I ZF Transmission Service Manual SDLG mm 20 Take out the thrust washer on the KR clutch pressure spring Figure 3 138 1 Thrust washer ro 21 Take down the elastic retainer ring fixing the K2 clutch bearing plate l Figure 3 139 1 Elastic retainer ring 22 Take out the bearing plate on the K2 clutch friction lining Figure 3 140 1 Bearing plate 66 A WR IS I ZF Transmission Service Manual SDLG 23 Take out the external friction lining of the K2 clutch Figure 3 141 1 External friction lining 24 Take out the internal friction lining of the K2 clutch Figure 3 142 1 Internal friction lining 25 Take out the external and internal friction linings and place them aside Figure 3 143 67 A LU ZR IS I ZF Transmission Service Manual SDLG 26 Take out the K2 clutch piston Figure 3 144 1 Piston 27 After removing the roller bearing of the K2 clutch the removal is completed Figure 3 145 1 Needle bearing 2 Check valve 3 2 5 K3K4 Clutch Removal 1 Take down the K4 clutch gear bearing Figure 3 146 1 K3K4 clutch assembly 68 A LU ZR IS I ZF Transmission Service Manual SDLG 2 Place the bearing aside 1 Figure 3 147 1 Needle bearing ae 3 Take down the lining seal ring component and roller of the needle bearing of the K3 clutch gear Figure 3 148 1 Rollerx12 2 K3 clutch gear re
15. Upon assembling align it at the positioning pin hole Upon knock in ensure that the force which is applied on the connecting shell is uniform Figure 4 110 1 Torque converter connecting shell 4 After screwing down the bolt between the transmission body flange and connecting shell the assembling is completed Attention Align at the pin position and repeatedly screw down the bolt in accordance with the diagonal sequence Nm 68N m Figure 4 111 1 Tension pinx2 2 Hexagon head screw M10 50 x14 Lis A LU ZR IS I ZF Transmission Service Manual SDLG 4 2 10 Main PTO Component Assembly 1 After installing the main PTO component and screwing down the bolt and nut between the PTO and the transmission body the assembling is completed Attention Repeatedly screw down the bolt in accordance with the diagonal sequence Wn 23N m 1 2 mu Figure 4 112 1 Hexagon head screwx10 2 Hexagonal nut M8 x1 4 2 11 Oil Filter Assembly 1 Install additional O ring onto the oil filter and screw in the transmission body Figure 4 113 1 O ring 2 Oil filter 2 Screw down the oil filter with the belt spanner Figure 4 114 114 A WR IS I ZF Transmission Service Manual SDLG w777 123 4 Figure 4 115 1 Oil passage plate 2 Baffle plate 3 Paper pad 4 Paper pad t77 a Figure 4 116 1 Head cap screwx3 DY om e 2 ee _ s a te 2 ri 1
16. ZR IS I ZF Transmission Service Manual SDLG 14 Take out the piston and seal ring of the K4 clutch 1 2 3 Figure 3 159 1 Seal ring 2 K3 clutch piston 3 Seal ring 15 The removal of the K4 clutch is completed Figure 3 160 a 16 Take out the elastic retainer ring of the K3 clutch bearing plate Figure 3 161 1 Elastic retainer ring T3 A LU ZR IS I ZF Transmission Service Manual SDLG 17 Take out the K3 clutch bearing plate Figure 3 162 1 Bearing plate 18 Take out the external and internal friction linings of the K3 clutch Figure 3 163 1 Internal friction lining 2 External friction lining q 19 Press down the K3 clutch pressure spring with the clutch spring removal tooling Figure 3 164 1 Clutch spring removal tooling 2 Pressure spring 74 A WR IS I ZF Transmission Service Manual SDLG 20 Take down the retainer ring fixing the pressure spring with the snap ring pliers Figure 3 165 1 Retainer ring 21 Take out the retainer ring and guide ring of the K3 clutch in turn Figure 3 166 1 Retainer ring 2 Guide ring 22 Take out the upper guide ring pressure spring and lower guide ring of the K3 clutch in turn Figure 3 167 1 Guide ring 2 Pressure spring 19 AN W ZR IS I ZF Transmission Service Manual SDLG 23 Take out the piston and seal ring of the K3 clutch f Figure 3 168 1 Seal ring 2 K4 clutch piston 3 S
17. i 4 Take down the gear washer and thrust washer f K of the K3 clutch oO Figure 3 149 1 Washer 2 Thrust washer 69 A LU ZR IS I ZF Transmission Service Manual SDLG 5 Take down the gear and thrust washer of the K4 clutch 1 2 3 Figure 3 150 1 Thrust washer 2 K4 clutch gear 3 Thrust washer Ua 6 Take down the elastic retainer ring of the K4 clutch Figure 3 151 1 Elastic retainer ring 7 Take out the bearing plate of the K4 clutch Figure 3 152 1 Bearing plate TO A WR IS I ZF Transmission Service Manual SDLG Take out the external and internal friction linings of the K4 clutch Figure 3 153 1 Internal friction lining 2 External friction lining 9 Install the clutch tooling onto the clutch Figure 3 154 1 Clutch spring removal tooling 10 Screw down the tooling nut and press down the clutch spring Figure 3 155 1 Clutch spring removal tooling 2 Pressure spring cal A LU ZR IS I ZF Transmission Service Manual SDLG 11 Take down the retainer ring fixing the pressure spring with the snap ring pliers Figure 3 156 1 Retainer ring 12 Take out the retainer ring and the guide ring of the K4 clutch in turn Figure 3 157 1 Retainer ring 2 Guide ring 13 Take out the upper guide ring pressure spring and lower guide ring on the K4 clutch in turn 1 2 Figure 3 158 1 Guide ring 2 Pressure spring 12 A LU
18. is necessary to fill the recommended lubricating oil till the oil level rises to the correct scale range of the corresponding temperature see Figure 2 15 F Attention According to different types of transmissions the oil dipstick and filler pipe will have different lengths and shapes In addition the filler pipe and transmission have two connection methods One is to connect the filler pipe at the side of the torque converter and another is to connect the filler pipe at the brake side The following Figure shows the connection condition between the filler pipe and the oil dipstick and the transmission Torque converter side Insert the oil dipstick and clockwise screw it down A WRIS I ZF Transmission Service Manual SDLG OIL DIPSTICK Oil dipstick f 3 fal j 4 Be Ns Hot oil level range Hot aN HOT i r Waa IE cou Or Cold i 9 Cold oil level range 1 Oil filler with oil dipstick 2 Oil drain plug M38x1 5 Figure 2 15 2 Oil replacement When the vehicle reaches the first 100 working hours the first oil replacement shall be done After that the oil replacement shall be done once every 1000 working hours or every year During oil replacement it 1s recommended to stop the vehicle in a flat place keep the transmission at the working temperature take out the oil drain plug and seal ring and drain out residual oil Start the engine and run it at idle speed
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20. the output shaft with the snap ring pliers and remove the ball bearing piston ring and compensation washer Figure 3 77 1 Ball bearing 2 Piston ring 30x2 3 Snap ring 30x1 5 4 Compensation washer 45 A LU ZR IS I ZF Transmission Service Manual SDLG 6 Knock the output shaft with the copper rod and take down the variable speed pump cover internal gear and other component Figure 3 78 1 Variable speed pump shell 2 Variable speed pump cover 7 Remove the internal gear of the variable speed pump output shaft variable speed pump cover and ball bearing Figure 3 79 1 Internal gear of the variable speed pump 2 Variable speed pump cover 8 Take out the external ring gear of the variable speed pump 1 2 Figure 3 80 1 Variable speed pump shell 2 External ring gear 46 A WR IS I ZF Transmission Service Manual SDLG 9 Take down the safety valve of the oil inlet of the torque converter on the oil feed flange steel ball and pressure spring Figure 3 81 1 Steel ball 2 Pressure spring 10 Take down the snap ring fixing the ball bearing on the drive shaft with the snap ring pliers Figure 3 82 1 Snap ring 11 Knock the drive shaft with the copper rod for removal Figure 3 83 1 Drive shaft 2 Copper rod 47 A LU ZR IS I ZF Transmission Service Manual SDLG 12 Take down the driving gear ball bearing and roller bearing Figure 3 84 1 Roller b
21. variable speed valve and the transmission body 20N m Attention Repeatedly screw down the bolt in accordance with the diagonal sequence 116 AX wis SDLG 1 Figure 4 121 1 Head cap screw Figure 4 122 1 Oil pipe Figure 4 123 ZF Transmission Service Manual 7 Screw down 1 bolt between the variable speed valve and the transmission body 20N m 8 Install the oil pipe of the variable speed valve Nm 3543 5N m 9 From top to bottom six oil holes on the oil passage plate are K2 K1 K3 K4 KR and KV oil pipes which are connected with the oil passage holes on the K1 K2 and K3 shafts Attention After adjusting the hose position screw down the bolt again 55 5 5N m 117 A WR GS ZF Transmission Service Manual SDLG 10 The assembling of the transmission control valve and the oil pipe component is completed Figure 4 124 4 2 13 Torque Converter Assembly 1 After installing the intermediate ring and the torque converter into the connecting shell the assembling is completed pe A Attention As there is no axial positioning after installing the torque converter fixing measures shall be adopted to avoid its falling Figure 4 125 1 Torque converter 2 Intermediate ring 2 The torque converter assembling is completed 118 A WRIS I ZEF Transmission Service Manual SDLG 5 Malfunction Diagnosis and Troubleshooting 5 1 Malfunction D
22. with the belt spanner for removal Figure 3 12 1 Oil filter Figure 3 13 1 Belt spanner wf ee Fe r 2 After taking down the O ring the removal is completed wc 4 Figure 3 14 1 O ring 24 A LU ZR IS I ZF Transmission Service Manual SDLG 3 1 4 Removal of the Auxiliary PTO Wheel Hub 1 Take down the bolt between the auxiliary PTO wheel hub and the transmission body EA Figure 3 15 1 Hexagon head screw M8 16 x8 2 Auxiliary PTO wheel hub 2 After pushing out the wheel hub with the crowbar and taking down the PTO wheel hub and its seal ring the removal is completed Figure 3 16 1 Auxiliary PTO wheel hub 2 Crowbar 3 1 5 Input Device Removal 1 Remove the hexagon bolts between the pump impeller bearing seat and the oil feed flange Figure 3 17 1 Oil feed flange 2 Pump impeller bearing seat 3 Hexagon head screw M8 28 x8 20 A LU ZR IS I ZF Transmission Service Manual SDLG 2 Slightly knock the bearing seat with the copper rod for loosening Figure 3 18 1 Copper rod 2 Pump impeller bearing seat 3 Take down the bearing seat and the packing Figure 3 19 1 Pump impeller bearing seat 2 Packing 4 Take down the bolt between the main PTO wheel hub and the transmission body Figure 3 20 1 Hexagon head screw M8 20 x10 2 Main PTO wheel hub 26 A WR IS I ZF Transmission Service Manual SDLG Figure 3 21 1 Shackle bolt mount
23. wrap up if the speed sensor cable wire is worn out or replace the worn out cable wire 7 Check if the transmission oil pressure on Check the transmission oil pressure the instrument panel is normal gauge 119 A SDLG WR IS I ZF Transmission Service Manual 3 Functions of the parts and common malfunction troubleshooting 1 Electric control box After turning on the electric lock switch and turning the gearshift handle to the neutral gear the electric control box is in a ready state To shift the gear after the vehicle start rotate the gearshift handle to select certain gear and the electric control box can based on the electric signal from the output speed sensor and the gearshift handle automatically judge 1f it can turn to the preselected gear at the current speed If these two have too large speed difference the computer can command the solenoid valve to engage the transmission with certain applicable min speed gear and then turn to the preselected speed gear at an interval of 2 5s For example if engaging the third gear from the first gear the computer will identify the speed signal of the speed sensor and judge if the speed is qualified after receiving the electric signal from the gearshift handle if the speed is unqualified it will automatically send the electric signal to the solenoid valve and turn to the second gear firstly after the speed reaches 14km h it will turn to the third gear to mitigate impact Common
24. 1 75 2 Ball bearing 42 A WR IS I ZF Transmission Service Manual SDLG Figure 3 69 1 Elastic retainer ring SP85 x2 Figure 3 70 1 Driving gear 2 PTO shaft 3 Ball bearing Figure 3 71 1 Retainer ring SB52 2 Needle bearing 3 Expand and fix the ball bearing elastic retainer ring with the screwdriver and knock the PTO shaft from another side 4 Take down the driving gear PTO shaft and ball bearing 5 After taking down two retainer rings fixing the needle bearing on the PTO wheel hub and removing two elastic retainer rings fixing the ball bearing the removal is completed 43 A LU ZR IS I ZF Transmission Service Manual SDLG 3 2 2 Input Component Removal 1 Remove 4 bolts between the variable speed pump and the oil feed flange Figure 3 72 1 Input component Figure 3 73 1 Hexagon head screw M8 85 x4 2 Remove 4 bolts between the variable speed pump and the oil feed flange Figure 3 74 1 Hexagon head screw M8 115 x4 44 A LU ZR IS I ZF Transmission Service Manual SDLG 3 Knock the output shaft with the copper rod to knock out the variable speed pump 12 Figure 3 75 1 Copper rod 2 Output shaft 4 Take down the variable speed pump packing and output shaft and remove the bolt between the variable speed pump cover and the variable speed pump shell 1 2 Figure 3 76 1 Hexagon head screwx4 2 Output shaft 5 Take down the bearing snap ring from
25. Brake drum wheel 2 Contact roller tension spring 7 Install the output flange O ring distance washer and pressure plate in turn Figure 4 65 1 Pressure plate 2 O ring 3 Distance washer A 0 6 4 Output flange 8 Screw down the bolt between the pressure plate and the output shaft a Nm 46N m Figure 4 66 1 Lock washer 2 Hexagon head screw M10 30 x2 98 A LU ZR IS I ZF Transmission Service Manual SDLG 9 Install the lock washer with the lock washer assembling tooling 1 Figure 4 67 1 Lock washer assembling tooling 29380017101 10 Install the snap ring bearing adjustable washer and snap ring at the front end of the output shaft in turn Attention Select the adjustable gasket with different thickness so as to ensure that the axial clearance of the bearing is 0 1mm 0 3mm Figure 4 68 1 Roller bearing 2 Snap ring 120 4 x2 _ 11 Install the oil seal into the transmission body with the tooling Attention Replace the removed oil seal with a new one 1 2 Figure 4 69 1 Oil seal 2 Oil seal assembling tooling 29380017071 ao A LU ZR IS I ZF Transmission Service Manual SDLG 12 Install the output flange onto the output shaft Figure 4 70 1 Output flange 13 Place the O ring distance washer and pressure plate in turn 1 2 3 Figure 4 71 1 Pressure plate 2 Distance washer A 0 6 3 O ring 14 Screw down the bolt between the pressure
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27. ZF Transmission Service Manual A WRIS I ZEF Transmission Service Manual SDLG Preface The Service Manual introduces the ZF 4WG200 4WG158 6WG200 also applied transmission removal and assembling process and offers the transmission service process technology and standard requirements which can help the service personnel understand the transmission removal and assembling methods more profoundly as well as lay a solid technical foundation for the service personnel to correctly judge the malfunction and do troubleshooting The Service Manual mainly includes following content Chapter I Introduction The chapter mainly introduces the transmission service precautions as well as symbol meanings and common thread tightening torque value in the text Chapter II Transmission System The chapter mainly introduces the mechanical principles of different gears of the transmission as well as the transmission operation and maintenance Chapter HI Transmission Removal The chapter introduces the correct parts removal steps as well as precautions during removal Chapter IV Transmission Assembling The chapter introduces the correct parts assembling steps as well as precautions during assembling Chapter V Malfunction Diagnosis and Troubleshooting The chapter introduces the malfunction diagnosis and troubleshooting of the transmission system and ZF transmission Attention Due to product improvements relevant parts in the Service Manual w
28. aging 16 A WRIS I ZEF Transmission Service Manual SDLG some gear and applying the clutch but the pressure drops to the min pressure lower than the specified pressure the pressure will quickly drop temporarily in case of gear shift it is necessary to do troubleshooting If the control pressure is too low the clutch will be damaged for the clutch without sufficient contact pressure will make the friction lining continuously slip and become too hot 3 Maintenance 1 Oil level check Park the vehicle in a flat place Turn the transmission gearshift handle to the neutral gear N and the parking brake to the brake position Idly run the engine with about 1000rpm Counterclockwise loosen the oil dipstick and then take it out and wipe it off Insert the oil dipstick in the oil level pipe and screw it down keep it for about 3s after reaching the target position and then take it out twice measurement at the least At 40 C the oil level shall be between the lower scale cold and the middle scale At 80 C the oil level shall be between the upper scale hot and the middle scale The cold vehicle oil level check is only to ensure that the transmission and the torque converter have sufficient circulating flow The final standard to determine the oil level is to meet the hot vehicle oil level requirements amp Attention If the oil level is lower than the min scale it
29. and forming the transmission subassembly The power transmission route Driving gear Zo reverse gear input gear Zr reverse gear clutch KR KR2 ring gear assembly Z r2 second gear clutch Z second gear combination gear Z2 gt gear Z of the third gear output shaft gear Z oupu output shaft as shown in Figure 2 10 10 A WR IS I ZEF Transmission Service Manual SDLG LoP Zr gt ZrR Z2 92392 output Z output Figure 2 10 7 Third reverse gear The solenoid valve M1 acts and the transmission pressure oil flows into KRK3 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches and forming the transmission subassembly The power transmission route Driving gear Zo reverse gear input gear Z reverse gear clutch KR KR2 ring gear assembly Zr2 K34 ring gear assembly Z34 third gear clutch K3 gear Z3 of the third gear output shaft gear Z oupw output shaft as shown in Figure 2 11 Lo LR LR 234723 ZL output Z output Figure 2 11 A WR GS ZF Transmission Service Manual SDLG The working conditions of the corresponding solenoid valves and clutches are shown in Table 2 2 Table 2 2 e Electrified solenoid valve D e D e gt oom f I f de omx je l poms Jejeje om Jeje o s f l ded The pressure measuring ports of all gears are shown in Figure 2 12 d ajz ajz U Third gear Relief val
30. anual SDLG 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 948L wheel loader adopts the 4WG158 gearbox assembly the SDLG 958L 959 968 wheel loader adopts the 4WG200 gearbox assembly which can realize speed switching between 4 forward gears and 3 reverse gears The SDLG G9190 grader adopts the 6WG200 gearbox assembly which can realize speed switching between 6 forward gears and 3 reverse gears rm 1 Connecting socket 2 Torque converter shell i 3 Transmission control valve 4 Transmission pressure measuring 1 port 5 Torque converter oil temperature measuring port 6 Transmission oil outlet 7 Oil suction pipe 8 Transmission housing 9 Nameplate Nn BWN Re Figure 2 1 10 Lifting ring screw 11 Oil filter 12 Auxiliary PTO 13 Main PTO 14 KV 15 KR 16 K2 17 K1 18 K3 19 K4 20 Rotation speed sensor 21 Parking brake Figure 2 2 5 A LU ZR IS I ZF Transmission Service Manual SDLG Figure 2 3 1 Auxiliary PTO 2 Variable speed pump 3 KVKI clutch assembly 4 Intermediate shaft component 5 KRK2 clutch assembly 6 K3K4 clutch assembly 7 Output shaft assembly Figure 2 4 1 M4 2 M3 3 M5 4 M2 5MIi A WR IS I ZF Transmission Service Manual
31. ate shaft and the bearing component the removal is completed Figure 3 61 1 Intermediate shaft gear 2 Roller bearing Figure 3 62 1 Thrust washer 40 A WRIS I ZF Transmission Service Manual SDLG 3 1 22 Removal of the Output Shaft Rotation Speed Sensor 1 Remove the rotation speed sensor from the transmission body and take down the adjustable washer and the seal ring Figure 3 63 3 1 23 Removal of the Seal Cover of the 1 Rotation speed sensor Transmission Body 1 Take down the seal cover from the transmission body Figure 3 64 3 1 24 Removal of the Torque Converter i Seat cover Pressure Regulating Valve 1 Remove the screw plug fixing the valve sleeve component Figure 3 65 1 Valve sleeve component 2 Screw plug CM30 1 5 3 O ring 41 A LU ZR IS I ZF Transmission Service Manual SDLG 2 After taking out the valve sleeve components valve sleeve valve stem pressure spring and gasket from the torque converter pressure valve hole of the transmission body the removal is completed 3 2 Transmission Assembly Component Removal 3 2 1 Main PTO Removal Figure 3 66 1 Pressure spring 2 Valve stem 3 Valve sleeve 1 Remove the retainer ring fixing the driving gear on the PTO shaft with the snap ring pliers Figure 3 67 1 Retainer ring SW47 Ei 2 Remove the snap ring fixing the inner ring of the ball bearing on the PTO shaft Figure 3 68 1 Snap ring 45
32. bleshooting method Re adjust or replace the spring fill oil till reaching the specified oil level clean or dredge it replace the rectangular ring do inspection or replacement 3 Too high oil temperature Malfunction cause Too long operation time insufficient or excessive oil in the transmission clutch facing slipping clutch release failure Troubleshooting method Stop or idly run the vehicle for a certain period fill oil till reaching the overflow hole check the oil pressure and seal ring check the position of the clutch control oil circuit or control lever 4 Low transmission oil pressure of certain gear Malfunction cause Damaged rectangular ring of the piston damaged oil circuit seal ring oil leakage or blockage of the oil passage Troubleshooting method Replace the rectangular ring of the piston replace the seal ring do check and troubleshooting 5 Disordered gear Malfunction cause Leakage of the shaft end seal ring Troubleshooting method Replace the seal ring 6 System oil leakage Malfunction cause Loose connector damaged seal ring Troubleshooting method Screw down the connector replace the seal ring 7 Automatic oil level rise of the transmission oil pan The cause is that the input shaft oil seal of the steering pump or the working pump is damaged the oil of the hydraulic system flows to the transmission oil pan via the torque converter gear case and increases the oil level The old oil seal
33. can be replaced with a new one according to the damage conditions 123 Shandong Lingong Construction Machinery Co Ltd Address Lingong Industry Park Linyi Economic Development Zone Shandong China Tel 0086 531 66590966 Fax 0086 531 66590959 Customer Service Tel 0086 531 66590955 Email export sdig com cn http www sdig cn
34. cccccccccececeeeeeeeessseeeeeeeeeeeeeeeeeeeeeaeeeeeeseeeeeeeeeeeeeeeeeeeaagagaeeeeaees 20 Seb Torgue COMVerter Removal rrenen un EEA RER E AER ARERR SAO RE Era 20 3 1 2 Transmission Control Valve Removal cccccccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 21 EOE T E ON e aa E E A N 24 3 1 4 Removal of the Auxiliary PTO Wheel Hub ce eeecccceeeccccceecceeeeeaeeeeeesssseeeeeceeeeeeeeeseeaeeeeeeesees 25 Leime IE e RO eeren rr e E e E 25 3 1 6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO cc ccccccccceeeeeeeeseeeeeees 28 31 7 ey Kol ClotchAssembly REMIOY allenic sins otatiacsacatscatedutecqueccsdaniatutaustecatacntedetasusaddidsusatelacenecatecubedeneauetes 29 3 1 8 KRK2 Clutch Assembly Removal ccccccccccccccccscnssssseeseeeeeeeceeeeeeeeeeeeaaaeeesesseeeeeeeeeeeeeeeeeeeeaaaaeeeeeees 30 aul KSK4 Clitciv Assembly REMOVAL serseri 32 3 1 10 Removal of the Parking Brake and the Output Device ccsessseeeeseeeeeeeceeeeeeeeeeeeaaeaeeeeeees 33 3 1 21 Intermediate Shaft Assembly Removal cccccccccccccccccccccceecceeeeeeeesseeeeececeeeeeeeeeeeaaaeeeeeseees 39 3 1 22 Removal of the Output Shaft Rotation Speed Sensor cccccccssssesessseeeeeecceeeeeeeeeeeeeeeaeeeeeees 4 3 1 23 Removal of the Seal Cover of the Transmission Bod y cccccccccccssssssseesseeeeeecceeeeeeeeeeeeaaeaeeeeeees 4 3 1 24 Removal of the Torque Converter Pressure Regulating
35. cified in 4 2 4 K3K4 Clutch Assembling Select the adjustable washer with different thickness so as to ensure that axial clearance of the KRK2 clutch shaft is O lmm 0 3mm _ after that the assembling is completed 4 2 7 KVK1 Clutch Assembly 1 Coat the thrust washer of the clutch assembly with grease 2 Place the washers onto the transmission body wall 109 AX wis SDLG Figure 4 100 1 Clutch assembling tooling 2 KVKI1 clutch assembly Figure 4 101 1 Hexagon nut M8 x2 Figure 4 102 1 KVK1 clutch shaft ZF Transmission Service Manual 3 Install the clutch tooling onto the KVKI1 clutch and place it into the transmission body poe A Attention When placing the clutch jack up the clutch bottom with the tooling to avoid clutch falling 4 Take out the clutch shaft installation tooling install the KVK1 clutch shaft and screw down the nut fixing the KVK1 clutch shaft Attention The KVK1 clutch gear can flexibly rotate A 23N m 5 Slowly jack up the clutch assembly with the crowbar to make it have axial runout measure and record the axial clearance of the clutch the measurement method can follow that specified in 4 2 4 K3K4 Clutch Assembling Select the adjustable washer with different thickness so as to ensure that axial clearance of the KRK2 clutch shaft is O lmm 0 3mm after that the assembling is completed 110 A WR IS I ZF Transmission Service Manual SDLG 4 2 8 Au
36. clean pollutants on the surface of the transmission torque converter assembly so as to avoid polluting the parts during removal 5 During operation it is necessary to wear safety boots and safety helmet It is not allowed to wear unqualified work clothes it is necessary to fasten buttons of the work clothes When knocking 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 the removed parts 7 When applying the traveling crane or other hoisting equipment check relevant spreader for damages 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 avoid parts collision It is not allowed to work in the area under the hoisted parts A WRIS I ZF Transmission Service Manual SDLG A Attention As the torque converter has no axial positioning it is necessary to prevent its slipping in case of removal and assembling of the transmission as shown in Figure 1 1 Figure 1 1 8 In case of simultaneous operation with two or more persons they shall reach an agreement in the 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 inse
37. e automatically turned to the second reverse gear from the first forward gear When being driven backwards to a proper position push the gearshift handle forwards to the forward gear and change speed according to following process 2R 2F 3F 2F Before being driven to the dump truck and discharging materials onto the dump truck change speed according to following process 2F 2R 3R 2R and then the loader will return to the start point KD function will be released after rotating the gearshift handle In case of material excavation it is unnecessary to rotate the loader handle to select the speed gear just perform operation according to steps shown in Figure 2 14 Press Pull Push down KD backwards forwards key 2F ni ae i D i a F E i gt a ABD he KT amaya 1F aHa 1F i A KD Figure 2 14 2 1 5 Operation and Maintenance of ZF Power Gearshift Transmission 1 Application precautions 1 When checking the transmission oil level the engine shall run at idle speed about 1000 rpm and the oil temperature shall be kept at the normal working temperature 14 A WRIS I ZEF Transmission Service Manual SDLG 2 When the oil temperature is 40 C the oil level shall be between the middle and lower scale lines of the oil dipstick When the oil temperature is 80 C the oil level shall be between the middle and upper scale lines of the oil dipstick 3 Strictly follow the maintenance requirements a
38. e dial indicator contact onto the bearing plate and select different positions for three measurements at the least The dial indicator reading is the K4 clutch piston stroke Select the internal friction lining with different thickness to ensure that the piston stroke is stroke 1 8mm 2 2mm Figure 4 28 1 Dial indicator 28 Install the thrust washer into the K3 clutch gear Attention The thrust washer shall be coated with grease Figure 4 29 1 K3 clutch gear 2 Thrust washer 29 Install the gasket and the thrust washer into the K3 clutch Figure 4 30 1 Thrust washer 2 Washer 86 AX wis SDLG Figure 4 31 1 K3 clutch gear Figure 4 32 1 Rollerx12 Figure 4 33 1 Thrust washer 2 Thrust washer ZF Transmission Service Manual 30 Install the K3 clutch gear Attention Before installing the gear it is necessary to perform alignment to the internal friction lining splines of the clutch 31 Install the lining seal ring component and roller of the internal needle bearing of the K3 clutch gear Attention The roller shall be coated with grease to prevent the clutch assembly dropping when being installed into the transmission body 32 Install the thrust washer into the K4 clutch cylinder clip and gear Attention The thrust washer shall be coated with grease 87 AX wis SDLG Figure 4 34 1 Needle bearing Figure 4 35 1 K4 clutch gear
39. e nuts on the tooling and press down the clutch spring 7 Install the retainer ring into the clutch cylinder clip groove with the snap ring pliers Figure 4 8 1 Retainer ring 2 Snap ring pliers 8 Take down the clutch spring removal and assembling tooling Figure 4 9 9 AX wis x SDLG 1 Figure 4 10 1 External friction lining 1 Figure 4 11 1 Internal friction lining Figure 4 12 1 Bearing plate ZF Transmission Service Manual 9 Firstly place the external friction lining into the K3 clutch Attention During use if the external friction lining of the clutch is worn out and more than 2 3 parts of the pattern groove of the friction lining are worn out timely replacement shall be done 10 Place the internal friction lining into the K3 clutch Attention Firstly place the external friction lining into the K3 clutch and then place the external and internal friction linings in turn including 10 external friction linings and 9 internal friction linings 11 Place the bearing plate into the K3 clutch 80 AX wis SDLG Figure 4 13 1 Elastic retainer ring Figure 4 14 1 Dial indicator Figure 4 15 1 Retainer ring 2 Needle bearing ZF Transmission Service Manual 12 Install the elastic retainer ring into the K3 clutch 13 Slightly push the K3 clutch friction lining upwards to the upper limit position with the screwdriver record the c
40. e plate 3 Oil shield r Figure 4 60 on ZF Transmission Service Manual 16 After knocking in the pump impeller bearing seat and screwing down the bolt between the pump impeller bearing seat and the oil feed flange the assembling is completed Nm 23N m 4 2 Transmission Assembly 4 2 1 Output Part Assembly 1 Place the output shaft gear install the baffle plate and the oil shield into the transmission body and then fix them with two bolts M8 16 and the washer 2 Knock out the roller bearing and place it at the output gear shaft end and then place it into the oil shield install the spacer sleeve and insert the output shaft 96 AX wars SDLG Figure 4 61 1 Output shaft Figure 4 62 1 Adjustable gasket 2 Snap ring 120 4 1 2 Figure 4 63 1 Oil seal 2 Oil seal assembling tooling 29380017071 ZF Transmission Service Manual 3 Adjust the washer in turn Attention Select the adjustable washer with different thickness so as to ensure that the axial clearance of the bearing is 0 lmm 0 3mm 4 Install the snap ring 5 Install the oil seal into the transmission body with the tooling Attention Replace the removed oil seal with a new one ot A LU ZR IS I ZF Transmission Service Manual SDLG 6 Install the parking brake drum wheel Attention During installation take protection measures to avoid tension spring detachment Figure 4 64 1
41. e shaft and install the ball bearing Figure 4 51 1 Drive shaft 2 Ball bearing 93 A WRIS I ZF Transmission Service Manual SDLG Figure 4 52 1 Output shaft ball bearing 2 Elastic retainer ring 40x1 75 Figure 4 53 1 Adjustable washer Figure 4 54 1 Steel ball P20mm 2 Pressure spring 2 5x16 95x57 2 4 10 Install the elastic retainer ring 11 Install the adjustable washer into the gear pump hole Attention Ensure that the axial run out clearance of the output shaft bearing is 0 2mm 0 4mm 12 Install the steel ball and the pressure spring into the safety valve hole of the torque converter on the oil feed flange 94 A WR IS I ZF Transmission Service Manual SDLG Figure 4 55 1 Oil pump packing Figure 4 56 1 Hexagon head screw M8 115 x4 1 Hexagon head screw M8 85 x4 Figure 4 57 1 Packing 13 Place the oil pump packing on the oil feed flange oil pump surface coat it with grease and insert the oil pump component into the oil feed flange component hole 14 Screw down the bolt between the oil pump component and the oil feed flange component 23N m 15 Place the packing of the pump impeller bearing seat on the oil feed flange surface 95 AX URISI SDLG p lt Figure 4 58 1 Hexagon head screw M8 28 x8 _ gt _ id A P P oat Ea 4 Dama gn 5 1 la E oe gt A ee 5 y 1 2 2 Figure 4 59 1 Output shaft gear 2 Baffl
42. eal ring 24 Remove the needle bearing and check valve of the K3K4 clutch Figure 3 169 1 Check valve 2 Needle bearing 25 The K4 clutch removal is completed Figure 3 170 76 AX wis x SDLG Figure 4 1 1 Retainer ring 2 Needle bearing Figure 4 2 1 Seal ring 2 Seal ring Figure 4 3 1 Pressure oil surface 2 Friction lining ZF Transmission Service Manual 4 Transmission Assembly 4 1 Assembling of the Transmission Assembly 4 1 1 K3K4 Clutch Assembly 1 Knock the needle bearing into the clutch bearing hole and install the retainer ring Attention Before assembling clean all parts 2 Install the seal ring into the piston groove and install the piston component into the clutch cylinder Attention When installing the seal ring the sealing surface of the seal ring shall face towards the pressure oil surface 7 A LU ZR IS I ZF Transmission Service Manual SDLG 3 Place the guide ring and the pressure spring into the clutch cylinder Figure 4 4 1 Guide ring 2 Pressure spring 3 Guide rin z 4 Place the guide ring and the retainer ring into the clutch cylinder Figure 4 5 1 Guide ring 2 Retainer ring 5 Install the spring removal and assembling tooling onto the clutch Figure 4 6 1 Clutch spring removal and assembly tooling 29380017591 29380017601 T8 A LU ZR IS I ZF Transmission Service Manual SDLG 6 Screw down th
43. earing 2 Driving gear 3 Ball bearing 13 Remove the plunger ring from the drive shaft Figure 3 85 1 Drive shaft 2 Plunger ring 3 2 3 KVK1 Clutch Removal 1 Take down the compensation washer and thrust washer of the KVKI1 clutch ar 2 je 3 d Figure 3 86 1 KV clutch assembly 2 K1 clutch assembly 48 A WRIS I ZF Transmission Service Manual SDLG 1234 Figure 3 87 1 Compensation washer 2 Thrust washer 3 Thrust washer 4 Thrust washer pA s Figure 3 88 1 Rollerx14 Figure 3 89 1 Roller bearing washer 2 Take down the roller of the roller bearing on the KV clutch gear 3 Take down the washer of the KV clutch gear roller bearing 49 A LU ZR IS I ZF Transmission Service Manual SDLG 4 Take down the roller of the roller bearing on the KV clutch gear Figure 3 90 1 Rollerx14 5 Take down the KV clutch gear and bearing thrust washer Figure 3 91 1 Thrust washer 2 KV clutch gear 6 Take down the thrust washer from the KV clutch Figure 3 92 1 Thrust washer 2 Thrust washer 50 A LU ZR IS I ZF Transmission Service Manual SDLG 7 Take down the elastic retainer ring fixing the KV clutch bearing plate Figure 3 93 1 Elastic retainer ring 8 Take down the bearing plate of the KV clutch friction lining Figure 3 94 1 Bearing plate 9 Take out the external friction lining of the KV clutch Figure 3 95 1 External fricti
44. g 30 Take out the pressure spring and guide ring of the K1 clutch Figure 3 116 1 Lower guide ring 2 Pressure spring 3 Upper guide ring D8 A WRIS I ZF Transmission Service Manual SDLG 31 Take out the K1 clutch piston Figure 3 117 1 K1 clutch piston wr 32 After removing the K1 clutch needle bearing the removal is completed Figure 3 118 1 Needle bearing 2 Check valve 3 2 4 KRK2 Clutch Removal 1 Take down the roller of the KR clutch roller bearing Figure 3 119 1 KR clutch assembly 2 K2 clutch assembly 39 A LU ZR IS I ZF Transmission Service Manual SDLG 2 Take out 14 rollers in the external layer Figure 3 120 1 Rollerx14 3 Take out the washer of the KR clutch roller bearing Figure 3 121 1 Roller bearing washer 4 Take out the roller of the KR clutch roller bearing Figure 3 122 1 Rollerx14 60 A WRIS I ZF Transmission Service Manual SDLG 5 Remove the KR clutch gear and take out the thrust washer from the bearing Figure 3 123 1 KR clutch gear 2 Thrust washer P 6 Take out the thrust washer from the KR clutch Figure 3 124 1 Thrust washer 2 Thrust washer 7 Take down the elastic retainer ring fixing the KR clutch bearing plate Figure 3 125 1 Elastic retainer ring 61 A WR IS I ZF Transmission Service Manual SDLG 8 Take out the bearing plate of the KR clutch friction lining Figure 3 126
45. he internal leakage will increase the heat quantity from two aspects When the high pressure oil passes through the damaged seal it will leak and result in friction thus the oil temperature will continue rising As the oil leakage will reduce the oil flow in the system to fully engage the clutch the hydraulic pump shall convey much more oil to produce necessary oil pressure namely the engine shall be further accelerated to make the oil delivery pump output larger flow Such vicious circulation will finally result in too hot or damaged clutch and even clutch failure 2 Common malfunction diagnosis and troubleshooting method of the transmission and its oil circuit system 1 Gear engagement failure Malfunction cause Incorrect gearshift position oil leakage of the clutch piston low transmission pressure blocked oil circuit in the transmission body Troubleshooting method Engage the gear again or check the transmission control valve remove check and replace the rectangular ring The details of the troubleshooting method of the low transmission pressure are shown in 2 Removal cleaning and dredging 2 Low transmission pressure Malfunction cause Improper adjustment of the main pressure regulating valve broken spring and spring failure low transmission oil level blocked filter screen or oil passage oil leakage of the clutch variable speed oil pump failure 122 A WRIS I ZEF Transmission Service Manual SDLG Trou
46. iagnosis and Troubleshooting of the Transmission System 1 Vehicle start failure Table 5 1 Malfunction Point Troubleshooting Method Check if engaging the neutral gear of the E h l l Check if the EST electric control box and Push and press the plug till there is wire plug are loose a click sound Check 1f the battery is fully charged Charge or replace the battery Check if the starter circuit has malfunction oo 4 Return the circuit to normal and if the starter fuse is burnt out 2 Normal vehicle start but traveling failure Table 5 2 Malfunction Point Troubleshooting Method Check if the transmission has sufficient oil and check the oil level in case of cold and Adjust the oil level to normal hot states Check if the wire plug of the transmission 2 Screw down the plug control valve is screwed down 3 Check if the EST electric control box and Push and press the plug till there is wire plug are loose a click sound Check if the plug connecting with the 4 Firml t the plug gearshift selector cable is loose Check if the locking switch of the gearshift Turn on the neutral gear locking selector neutral gear is turned on switch Check if the parking brake is released Loosen the parking brake Check if the ventilating valve on the Clean the ventilating valve and transmission is blocked and if oil flows out check if the oil quantity is proper Check if the speed sensor plug is loose and Screw down the plug and
47. igure 3 107 1 Elastic retainer ring 19 Take down the snap ring fixing the K1 clutch gear bearing with the snap ring pliers and take down the adjustable washer and the bearing component 20 Take down the gear and thrust washer of the K1 clutch 21 Take down the elastic retainer ring fixing the K1 clutch bearing plate 00 A LU ZR IS I ZF Transmission Service Manual SDLG Figure 3 108 1 K1 clutch bearing plate f X Figure 3 109 1 External friction lining Figure 3 110 1 Internal friction lining 22 Take down the bearing plate of the K1 clutch friction lining 23 Take out the external friction lining of the K1 clutch 24 Take out the internal friction lining of the K1 clutch 56 A WRIS I ZF Transmission Service Manual SDLG 25 Take out the external and internal friction linings and place them aside Figure 3 111 26 Install the clutch spring removal tooling onto the clutch Figure 3 112 1 Clutch spring removal tooling 29380017591 29380017601 27 Screw down the nuts on the clutch tooling and press down the clutch spring Figure 3 113 1 Pressure spring 57 A LU ZR IS I ZF Transmission Service Manual SDLG 28 Take down the retainer ring fixing the K1 clutch pressure spring with the snap ring pliers Figure 3 114 1 Retainer ring 29 Take out the retainer ring and the guide ring Figure 3 115 1 Guide ring 2 Retainer rin
48. ill be subject to change without further notice For the newest data and information please consult with or get them from Shandong Lingong Construction Machinery Co Ltd A WRIS I ZEF Transmission Service Manual SDLG Table of Contents FOCO O a E E E E E E E E i LESIR PCO e E E E ton watantcers 1 2 Instructions OF Marks and Symbols cote seasuccasasaadenosaiarnwspriadiensnsaaunndannadenantiacuumnasarenwsaiacwnsentalsiacsteasuaamanameumnaunns 3 1 3 Common Bolt Hehtening Toric Table xa cxsscaces acacec cre sqreues dcusosaaacuncsal denneceeeuiodtissduuaaisssdueekedccunenaneduacinbdaunatabes 3 2 Transmission Syste esisiini a aaea aiaa siada aai 5 2 I Transmission INGO GU CUO N ssis i a dawson a E a a E a ieansendiaalueadic 5 2 1 1 General Overview of the Transmission eseeseeeeeeeeeeeeeeeeeeereeeeeeeeeeereeeeeeeereeereeeeeeeeeereeeeeeeeeeeeeeeeees 5 2 1 2 Basic Parameters of the Transmission torque Converter ASSeEMDLY ccccccccccceeeceesesseeesseseeeeeeees 7 2 1 3 Mechanical Principles of the Gears of the Transmission 4WG158 200 00 ccccssssseeesseeeeeeeeeees 7 2 1 4 Introduction to KD Key Functions 4WG158 200 ssseseenessssssssssssssssseeerrresssssssssssssseeerrressssssss 12 2 1 5 Operation and Maintenance of ZF Power Gearshift Transmissin sssssssesseeeeesssssseeeseseeeeees 14 Dy WIGAN Wat STO IR CUNOV a EE E EEA 20 3 1 Transmission Assembly Removal cccccccc
49. illing shall be much more than that for the subsequent normal maintenance As the torque converter oil on the vehicle will flow to the transmission via the oil radiator and oil pipe under a stationary state the oil level shall be correctly controlled under the thermal equilibrium temperature in case of neutral gear engagement upon parking idle engine running and normal transmission operation The oil level can be tested when the control handle is turned to the neutral gear When checking the oil level it is necessary to insert the oil dipstick to the lower limit of the oil pipe When cleaning the main oil circuit filter pay attention that no dirt and sediment can enter into the oil circuit In addition it is necessary to place a cover plate to prevent the parking brake from oil immersion When installing the filter it shall not be screwed down too tightly 2 Traveling and gear shift In case of engine start it is necessary to confirm that the gearshift handle is turned to the neutral gear For the sake of safety before engine start the parking brake shall be in a brake A W RISI ZF Transmission Service Manual state so as to ensure that the vehicle will not be started due to engine start After engine start release the parking brake properly select the traveling direction and gear slowly throttle up the vehicle for start In case of vehicle traveling the torque converter will replace the function of the main clutch When the road co
50. ing hole 2 Main PTO r t Figure 3 22 1 Variable speed pump component 2 Copper rod Figure 3 23 1 Input device 5 Pull out the main PTO component with two Shackle bolts M20 Attention During removal the transmission shall be placed flatly the PTO port shall face upwards and the force applied on two shackle bolts shall be uniform 6 Hold one about 30 400mm copper rod by left hand to jack up the variable speed pump end cover and hold another copper rod by right hand to knock out the oil feed flange and the variable speed pump component and place them aside EE A Attention The copper rod shall be used to slightly knock the oil feed flange and the variable speed pump component so as to avoid component slipping 7 After taking down the input device the removal is completed Attention Slowly take down the input device to avoid slipping Al A WR GS ZF Transmission Service Manual SDLG 3 1 6 Removal of the Lubricating Oil Pipe Component and Auxiliary PTO 1 Respectively screw off hollow bolts M18 at both ends of the transmission lubricating oil pipe and then take out the oil pipe Figure 3 24 1 Lubricating oil pipe component 2 Take down the snap ring from the PTO shaft with the snap ring pliers Figure 3 25 1 Snap ring 45 1 75 2 Snap ring pliers 3 Knock out the PTO shaft with the copper rod and take down the PTO driving gear 1 2 3 Figure 3 26 1 Dri
51. ion pressure oil flows into K3K4 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches and forming the transmission subassembly The power transmission route Driving gear Zo forward gear input gear Zy intermediate gear Z intermediate gear Z4 of the fourth gear fourth gear clutch K4 K34 ring gear assembly Z34 third gear clutch K3 gear Z of the third gear output shaft gear Z outpu output shaft as shown in Figure 2 8 Lo Ly Z intermediate gt Z4 2347 23 L output 5 First reverse gear The 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 clutches and forming the transmission subassembly The power transmission route Driving gear Zo reverse gear input gear Zrp reverse gear clutch KR KR2 ring gear assembly Z r2 KV1 ring gear assembly Zy first gear clutch K1 gear Z of the first gear second gear combination gear Z2 gear Z3 of the third gear output shaft gear Z output Output shaft as shown in Figure 2 9 Lo LR LR Ly 1 LZ 7 Ln 3 ZL output KV K1 Z output f 4 Figure 2 9 6 Second reverse gear The solenoid valves M1 and M4 act and the transmission pressure oil flows into KRK2 clutch thus respectively pushing the piston to move pressing the interior friction lining out of the clutches
52. ip 1 Electric control box of the 4WG200 transmission The vehicle structural part has malfunction after welding the vehicle structural parts it is found out that the vehicle can t be started After check it 1s found out that the electric control box is burnt out After starting the vehicle turn off the electric lock Several minutes later the counter on the instrument panel smokes and the vehicle can t be driven After check it is found out the cause is violation to the operation regulations The electric lock 1s turned off when the engine dosen t stop In such case the generator can t charge the storage battery and sometimes it will product higher surge voltage which will result in dozens of amperes transient current and electric control box damage However if connecting the generator with the storage battery circuit it will stabilize the circuit voltage Accordingly it is necessary to turn off the electric lock after the engine stops 2 Output speed sensor The output speed sensor is used to record the rotation frequency of the output gear so as to help the computer compare the preselected speed with the current speed and make the gearshift decision The resistance value of the output speed sensor is 1020 100 if the resistance value is O or it means that the sensor has short circuit or open circuit which shall be replaced Common malfunction example The vehicle has the first and second gears while no third and fo
53. just the transmission to a proper position slightly knock the connecting shell periphery with the copper rod and take down the connecting shell ee Attention Upon knocking ensure that the force which is applied on the connecting shell periphery is uniform 3 1 2 Transmission Control Valve Removal 1 Take down 6 hexagon socket head cap bolts from the transmission control valve with the hexagon socket spanner Attention Strictly follow the sequence of From outside to inside and diagonal removal to remove bolts 2 Respectively take down 11 hexagon socket head cap bolts from the transmission control valve with the hexagon socket spanner Attention It is recommended to place two screws in the removed thread holes at the top so as to avoid control valve sliding due to removal of the head cap screws Strictly follow the sequence of From outside to inside and diagonal removal to remove bolts Al AX wis SDLG a as T gt M T dtu iT DA Jii ica Figure 3 6 1 Valve pad 2 Cover plate 3 Paper pad 4 Transmission control valve Figure 3 7 1 Oil pipe connector of the oil passage plate 2 Oil passage connector of the clutch aa o OUY rT rm aa i l Figure 3 8 1 Head cap screwx8 ZF Transmission Service Manual 3 Take down the transmission control valve paper pad cover plate and valve pad Attention After removing the transmission contro
54. l valve do well in its cleaning and protection 4 Take down six oil pipes from the oil passage plate in turn which are K2 K1 K3 K4 KR and KV from top to bottom In addition remove the oil passage connector on the clutch shafts and take down six oil pipes Attention Do well in oil pipe connector protection and mark the oil pipe number with the marker After removing the connectors do well in their cleaning and protection 5 Take down 8 hexagon socket head cap bolts between the oil passage plate and the transmission Attention Strictly follow the sequence of From outside to inside and diagonal removal to remove bolts AZ A WR IS I ZF Transmission Service Manual SDLG 6 Take down 3 hexagon socket head cap bolts between the oil passage plate and the transmission Attention It is recommended to place two screws in the removed thread holes at the top so as to avoid control valve sliding due to removal of the head cap screws Figure 3 9 1 Head cap screwx3 7 Take down the oil passage plate packing 1 cover plate and paper pad Attention After removing the oil passage plate do well in its cleaning and protection Figure 3 10 l Packing 2 Cover plate 3 Oil passage plate 4 Paper pad 8 The transmission control valve removal is completed Figure 3 11 23 A LU ZR IS I ZF Transmission Service Manual SDLG 3 1 3 Oil Filter Removal 1 Rotate the oil filter
55. lutch piston stroke which is measured by the dial indicator and the K3 clutch assembling is completed Attention Press the dial indicator contact onto the bearing plate and select different positions for three measurements at the least The dial indicator reading is the K3 clutch piston stroke Select the internal friction lining with different thickness to ensure that the piston stroke is 1 8mm 2 2mm 14 Knock the K4 clutch needle bearing into the clutch bearing hole and install the retainer ring 8l A WR 1S ZF Transmission Service Manual SDLG 15 Install the seal ring into the K4 clutch piston groove Attention When installing the seal ring the sealing surface of the seal ring shall face towards the pressure oil surface Refer to Figure 4 3 Figure 4 16 1 Seal ring 2 Seal ring 3 16 Install the K4 clutch piston into the clutch Figure 4 17 17 Install the guide ring and the pressure spring into the clutch cylinder Figure 4 18 1 Guide ring 2 Pressure spring 3 Guide ring 82 A WR IS I ZF Transmission Service Manual SDLG 18 Install the guide ring and the retainer ring Figure 4 19 1 Guide ring 2 Retainer ring 19 Install the clutch spring removal and assembling tooling onto the clutch Figure 4 20 1 Clutch spring removal and assembling tooling 29380017591 29380017601 20 Screw down the nuts on the clutch removal tooling and press down the clutch spring
56. malfunction example In case of the loader maintenance clean it with water after that it is found out that the vehicle is unavailable for gear shift and can t be started After check it is found out that the electric control system of the vehicle has normal circuit connection which is free from mechanical malfunction The cause is that the electric control box is affected with damp during cleaning after being dried the complete vehicle has a normal traveling Accordingly during the vehicle cleaning and maintenance it is necessary to pay attention to the waterproof protection of the computer box and the handle The vehicle has normal traveling originally however after parking for oil filling it is found out that the vehicle engine can be started while the vehicle can t be driven After check it is found out that both the electric control system circuit and the transmission oil pressure are normal Later it is found out that the lower plug of the electric control box is improperly inserted The cause 1s that there is a clip fixing the electric control box plug on the electric control box when there is one click sound after inserting both ends of the wire plug into the pin it means that the clip has firmly fixed the plug or else vibration arising from vehicle traveling will loosen the plug Figure 5 1 120 A WRIS I ZF Transmission Service Manual SDLG 1 Electric control box of the transmission 2 Cable plug 3 Cl
57. n as there is pressure inside Aeenton Special attention shall be given to the technical requirements in case of operation to ensure that the operation is qualified Part or device weight or removal and assembling method Weight Attention shall be given to selection of the spreader and its operation posture Tightening Special attention shall be given to the tightening torque of torque the component in case of assembling The place which needs adhesive and lubricating grease Coating i coating Fill the engine oil water and fuel with certain capacity Draining The place needing oil pce draining and draining 1 3 Common Bolt Tightening Torque Table Table 1 2 Nominal diameter of bolt mm Yield grade o N mm Tightening torque Nm 109 900 13 16 30 36 65 78 110 130 180 210 1080 16 21 38 51 75 100 131 175 209 278 Nominal diameter of bolt mm Yield grate N mm Tightening torque Nm 193 257 264 354 376 502 521 683 651 868 109 900 280 330 380 450 540 650 740 880 940 1120 1080 326 434 448 597 635 847 864 1152 1098 1464 3 A WRIS I ZF Transmission Service Manual Yield Nominal diameter of bolt mm strength N mm Bolt strength grade Tightening torque Nm 952 1269 1293 1723 1759 2345 2259 3012 2923 3898 109 900 1400 1650 1700 2000 2473 3298 2800 3350 4111 5481 1080 1606 2142 2181 2908 2968 3958 3812 5082 4933 6577 A WR IS I ZF Transmission Service M
58. nd periodically replace the transmission oil and the filter 4 Before starting the vehicle engine ensure that the control handle is at the neutral gear 5 Before every traveling loosen the parking brake release the brake 6 In case of engaging or separating the engine and the transmission and lifting the transmission try to avoid torque converter detachment 7 During parking the gearshift handle shall be turned to the neutral gear 8 The normal working oil temperature shall be kept between 80 110 C when bearing the heavy load it can rise to 120 C in a short time It is necessary to pay special attention to the control oil pressure of the transmission If transmission is discovered to be abnormal during use it is necessary to stop the vehicle for check 9 When the vehicle has malfunction and needs electric welding maintenance it is necessary to remove the cable plug on EST computer controller cut off the circuit leading to the computer controller or else the computer controller may be burnt due to impact current during electric welding 2 Operation 1 Preparations and maintenance before traveling Before transmission operation it is recommended to properly fill the lubricating oil with specified specification In case of initial oil filling of the transmission it is necessary to consider that the oil radiator filter and connecting pipe shall be filled with oil Accordingly the lubricating oil in the first f
59. nditions are good the vehicle can be driven with a high gear If the vehicle is stopped but the engine still runs and the transmission gear is engaged the engine will not be stopped For some traction force may be produced when the engine passes the torque converter at idle speed the vehicle may crawl on a straight pavement The rational method is to turn the parking brake to a brake state upon each parking To park the vehicle for a long time the control handle shall be turned to the neutral gear During traveling it is recommended to loosen the parking brake of the vehicle From experience we draw a conclusion that the operator is hard to immediately find out that When the torque converter speed changes due to large output torque ratio of the torque converter the vehicle can overcome the brake torque and forcedly travel even under the normal operation conditions The consequence is that the torque converter oil temperature will rise and the brake will become too hot Due to impact of the torque converter when shifting to low speed gear from the high speed gear the engine rotation speed will increase specially the gear shift with skipping a grade Accordingly if conditions permit when shifting to low speed gear from the high speed gear firstly step down the foot brake perform deceleration slowly and then shift gear When the vehicle travels at high speed and the traveling direction is changed it is necessary to reduce the engine rotati
60. nical malfunction And the cause is that the oil level is not checked as specified after oil replacement which is seriously insufficient After filling oil till reaching the normal oil level the vehicle can be normally driven 5 2 Malfunction Diagnosis and Troubleshooting of Transmission 1 Cause of the gearshift clutch malfunction The transmission clutch is a kind of vulnerable part When engaging the transmission clutch the hydraulic pressure will pass through the piston overcome the spring force and press down the friction lining The friction lining will contact with the metal plate and both of them will be pressed down along with the hydraulic pressure increase In case of each gearshift friction will occur between the friction lining and the steel sheet Though the friction heat quantity arising from the coolant has been considered in design the cooling effect is limited When becoming thinner the clutch will need more hydraulic oil to bring full engagement between the friction lining and the steel sheet in such case the diesel engine shall be further accelerated When accelerating the engine to very high idle speed the friction lining slipping time on the steel sheet will be extended accordingly and the friction heat quantity will be larger as well When the increase of the hydraulic oil heating time and temperature can change the sealing characteristics of the transmission there will be internal leakage in the transmission And t
61. ol valve to act and cut off the pressure oil passage of the transmission clutch namely the transmission power from the engine In such case all power of the engine will be transmitted to the working pump of the loader Accordingly when the first and second gears work the working hydraulic system of the loader will have more sufficient power to perform excavation operation thus improving the working efficiency of the working device In addition when pressing down the emergency parking brake button the emergency parking brake pressure switch will also act the pressure switch will turn on the power circuit and the computer circuit and then the computer will command the transmission control valve to act namely the transmission power from the engine will be cut off in case of emergency brake thus improving the brake effect 3 Neutral gear locking function and neutral gear start interlock function for vehicle safety improvement The gear control handle DW is designed and installed at the lower left part of the steering wheel if rotating the handle the speed can be changed to the first second third and fourth gears as shown in Figure 2 13 If pushing the control handle forwards the vehicle will be driven forwards if pushing the control handle backwards the vehicle will be driven backwards if the control handle stays at the neutral gear the vehicle will keep still Figure 2 13 Gear Control Handle of 4WG200 Transmission The ne
62. oling install the K4K3 clutch shaft and screw down the nut fixing the clutch assembly Attention The K3K4 clutch gear can flexibly rotate 23N m Figure 4 87 1 K3K4 clutch assembly 2 Hexagon nut M8 x2 105 AX wis SDLG Figure 4 88 1 Magnetic meter seat 3 Crowbar Figure 4 89 1 Rotation speed sensor 2 Adjustable washer 3 Packing washer Figure 4 90 2 K3 gear 2 Dial indicator i 1 Rotation speed sensor ZF Transmission Service Manual 6 Slowly jack up the clutch assembly with the crowbar to make it have axial runout and then record the dial indicator reading Attention Select the adjustable washer with different thickness so as to ensure that the axial clearance of the clutch assembly is 0 l1mm 0 3mm after that the assembling is completed 4 2 5 Rotation Speed Sensor Assembly 1 Screw the rotation speed sensor into the mounting hole Attention Before screw in observe the mounting hole and rotate the clutch to align the K3 gear top at the hole center after that slowly screw in the sensor to make it contact with the gear top 106 A LU ZR IS I ZF Transmission Service Manual SDLG 2 Screw out the rotation speed sensor by 120 192 and measure the clearance between the sensor and the transmission body with the feeler gauge Attention Ensure that the distance between the sensor and the K3 gear top is 0 5mm 0 8mm Specifications of the ro
63. on lining ol A LU ZR IS I ZF Transmission Service Manual SDLG Figure 3 96 1 Internal friction lining a ag t Pida oaa Figure 3 97 Figure 3 98 1 Clutch spring removal tooling 29380017591 29380017601 10 Take out the internal friction lining of the KV clutch 11 Take out the external and internal friction linings and place them aside 12 Install the clutch spring removal tooling onto the clutch 52 A LU ZR IS I ZF Transmission Service Manual SDLG 13 Screw down the nut on the clutch tooling and press down the clutch spring Figure 3 99 1 Pressure spring 14 Take down retainer ring fixing the pressuring spring of the KV clutch with the snap ring pliers Figure 3 100 1 Retainer ring 15 Take down the retainer ring and the guide ring Figure 3 101 1 Guide ring 2 Retainer ring D3 A LU ZR IS I ZF Transmission Service Manual SDLG 16 Take out the pressure spring and guide ring of the KV clutch Figure 3 102 1 Lower guide ring 2 Pressure spring 3 Upper guide ring 17 Take out the KV clutch piston Figure 3 103 1 KV clutch piston Ew 18 Remove the needle bearing of the KV clutch Figure 3 104 1 Check valve 2 Needle bearing 54 A WRIS I ZF Transmission Service Manual SDLG Figure 3 105 1 Adjustable washer 2 Snap ring 75 2 5 Figure 3 106 1 Thrust washer 2 Thrust washer 3 K1 clutch gear F
64. on speed 3 Suspension and parking As there is no rigid connection between the engine and the torque converter output shaft when the vehicle is parked on the slope upslope or downslope while the driver wants to leave the vehicle to avoid vehicle sliding we recommend to apply the parking brake and place stop blocks under wheels 4 Dragging The max dragging speed is 10km h and the max dragging distance is 10km When the distance is longer the vehicle with malfunction shall be placed on other vehicle for transportation 5 Oil temperature The transmission oil temperature shall be monitored with the temperature sensor The max oil temperature of the torque converter outlet shall not be higher than 120 C the normal control component and the transmission with sufficient traveling mileage will not have higher temperature If the oil temperature is higher than 120 C the vehicle shall be stopped for oil leakage check And the transmission shall be turned to the neutral gear and the engine shall run at 1200 1500rpm In such case the oil temperature will quickly reduce to the normal value within about 2 3 min If the oil temperature doesn t fall down it means that the system has malfunction and operation can be continued after troubleshooting Normal gear shift oil pressure range 1 6 amp 1 8MPa 16 18bar To monitor the control pressure it is necessary to install a pressure gauge or pressure monitoring meter In case of eng
65. plate and the output shaft 46N m Figure 4 72 1 Hexagon head screw M10 30 x2 100 A WR IS I ZF Transmission Service Manual SDLG Figure 4 73 1 Lock washer 2 Lock washer assembling tooling 29380017101 1 2 Figure 4 74 1 Nut M10 x2 2 Butterfly pressure plate l Figure 4 75 1 Hexagon head screw M10 25 x6 15 Lock the lock washer with the tooling 16 Screw down 2 bolts M10 25 between the butterfly pressure plate and the pressure plate and then install the additional washer and nut 68N m 17 After installing the bolt and washer between the pressure plate and the output flange the assembling is completed a Nm 68N m 101 A LU ZR IS I ZF Transmission Service Manual SDLG 4 2 2 Intermediate Shaft Component Assembly 1 Install the roller bearing into the bearing hole of the intermediate shaft gear and fix it with grease for standby 1 2 3 4 Figure 4 76 1 O ring 2 Intermediate shaft 3 Roller bearing 4 Intermediate shaft gear 2 Place the intermediate shaft gear component into the gear groove of the transmission body insert the intermediate shaft and install the gasket 1 2 Figure 4 77 1 Intermediate shaft gear 2 Gasket 3 Install the screw and then install the sealing washer 80N m Figure 4 78 1 Head cap screwx1 102 A WRIS I ZF Transmission Service Manual SDLG 4 The intermediate shaft assembling is completed
66. rt hands and fingers For parts to be directly assembled by hand it is necessary to pay attention that the gripping position is free from squeezing danger 11 It is necessary to test the removed parts the parts whose application performance is affected shall 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 is necessary to apply relevant protection measures to avoid damages 14 When assembling the parts the applied tools shall match with the thread fastener so as to avoid damages 15 When screwing down the connector body and screw plug it is not allowed to use pneumatic wrench and other similar tightening tools It is necessary to screw them down by hand and then with the torque wrench with corresponding capacity so as to reach the corresponding torque value 16 When draining out fluid in the transmission it is necessary to slowly screw off the oil drain plug so as to avoid fluid spraying A WR IS I ZEF Transmission Service Manual SDLG 1 2 Instructions of Marks and Symbols To ensure that the Manual can play a role it is necessary to use marks specified in Table 1 1 for aspects of the important safety and quality requirements Table 1 1 Special attention shall be given to the safety in case of operation Safety k Special attention shall be given to the safety in case of operatio
67. tation speed sensor M18x1 5 Figure 4 91 1 Rotation speed sensor 3 Select the proper adjustable washer and assemble it onto the sensor and then screw down the sensor and coat it with the sealant after that the assembling is completed 7 AT262 sealant Figure 4 92 4 2 6 KRK2 Clutch Assembly 1 Coat the thrust washer of the clutch assembly with grease Figure 4 93 1 KRK2 clutch assembly 107 SDLG 1 Figure 4 94 1 Washer 12 Figure 4 95 1 KRK2 clutch 2 Clutch shaft positioning tooling 29380017611 Figure 4 96 1 Hexagon nut M8 x2 A WR IS I ZF Transmission Service Manual 2 Place the washers onto the transmission body wall 3 Install the clutch tooling onto the KRK2 clutch and place it into the transmission body gt A Attention When placing the clutch jack up the clutch bottom with the tooling to avoid clutch falling 4 Take out the clutch shaft installation tooling install the KRK2 clutch shaft and screw down the nut fixing the KRK2 clutch shaft Attention The KRK2 clutch gear can flexibly rotate Nm 23N m 108 AX wars SDLG Figure 4 97 1 KRK2 clutch shaft Figure 4 98 1 KVKI1 clutch assembly Figure 4 99 1 Washer ZF Transmission Service Manual 5 Slowly jack up the clutch assembly with the crowbar to make it have axial runout measure and record the axial clearance of the clutch the measurement method can follow that spe
68. to avoid damages And the special removal tooling can also be used Figure 3 51 1 Oil seal 12 Remove the front end bearing snap ring and compensation washer of the output shaft with the snap ring pliers Phat pea SHH a an 0 Figure 3 52 1 Snap ring 120 4 2 Compensation washer 13 Knock the rear end of the output shaft with the copper rod Figure 3 53 1 Rear end of the output shaft 2 Copper rod 37 A LU ZR IS I ZF Transmission Service Manual SDLG 14 Take down the output shaft bearing and shaft sleeve 1 2 3 Figure 3 54 1 Bearing 2 Output shaft 3 Shaft sleeve 15 Take out the output gear and remove the bolt between the retainer oil shield and transmission body Figure 3 55 1 Output gear 2 Connecting retainer 3 Hexagon head screw M8 16 x2 16 Take out the oil shield and the retainer Figure 3 56 1 Output gear 2 Oil shield 3 Retainer 38 A WR IS I ZF Transmission Service Manual SDLG 17 The removal is completed Figure 3 57 3 1 21 Intermediate Shaft Assembly Removal 1 Remove the sealing washer l Figure 3 58 1 Sealing washer 2 Remove the bolt between the intermediate shaft and the transmission body Figure 3 59 1 Head cap screw 39 A LU ZR IS I ZF Transmission Service Manual SDLG 3 Take out the intermediate shaft and the O ring Figure 3 60 1 Intermediate shaft 2 O ring 4 After taking out the intermedi
69. uries Ad wit be made as the safety mark in the Manual The precautions with shall be paid high attention to In case of potential dangers it is recommended to consider the own safety first of all and then consider taking necessary safety measures A Safety Tips During assembling and removal wrong operation method will lead to parts damages service life shortening service performance deterioration and other unsafe factors Accordingly when assembling 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 standard equipped 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 storing removed parts shall be prepared and the corresponding tools and parts shall be placed in a proper site In addition the working area shall be kept clean which shall be free from oil dirt and pollutants Smoking is only allowed in the specified place smoking is not allowed during operation and corresponding fire extinguishers shall be prepared 3 The welding operation can only be conducted by the trained personnel with welding experience During welding welding gloves retainer goggles work cap and other work clothes applicable for welding operation 4 Before removing the transmission torque converter assembly it is necessary to
70. urth gears Check steps After turning off the electric lock screw off the output speed sensor plug and check it with the universal meter If the resistance value is 0 it means the speed sensor is damaged The complete vehicle is unavailable for any gearshift After check it is found out that the oil level is normal and the cable wire between the electric control box and the speed sensor is worn out by metal after re wrapping the vehicle returns to normal 3 Gearshift handle Its inside mainly has two inching switches by forwards and backwards pulling the handle and rotating the handle sleeve the direction and speed can be selected Common malfunction example The user reflects that the loader can t be accelerated to the fourth gear After check it is found out that the transmission oil level is normal but the 8 wire of the 12 hole plug connecting with the gearshift handle is loose and the cause is that the 8 wire has poor contact When engaging the fourth gear the computer can only receive the electric signal from the third gear accordingly the loader is unavailable for the fourth gear 4 Other typical malfunction After the transmission oil replacement the vehicle can t be driven after about 20m traveling 121 A W RISI ZF Transmission Service Manual after stop and restart it can only be driven for 10 20m After check it is found out that the electric control system has normal circuit which is free from mecha
71. utral gear safety lock is used to avoid vehicle movement due to misoperation When turning the safety lock to position D the vehicle gear will be engaged for traveling when turning the safety lock to position N the vehicle will be locked at the neutral gear If engaging the neutral gear and rotating the locking button of the neutral gear safety lock of the gearshift handle to the locking position at position N the vehicle will be locked at the neutral gear to avoid gear engagement due to misoperation A W RISI ZF Transmission Service Manual The engine can be started if engaging the neutral gear When engaging the neutral gear and opening the electric lock the gearshift handle will send an electric signal to the start interlock relay and then the start circuit will be connected or else the engine can t be started 4 Working process of KD key of ZF transmission With KD function namely the forced low gear shift function the loader working efficiency can be greatly enhanced During operation the loader will be started at the second gear and then driven at the third gear when approaching to sand and stone material piles the second gear will be engaged In case of material excavation if pressing down KD key without rotating the gearshift handle the vehicle speed will be automatically reduced to the first gear When the bucket is full pull the gearshift handle backwards to the reverse gear and the vehicle can b
72. ve Transmission pressure Second gear Fourth gear First gear TA Reverse cea Nee ari Forward gear CA Ne s E A Figure 2 12 Standard pressure of all measuring ports The pressure of the first gear and the second gear is 16bar the pressure of the third gear and the fourth gear is 18bar and the relief valve pressure is 1Obar The KV forward KR reverse clutch pressure will change along with gear changes and the transmission pressure is same as that of the corresponding gear 2 1 4 Introduction to KD Key Functions 4WG158 200 1 KD Kick Down function namely the low gear shift function There is one button at the end of DW 2 gearshift handle which is the KD key and it can be used to decrease the vehicle speed to the first forward gear from the second forward gear A SDLG WR IS I ZEF Transmission Service Manual 2 Brake power cutoff function of the first gear and the second gear In the electric control system two pressure cutoff switches one is the service brake pressure switch and one is the emergency parking brake pressure switch can be connected When the driver steps down the foot brake pedal for brake due to interaction between the brake pressure and the service brake pressure switch the pressure switch will turn on the power circuit and the computer namely the electric control box circuit equivalent to one electric signal of the computer and then the computer will command the transmission contr
73. ving gear 2 PTO shaft 3 Retainer ring SW47 28 A WR GS ZEF Transmission Service Manual SDLG Figure 3 27 1 Ball bearing l 2 Figure 3 28 1 Clutch shaft removal tooling 2 KVKI1 clutch shaft Figure 3 29 1 Thrust washer 2 Thrust washer 3 Compensation washer 4 The auxiliary PTO removal is completed 3 1 7 KVK1 Clutch Assembly Removal 1 Screw off two hexagon nuts on the KVKI1 clutch shaft and pull out the clutch shaft with tooling 2 Take down the thrust washer and the compensation washer from the KVKI1 clutch shaft Attention When taking down the thrust washer and the compensation washer the transmission shall be placed flatly to prevent the washer falling down to the bottom of the transmission body 29 A LU ZR IS I ZF Transmission Service Manual SDLG 3 Take out the KVK1 clutch assembly from the transmission body A Attention When taking out the clutch assembly place the transmission in a proper position and the operation shall be slow to avoid slipping Figure 3 30 1 KVKI1 clutch assembly 2 Transmission body 4 The KVKI1 clutch assembly removal is completed F Attention Mark the KVK1 clutch with the marker for convenient distinguishing Figure 3 31 1 KVK1 clutch assembly 3 1 8 KRK2 Clutch Assembly Removal i rA 1 Screw off two hexagon nuts from the KRK2 aaa ee clutch shaft and pull out the clutch shaft with the tooling w k r
74. xiliary PTO Assembly 1 Place the transfer gear into the transmission body Figure 4 103 1 Transfer gear 2 Knock in the PTO shaft to make the retainer ring on the shaft fits with the gear Figure 4 104 1 PTO shaft 2 Retainer ring SW47 3 Install the bearing snap ring on the PTO shaft with the snap ring pliers Figure 4 105 1 Snap ring 45 1 75 111 AX wis SDLG Figure 4 106 1 PTO end cover Figure 4 107 1 Hexagon head screw M8 16 x8 Figure 4 108 1 Input component ZF Transmission Service Manual 4 Assemble the PTO end cover and install the additional packing Attention Replace the removed packing with a new one 5 After screwing down the bolt between the PTO end cover and the transmission body the assembling is completed 16N m 4 2 9 Input Component Assembly 1 Install the input device onto the transmission body install the additional packing and knock it in with the copper rod Attention Upon installation screw in two bolt positioning thread holes Replace the removed packing with a new one 112 A WR IS I ZF Transmission Service Manual SDLG 2 Assemble the lubricating oil pipe component and screw down the hollow screw between the oil pipe and the transmission body a Nm 34 5N m Figure 4 109 1 PTO lubricating oil pipe component a 3 Assemble the connecting shell and knock it in with the copper rod Attention

4.2 Transmission Assembly

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