ZF Transmission Service Manual

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

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

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

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

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

ZF Transmission Service Manual1.2 Instructions of Marks and SymbolsTo ensure that the Manual can play a role, it is necessary to use marks specified in Table 1-1for aspects of the important safety and quality requirements.Table 1-1MarkRemarksSpecial attention shall be given to the safety in case ofoperation.SafetySpecial attention shall be given

4. Before removing the transmission-torque converter assembly, it is necessary to 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