ZF WG-180 WG-200 Powershift Transmission Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
ZF WG-180 WG-200 Powershift Transmission Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 224
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
ZF WG-180 WG-200 Powershift Transmission Workshop Manual – PDF DOWNLOAD
ZF - POWERSHIFT TRANSMISSION WG-180/WG-200........................................................ 1 Preface........................................................................................ 4 General Working Instructions................................................................... 5 Important Labour Safety Instructions........................................................... 6 Denomination of Legal Standards................................................................ 7 Conversion Table for Dimensional Units......................................................... 8 Torque limits for screws....................................................................... 9 Inscriptions on the Model Identification Plate and Instructions for Spare Parts Orders......... 10 Possible versions Additional equipment......................................................... 11 List of lubricants TE-ML 03.................................................................... 12 1. ELECTRO-HYDRAULIC GEARBOX CONTROL........................................................... 14 1.1 Cast -iron gearbox control............................................................. 17 1.1.1 Version I: Standard Version (without WK and 2-stage pressure control valve).......... 17 1.1.1.1 Disassembly.................................................................... 17 1.1.1.2 Reassembly..................................................................... 20 1.2 Aluminium sand-casting gearbox control................................................. 28 1.2.1 Version I: with 4 solenoid valves and attached 2-stage pressure control valve.... 28 1.2.1.1 Disassembly................................................................ 28 1.2.1.2 Reassembly................................................................. 30 1.2.2 Version II: with 5 solenoid valves and attached WK-valve......................... 39 1.2.2.1 Disassembly................................................................ 39 1.2.2.2 Reassembly................................................................. 41 1.3 Aluminium die-cast gearbox control..................................................... 47 1.3.1 Version I: with WK-valve......................................................... 47 1.3.1.1 Disassembly................................................................ 47 1.3.1.2 Reassembly................................................................. 50 1.3.2 Version II: with 2-stage pressure control valve.................................. 59 1.3.2.1 Disassembly................................................................ 59 1.3.2.2 Reassembly................................................................. 61 1.3.3 Version III: with WK-valve and variable 2-stage pressure control valve........... 66 1.3.3.1 Disassembly................................................................ 66 1.3.3.2 Reassembly................................................................. 69 2. TORQUE CONVERTER............................................................................ 77 2.1 Disassembly............................................................................ 77 2.2 Reassembly............................................................................. 80 3. GEARBOX..................................................................................... 88 3.1 Disassembly............................................................................ 88 3.1.1 Converter charge pump and control pressure pump.................................. 88 3.1.2 Coaxial power take-off (mechanical control)...................................... 93 3.1.3 Lateral power take-off........................................................... 96 3.1.4 Remove emergency steering pump................................................... 97 3.1.5 Remove multi-disk clutches....................................................... 98 3.1.6 Remove countershaft assembly..................................................... 98 3.1.7 Dismantle multi-disk clutch......................................................100 3.1.8 Final drive, Version with drum brake.............................................102 3.2 Reassembly.............................................................................107 3.2.1 Final drive, Version with drum brake.............................................107 3.2.2 Speedometer......................................................................116 3.2.3 Clutch K4/K3.....................................................................118 3.2.3.1 Pre-assemble plate carrier K4/K3...........................................118 3.2.3.2 Install plate pack K4......................................................125 3.2.3.3 Pre-assemble and install spur gear K4......................................126 3.2.3.4 Install plate pack K3......................................................127 3.2.3.5 Pre-assemble and install spur gear K3......................................127 3.2.3.6 Install clutch K4/K3.......................................................127 3.2.4 Pre-assemble and install countershaft assembly ..................................132 3.2.5 Clutch KR/K2.....................................................................133 3.2.5.1 Plate pack KR..............................................................134 3.2.5.2 Pre-assemble and install spur gear KR......................................134 3.2.5.3 Plate pack K2..............................................................135 3.2.5.4 Pre-assemble and install spur gear K2......................................135 3.2.5.5 Install clutch KR/K2.......................................................137 3.2.6 Clutch KV/K1.....................................................................139 3.2.6.1 Plate pack KV..............................................................139 3.2.6.2 Pre-assemble and install spur gear KV......................................139 3.2.6.3 Plate pack K1..............................................................140 3.2.6.4 Pre-assemble and install spur gear K1......................................140 3.2.6.5 Install clutch KV/K1.......................................................142 3.2.7 Emergency steering pump..........................................................148 3.2.8 Lateral power take-off...........................................................149 3.2.9 Converter control valve..........................................................152 3.2.10 Converter charge pump and control pressure pump.................................153 3.2.11 Engine connection...............................................................160 3.2.12 Coaxial power take-off (controllable)...........................................161 3.2.13 Inductive transmitter...........................................................167 4. RETARDER....................................................................................168 4.1 Disassembly............................................................................168 4.2 Reassembly.............................................................................173 4.2.1 Pre-assemble and attach retarder.................................................173 4.2.2 Pre-assemble and attach retarder valve...........................................179 4.2.3 Install delivery lines...........................................................180 5. AXLE DELCLUTCH..............................................................................181 5.1 Disassembly............................................................................181 5.2 Reassembly.............................................................................185 6. AXLE DIFFERENTIAL...........................................................................192 6.1 Shift-control housing..................................................................192 6.1.1 Disassembly......................................................................192 6.1.2 Reassembly.......................................................................195 6.2 Differential...........................................................................200 6.2.1 Remove and dismantle differential................................................200 6.2.2 Pre-assemble and install differential............................................205 7. POWER TAKE-OFF CONTROLLABLE UNDER LOAS......................................................213 7.1 Disassembly............................................................................213 7.2 Reassembly.............................................................................218
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