ZF Powershift Transmission WG 180 & WG 200 Workshop Manual – PDF DOWNLOAD

Description

ZF Powershift Transmission WG 180 & WG 200 Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

ZF Powershift Transmission WG 180 & WG 200 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 224
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

ZF Powershift Transmission WG 180 & WG 200 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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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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