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ZF · 273 стр.
2-ha30
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Document text
Ch 2 page 1 TRANSMISSION Chapter 2 Transmission SHOP MANUAL
TRANSMISSION Ch 2 page 2 Chapter 2 Transmission Index General.....................................................................................................................5 Structure of the Repair Manual..................................................................................................6 Denomination of standard dimensions......................................................................................7 Conversion table .......................................................................................................................7 Torque limits for screws..........................................................................................8 Table..........................................................................................................................................8 Setting clutch.............................................................................................................................8 Labeling of type plate .............................................................................................9 Information on spare parts ordering..........................................................................................9 Type plate electronic control unit...............................................................................................9 Configuration of transmission.............................................................................10 Transmission schematics and gear schematics.......................................................................10 Gear schematics......................................................................................................................10 Measuring points and connections.....................................................................11 Table........................................................................................................................................11 Measuring points for pressure oil and temperature.................................................................11 Installation sheet......................................................................................................................12 Special tools for disassembly and reassembly..................................................13 Commercial tools for disassembly and reassembly.................................................................26 Removal of transmission, disassembly...............................................................31 Disassemble the structure bar.................................................................................................38 Disassemble the hydraulic hoses............................................................................................38 Positioning for disassembly and reassembly...........................................................................42 Removal and refitting various components..............................................................................43 Transmission............................................................................................................................43 LKV axle insert........................................................................................................................43 Separate axle insert LKV assy from transmission...................................................................44 Removal inner components of Trasnsmission...................................................45 Removal of speed sensor n4-output........................................................................................45 Disassembly of shifting block I and speed sensors.................................................................46 Engine connection ..................................................................................................................50 Oil supply ................................................................................................................................54 Removal of shifting block II, valve block primary ....................................................................54 pump and retarder...................................................................................................................54 Retarder...................................................................................................................................57 Valve block..............................................................................................................................59 Shifting block II .......................................................................................................................60 Primary pump .........................................................................................................................62 Removing output flanges.........................................................................................................63 Power take-off .........................................................................................................................64 Version with 1st PTO ..............................................................................................................64 Emergency steering pump ......................................................................................................65 Planetary drive “F” ..................................................................................................................66 Separate planetary drive from housing II ..............................................................................66 Dismantling planetary drive.....................................................................................................67 Removal input shaft and clutches ..........................................................................................74 Separate housing I and housing II ..........................................................................................74 Housing I ................................................................................................................................75 Differential “G” .........................................................................................................................78 Clutches “V”; “R”; “A”; “B”; “C”; “D”; “E” ....................................................................................78 Housing II ..............................................................................................................................80 Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ and Differential............................................................83 Clutch “E” ...............................................................................................................................84 Clutch “R” ...............................................................................................................................89 Clutch “B“ ...............................................................................................................................94 SHOP MANUAL
Ch 2 page 3 TRANSMISSION Chapter 2 Transmission Index Clutch “V“ ...............................................................................................................................99 Clutch “C“ .............................................................................................................................103 Clutch “D“ .............................................................................................................................108 Clutch “A“ ............................................................................................................................113 Dismantling differential ”G“ ...................................................................................................118 Reassembly of Transmission inner parts..........................................................124 Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ and Differential..........................................................124 Clutch ”E“ ..............................................................................................................................124 Clutch “R“ .............................................................................................................................132 Clutch “B“ .............................................................................................................................139 Clutch “V“ .............................................................................................................................146 Clutch “C“ .............................................................................................................................153 Clutch “D“ .............................................................................................................................160 Clutch “A“ .............................................................................................................................167 Check of the disk clearance all clutches ...............................................................................174 Assembling differential ”G“....................................................................................................175 Installation input shaft and clutches ......................................................................................182 Housing II .............................................................................................................................182 Clutches “V”;“R”;“A”;“B”;“C”;“D”;“E”........................................................................................186 Housing I ..............................................................................................................................189 Assemble housing I and housing II .......................................................................................192 Oil supply ..............................................................................................................................193 Shifting block II .....................................................................................................................193 Valve block ............................................................................................................................195 Retarder ................................................................................................................................197 Primary pump .......................................................................................................................200 Installation retarder, primary pump, valve block and shifting block II ....................................200 Engine connection ................................................................................................................204 Planetary drive “F”.................................................................................................................208 Mount planetary drive to housing II ......................................................................................215 Output to front and rear axle..................................................................................................217 Output to front axle with axle insert LKV .............................................................................217 Power take-off .......................................................................................................................219 PTO-gear – 1st power take-off ..............................................................................................220 PTO-input shaft .....................................................................................................................221 Emergency steering pump ....................................................................................................223 Reassembly of shifting block I and speed sensors:...............................................................224 Shifting block I.......................................................................................................................224 Refitting of speed sensor n4-output.......................................................................................229 Refitting breather, Oil sight level glass, Cover plate and screw plug.............230 Disassembly of LKV Axle Insert ........................................................................232 Disassembly..........................................................................................................................232 Dismantling multi-disk differential lock...................................................................................236 Disassembling input...............................................................................................................238 Assembling of LKV Axle Insert .........................................................................240 Installing input........................................................................................................................244 Adjusting differential bearing rolling torque and backlash......................................................246 Checking backlash on the slotted nut....................................................................................248 Checking contact pattern.......................................................................................................248 Assembling output.................................................................................................................249 Contact pattern examples of Gleason Tooth System.......................................255 Field of application:................................................................................................................255 Ideal contact pattern:
.........................................................................................255 Contact pattern setting: ........................................................................................................255 Flank glossary: ......................................................................................................................255 EXAMPLE 1: DEDENDUM TOOTH POSITION ....................................................................256 SHOP MANUAL
TRANSMISSION Ch 2 page 4 Chapter 2 Transmission Index EXAMPLE 2: ADDENDUM TOOTH POSITION ....................................................................257 EXAMPLE 3: “LINE” CONTACT PATTERN ...........................................................................258 Transmission assembly......................................................................................259 Clutch calibration...................................................................................................................267 Transmission oil check...........................................................................................................270 SHOP MANUAL