ZF Cpower CP 190 210 230 Level III CTM10101 Repair Manual EN - PDF DOWNLOAD

REPAIR MANUAL ZF – cPower CP 190/210/230 REPAIR LEVEL III

REPAIR MANUAL ZF-cPOWER CP 190/210/230 IM PORT AN T

INFORMATION:

Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit. Technical upgrading of ZF units and extension of design options may require differing operations which can be carried out by qualified specialists without greater difficulties by means of the perspective views included in the corresponding spare parts lists.

This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of issue of the manual.

ZF Friedrichshafen AG reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice. Upon request, ZF Friedrichshafen AG will advise which edition is the latest one.

Any maintenance work is to be done in accordance with the Operation Manual and the ZF List of Lubricants.

The ZF List of Lubricants is being continuously updated and can be obtained or viewed as follows: at all ZF plants at all ZF service organizations Internet www.zf.com ----------------------------------------------------------------------------------------------------------------------------------------

ATTENTION: Observe the vehicle manufacturer’s instructions and specifications for the installation and commissioning of the unit!

ZF Friedrichshafen AG

ZF Services Donaustr. 71 D - 94034 Passau

Copyright © ZF Friedrichshafen AG This document is protected by copyright.

Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.

Subject to technical modifications!

This document is a translation of the German original.

Design level 2013/10 2. Edition 2015/09

TABLE OF CONTENTS

TO OLS

DIS ASS EMBLY

WS/1 ... WH/5

1/1 ... 6/6

TABLE OF CONTENTS RE ASSEM BLY

8/1 ... 14/3

PREFACE

This manual describes a ZF series product with a design level valid at the date of edition.

1. Permanently trained staff 2. Specified equipment, e.g. special tools 3. State-of-the-art genuine ZF spare parts

GENERAL Structure of the Service Manual

Important information on work safety

The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding any damage to persons and products during maintenance and repair work.

Repair workshops must familiarize themselves with these regulations prior to starting any work.

The following safety references are used in this manual: reference info

INFO NOTE

product

DANGER

injury

damage to the

personal

When using detergents, observe the manufacturer’s instructions regarding their handling!

Instructions regarding cleanliness 1

Basics

2

Handling in accordance with cleanliness requirements

2.1

Environmental impacts

2.2

Working environment

2.3

Preparation

3

Components with additional cleanliness requirements -

VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION

BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis: Note: Nota:

Begriff Unit Unité

Formelzeichen Neu Formula Sign New Symbole Nouveau

Alt Old Vieux

Umrechnung Conversion Conversion

Bemerkungen Note Nota

TIGHTENING TORQUES FOR SCREWS (IN Nm) ACC. TO ZF STANDARD 148 Friction coefficient: µ tot.= 0.12 for screws and nuts without subsequent treatment, as well as for phosp. nuts. Tighten manually!

Unless otherwise specified, the tightening torques can be taken from the following chart:

Dimension

Metric ISO standard thread DIN 13, page 13 8.8 10.9

12.9

Dimension

Metric ISO fine thread DIN 13, page 13 8.8

12.9

10.9

TOOLS SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No.

Qty.

1/1

Assembly truck assy with tilting device 1

5870.350.000

1

1/1

Fixtures 2

AA00.854.658

1

1/5 14/6

HP-pump 3

5870.287.007

1

1/5 14/6

Minimess-coupling 4

5870.950.102

1

4/5 11/5

Lifting beam 5

5871.085.002 en

AA01.255.807

WS/1

Chapter/Fig.

1

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Eyebolt AA01.100.718

Grab sleeve 5873.002.038

Basic tool 5873.002.000

Load carrying fixture AA00.624.889

Mounting device AA00.622.885

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Grab sleeve 5873.001.057

Basic tool 5873.001.000

Assembly fixture 5870.345.088

Assembly fixture 5870.345.028

Grab sleeve AA00.870.766

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Cut-off device 5870.300.028

Extractor 5870.300.034

Grab sleeve 5873.002.037

Lifting device AA00.331.446

Grab sleeve 5873.002.036

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Inner extractor 5870.300.005

Counter support 5870.300.009

Rapid grip AA01.185.688

Pressure piece AA01.179.845

Inner extractor 5870.300.017

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Striker 5870.650.004

Press-fit mandrel AA01.206.586

Straightedge 5870.200.022

Digital depth gauge 4P46.002.042

Assembly fixture 5870.345.124

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Driver tool AA01.204.511

Driver tool 5870.048.319

Driver tool 5870.506.142

Driver tool 5870.048.057

Locating pins 5870.204.011

Qty.

Chapter/Fig.

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY CP 190/210/230 – 4664.052.010 Cons. Figure No.

Designation Order No. Locating pins 5870.204.063

Qty.

Chapter/Fig.

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure No.

Designation Order No. Magnetic stand 5870.200.055

Dial indicator 5870.200.057

Gage blocks 5870.200.066 5870.200.067

Digital depth gage 5870.200.072 5870.200.114

Digital caliper gage 5870.200.109 4P46.001.065 4P46.000.032

Qty

Chapter/Fig

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure No.

Designation Order No. Torque wrench 5870.203.030 5870.203.031 5870.203.032 5870.203.033 5870.203.034 5870.203.039 5870.203.016 5870.203.011 Hot-air blower 5870.221.500 5870.221.501

Plastic hammer 5870.280.004 Substitute nylon insert 5870.280.006 Lifting strap 5870.281.026

Qty

Chapter/Fig

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure No.

Designation Order No. Lifting chain 5870.281.047

Pry bar 5870.345.071

Striker 5870.650.004

Set of internal pliers 5870.900.013

Set of internal pliers 5870.900.014

Qty

Chapter/Fig

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure No.

Designation Order No. Set of external pliers 5870.900.015

Set of external pliers 5870.900.016

Two-armed puller 5870.970.001 5870.970.002 5870.970.003 5870.970.004 5870.970.006 5870.970.007 5870.970.026 5870.970.028

Qty

Chapter/Fig

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure No.

Designation Order No. Three-armed puller 5870.971.001 5870.971.002 5870.971.003 5870.971.004 5870.971.005 5870.971.006

Qty

Chapter/Fig

ZF – cPower CP - 190/210/230

Observe regulations for environmental protection - use suitable oil reservoir.

1. Disassembly of parking brake The brake manufacturer’s instructions and specifications are mandatory for any operations done on the brake system!

2. Disassembly of pressure filter, control unit, gearshift system and speed sensors 2.1 Disassembly of pressure filter

2.2 Disassembly of control unit

Pay attention to releasing bush.

2.3 Disassembly of gearshift system

2.4 Disassembly of duct plate

Pay attention to releasing O-rings.

2.5 Disassembly of speed sensors

3. Disassembly of pressure oil pump and output flanges 3.1 Disassembly of cover plates

3.2 Disassembly of pressure oil pump

Carry out a visual inspection for wear marks!

If you detect signs of wear, the pressure oil pump and the plate must be replaced!

It is not possible to replace single parts of the pressure oil pump!

3.3 Disassembly of output flanges

Pay attention to releasing O-rings.

DISASSEMBLY 4. Disassembly of hydrostatic unit Loosen hexagon screws.

Remove cover with seal.

Fig. 1

Loosen cylindrical screw and remove clamp (1).

3 2

Remove cable clips (2).

3

Separate plug connections (3) of the pressure sensors.

2

Remove pressure sensors.

1

Fig. 2

Separate plug connection (1).

Loosen cylindrical screws and remove solenoid (2).

1 2

Fig. 3

Loosen hexagon screws.

Fig. 4

5871.085.002 en

4/1

DISASSEMBLY Use the lifting device (S) to separate the hydrostatic unit from the transmission housing.

(S) Lifting beam

AA01.255.807

Fig. 5

Pull out connecting tubes (1) and splined shafts (2).

Fig. 6

Disassemble oil level indicator and cover plate.

Abb. 7

5871.085.002 en

4/2

5. Disassembly of clutches 5.1 Separate housing

Pay attention to wiring harness, risk of damage!!

5.2 Disassembly of output flange

5.3 Lift clutches out of the housing

5.4 Disassembly of clutch K1

5.5 Disassembly of clutch K2

5.6 Disassembly of clutch KV

5.7 Disassembly of clutch KR

6. Disassembly of planetary drive and motor shaft 6.1 Disassembly of planetary drive

Further disassembly is not possible!

Separation of ring gear and gear leads to damage of the parts!

Further disassembly is not possible!

Separation of planetary carrier and gear leads to damage of the parts!

6.2 Disassembly of motor shaft

7. Disassembly of housing 7.1 Disassembly of housing rear part

7.2 Disassembly of housing front part

8. Reassembly of housing 8.1 Reassembly of housing front part

Pay attention to position of the clamp, see following Figure.

8.2 Reassembly of housing rear part

Pay attention to the positions of the clamps, see following Figures.

9. Reassembly of planetary drive and motor shaft 9.1 Reassembly of planetary drive

Risk of burn injuries, wear protective gloves!

Use of the specified pressure piece ensures the exact installation position of the needle bearing.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Pay attention that the fixing holes of planetary pin and planetary carrier (see arrows) are aligned.

Flush-mount slotted pin.

Pay attention to installation position, install sun gear with the groove showing downwards (to the retaining ring).

Pay attention to the installation position of the running disks, install running disks with the chamfer showing to the axial roller cage.

Press shaft back until the disk (Fig. 8) between retaining ring and tapered roller bearing (Fig. 7) is jammed (clearance-free).

Pay attention to maximum press force of 30000 N!

Risk of burn injuries, wear protective gloves!

Use side „B“ of the press-fit mandrel.

Use of the specified press-fit mandrel ensures the exact installation position of the needle bearing.

Use side „A“ of the press-fit mandrel.

Use of the specified press-fit mandrel ensures the exact installation position of the needle bearing.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearings after cooling down.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Setting of bearing of planetary drive

Pay attention to exact position of the planetary drive, roll in planetary drive.

Any deviation from the necessary setting dimension (231.88 … 231.92 mm) must be corrected with a corresponding shim.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

9.2 Reassembly of motor shaft

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

10. Reassembly of clutches 10.1 Reassembly of clutch K1

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

twist-free

Check function of drain valve, ball must be freely movable.

Pay attention to installation position, see Figure.

new

Always use a new L-ring.

Pay attention to installation position of the single parts, see following sketch.

Setting of disk clearance = 2.85 ... 3.05 mm

To ensure a correct measuring result, install disk package without oil for the time being!

Install outer disks with the uncoated side facing the piston/end plate!

The number and arrangement of disks is indicated in the respective spare parts list.

In case of deviations from the required disk clearance, correct with appropriate snap ring.

Risk of burn injuries, wear protective gloves!

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Insert idler gear into the disk package by slight rotary motions (left/right).

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

With correctly mounted single parts, the closing and opening of the clutch is clearly audible.

10.2 Reassembly of clutch K2

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

Pay attention to installation position of the running disks, install running disks with the chamfer showing to the axial roller bearing.

twist-free

Check function of drain valve, ball must be freely movable.

Pay attention to installation position, see Figure.

Pay attention to installation position of the guide rings.

Setting of disk clearance = 2.0 ... 2.3 mm

To ensure a correct measuring result, install disk package without oil for the time being!

Install outer disks with the uncoated side facing the piston/end plate!

The number and arrangement of disks is indicated in the respective spare parts list.

In case of deviations from the required disk clearance, correct with appropriate snap ring.

Risk of burn injuries, wear protective gloves!

Insert inner disks at the idler by slight rotary motions (left/right).

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

With correctly mounted single parts, the closing and opening of the clutch is clearly audible.

10.3 Reassembly of clutch KV

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

twist-free

Check function of drain valve, ball must be freely movable.

Pay attention to installation position, see Figure.

Pay attention to installation position of the guide rings.

Setting of disk clearance = 2.0 ... 2.3 mm

To ensure a correct measuring result, install disk package without oil for the time being!

Install outer disks with the uncoated side facing the piston/end plate!

The number and arrangement of disks is indicated in the respective spare parts list.

In case of deviations from the required disk clearance, correct with appropriate snap ring.

Risk of burn injuries, wear protective gloves!

Pay attention to installation position of the running disk, install running disk with the chamfer showing to the axial needle bearing.

Insert idler gear into the disk package by slight rotary motions (left/right).

Pay attention to installation position of the running disk, install running disk with the chamfer showing to the axial needle bearing.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

With correctly mounted single parts, the closing and opening of the clutch is clearly audible.

10.4 Reassembly of clutch KR

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

twist-free

Check function of drain valve, ball must be freely movable.

Pay attention to installation position, see Figure.

Pay attention to installation position of the guide rings.

Setting of disk clearance = 2.0 ... 2.3 mm

To ensure a correct measuring result, install disk package without oil for the time being!

Install outer disks with the uncoated side facing the piston/end plate!

The number and arrangement of disks is indicated in the respective spare parts list.

In case of deviations from the required disk clearance, correct with appropriate snap ring.

Risk of burn injuries, wear protective gloves!

Pay attention to installation position of the running disk, install running disk with the chamfer showing to the axial needle bearing.

Insert idler gear into the disk package by slight rotary motions (left/right).

Pay attention to installation position of the running disk, install running disk with the chamfer showing to the axial needle bearing.

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

With correctly mounted single parts, the closing and opening of the clutch is clearly audible.

10.5 Lift clutches into the housing

10.6 Reassembly of output shaft

Risk of burn injuries, wear protective gloves!

Adjust tapered roller bearing after cooling down.

10.7 Connect housing

Pay attention to position of the clamps, see following Figure.

REASSEMBLY 11. Reassembly of hydrostatic unit Put on seal.

Fix cover plate with hexagon screws.

Tightening torque (M8/8.8)

MA = 23 Nm

Fig. 1

Install oil level indicator.

Tightening torque

MA = 8 Nm

Fig. 2

Complete connecting tubes.

1

1 = O-ring (13x2.5) 2 = Back-up ring (18.0x14.2x1.4) 3 = Connecting tube 4 = Back-up ring (20.0x15.1x1.4) 5 = O-ring (14x3)

2 3 4

5

Fig. 3

Wet seal elements of connecting tubes and teeth of the splined shafts with vaseline spray (ZF-order no.: AA01.386.160).

Install preassembled connecting tubes and splined shafts.

Fig. 4

5871.085.002 en

11/1

REASSEMBLY Use lifting device (S) to put the hydrostatic unit onto the transmission housing until contact is obtained.

(S) Lifting beam

AA01.255.807

Fig. 5

Fix hydrostatic unit with hexagon screws.

Tightening torque (M12/10.9)

MA = 115 Nm

Fig. 6

Fix solenoid (1) with four cylindrical screws.

Tightening torque (M6/8.8)

MA = 9,5 Nm

Establish plug connection (2).

2 1

Fig. 7

Screw in pressure sensor (1) and tighten.

2 1

Tightening torque

1

Establish plug connection.

2

Fix wiring harness with cable clips (2) and clamp (3).

3

Tightening torque (M8/8.8)

MA = 23 Nm

Do not guide cable through the locking of the plug; this can lead to loosening of the plug during operation.

Fig. 8

5871.085.002 en

MA = 45 Nm

11/2

REASSEMBLY Insert a new seal into the cover.

Seal groove must be clean and dry!

Fig. 9

Mount cover and fix it by means of hexagon screws in the specified order, see Figure below.

Tightening torque

Abb. 10

Tighten screws in the following order.

Abb. 11

5871.085.002 en

11/3

MA = 9.5 Nm

12. Reassembly of filter head, output flanges and pressure oil pump 12.1 Reassembly of filter head

12.2 Reassembly of output flanges

Wet outer diameter with spirit right before the assembly.

Use of the specified driver tool ensures the exact installation position of the shaft seal.

Wet outer diameter with spirit right before the assembly.

Use of the specified driver tool ensures the exact installation position of the shaft seal.

Wet outer diameter with spirit right before the assembly.

Use of the specified driver tool ensures the exact installation position of the shaft seal.

12.3 Reassembly of pressure oil pump

Mount inner and outer rotor with the chamfered tooth side facing the pump housing (downwards)!

Wet bearing surface of the driver (arrow) with sufficient Vaseline (ZF-order no.: 0671.190.016)!

This operation is necessary to avoid that scratches on the surface of the bearing are caused by the inner rotor, when inserting the pump.

12.4 Reassembly of cover plates

13. Reassembly or speed sensors, gearshift system, control unit and pressure filter 13.1 Reassembly of speed sensors

13.2 Reassembly of duct plate

13.3 Reassembly of gearshift system

Ensure correct position of both O-rings.

Pay attention to radial installation position of the plug, see following Figure.

Pay attention to cable, risk of damage!

Groove on the plug (1) must be in alignment with the stud (2) in the cover.

13.4 Reassembly of control unit

Observe installation position of cable/clamps, see Figure.

13.5 Reassembly of pressure filter

14. Reassembly of parking brake The brake manufacturer’s instructions and specifications are mandatory for any operations done on the brake system!

0.5 mm

0.5 mm

0.5 mm