The document is a shop manual for a Doosan DL250 wheel loader. It provides instructions for disassembling and reassembling the transmission and torque converter. Key steps include marking installation positions before disassembly, removing covers and housing components, checking parts for damage, and reassembling using the correct components, gaskets, screws and torque specifications. Periodic maintenance of transmission components is recommended by consulting recent documentation for any updates.
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This document provides part numbers and renewal times for components related to the crankcase, oil pan, flywheel, counterweights, V-grooved pulley, and crankshaft for Agrotron K 90, K 100, K 110, and K 120 Profiline tractor models. It includes part numbers for crankcases, bolts, plugs, gaskets, sleeves, shafts, seals, and other components. Renewal times are provided in days or hours and note when times include additional codes for procedures like disassembly.
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The document provides information about the frame, counterweight, trail axle, steer axle, power axle, and wheel hubs of models R 70-15/16, R 7011/7031. It includes technical specifications, descriptions of components, and instructions for removal and installation of parts. Torque values and limits for components are specified, such as 195 Nm for the counterweight bolts and 0.15-0.25 mm of axial play for the wheel hubs. Removal and installation procedures are outlined for the counterweight, steering axle, wheel hubs, half shafts, and wheel hub.
Caterpillar cat 325 c l excavator (prefix bkw) service repair manual (bkw0000...fjkskedmme
This document provides instructions for disassembling and assembling the final drive of a 325C excavator. The disassembly procedure involves removing over 30 individual parts from the final drive housing. Cleanliness is emphasized throughout. The assembly procedure instructs to apply lubricants to parts and use pressing tools to reinstall bearings and seals. Proper torque specifications and alignment marks are noted as important.
Claas arion 600 c (type a20) tractor service repair manualfjkskedmme
1) The document provides instructions for inspecting, measuring, and removing/refitting various cylinder head and valve components of an Arion 630-610 C engine, including the cylinder head, valves, rockers, turbocharger, alternator, fan hub, and exhaust manifold.
2) Specified values are provided for dimensions, clearances, and torque specifications when removing or tightening components.
3) Detailed steps and diagrams illustrate the inspection, measurement, removal and refitting processes for each component. Cautions and notes are included throughout.
The document provides instructions and definitions for parts books. It explains that the heading on parts pages will match the picture page. It defines the column headings for part numbers including reference number, part number, description, quantity, serial number range, interchangeability, and remarks. It notes country codes may be included and provides definitions for various country symbols.
Hyundai r170 w 3 wheel excavator service repair manualfksjksmmde
1) The document provides instructions for removing, disassembling, cleaning, assembling, and installing a pilot valve assembly.
2) Key steps include loosening bolts and fittings to remove parts, using solvents to clean individual components, applying lubricants and rust preventatives, and reassembling components in reverse order of disassembly while torquing fasteners to specified values.
3) Proper cleaning, lubrication, and assembly of O-rings and seals is important for correct valve function.
Deutz fahr agrokid 50 tractor parts catalogue manual (sn 1001 and up)fusjejedrfjskekem
The document provides standard renewal times for various parts of Agrokid 30, 40, and 50 tractor models. Times are given in days or hours for components like the cylinder head, camshaft, crankcase, and cylinder head cover. For example, the renewal time for an engine head is listed as 9.5 days, made up of 9 days plus 0.5 days for a specified code. Other parts like rockers and valves are listed with renewal times of 1.5 days or 10.5 days respectively.
Daewoo doosan dx520 lc excavator service repair manualfjjsekmsmmes
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order, applying torque specifications and Loctite to fasteners. The document contains illustrations of each step for servicing the travel motor gearbox.
Deutz fahr agrotron k120 profiline tractor parts catalogue manualfjsjejfksekmme
This document provides part numbers and renewal times for components related to the crankcase, oil pan, flywheel, counterweights, V-grooved pulley, and crankshaft for Agrotron K 90, K 100, K 110, and K 120 Profiline tractor models. It includes part numbers for crankcases, bolts, plugs, gaskets, sleeves, shafts, seals, and other components. Renewal times are provided in days or hours and note when times include additional codes for procedures like disassembly.
Still forklift r70 15 series service repair manualufjsjefjkkemd
The document provides information about the frame, counterweight, trail axle, steer axle, power axle, and wheel hubs of models R 70-15/16, R 7011/7031. It includes technical specifications, descriptions of components, and instructions for removal and installation of parts. Torque values and limits for components are specified, such as 195 Nm for the counterweight bolts and 0.15-0.25 mm of axial play for the wheel hubs. Removal and installation procedures are outlined for the counterweight, steering axle, wheel hubs, half shafts, and wheel hub.
Caterpillar cat 325 c l excavator (prefix bkw) service repair manual (bkw0000...fjkskedmme
This document provides instructions for disassembling and assembling the final drive of a 325C excavator. The disassembly procedure involves removing over 30 individual parts from the final drive housing. Cleanliness is emphasized throughout. The assembly procedure instructs to apply lubricants to parts and use pressing tools to reinstall bearings and seals. Proper torque specifications and alignment marks are noted as important.
Claas arion 600 c (type a20) tractor service repair manualfjkskedmme
1) The document provides instructions for inspecting, measuring, and removing/refitting various cylinder head and valve components of an Arion 630-610 C engine, including the cylinder head, valves, rockers, turbocharger, alternator, fan hub, and exhaust manifold.
2) Specified values are provided for dimensions, clearances, and torque specifications when removing or tightening components.
3) Detailed steps and diagrams illustrate the inspection, measurement, removal and refitting processes for each component. Cautions and notes are included throughout.
The document provides instructions and definitions for parts books. It explains that the heading on parts pages will match the picture page. It defines the column headings for part numbers including reference number, part number, description, quantity, serial number range, interchangeability, and remarks. It notes country codes may be included and provides definitions for various country symbols.
Hyundai r170 w 3 wheel excavator service repair manualfksjksmmde
1) The document provides instructions for removing, disassembling, cleaning, assembling, and installing a pilot valve assembly.
2) Key steps include loosening bolts and fittings to remove parts, using solvents to clean individual components, applying lubricants and rust preventatives, and reassembling components in reverse order of disassembly while torquing fasteners to specified values.
3) Proper cleaning, lubrication, and assembly of O-rings and seals is important for correct valve function.
Deutz fahr agrokid 50 tractor parts catalogue manual (sn 1001 and up)fusjejedrfjskekem
The document provides standard renewal times for various parts of Agrokid 30, 40, and 50 tractor models. Times are given in days or hours for components like the cylinder head, camshaft, crankcase, and cylinder head cover. For example, the renewal time for an engine head is listed as 9.5 days, made up of 9 days plus 0.5 days for a specified code. Other parts like rockers and valves are listed with renewal times of 1.5 days or 10.5 days respectively.
Daewoo doosan dx520 lc excavator service repair manualfjjsekmsmmes
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order, applying torque specifications and Loctite to fasteners. The document contains illustrations of each step for servicing the travel motor gearbox.
Daewoo doosan dx480 lc excavator service repair manualfjjsekmsmmes
This document provides maintenance and repair instructions for the travel motor and gearbox on Doosan excavators models DX480LC and DX520LC. The travel motor gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order, applying torque to fasteners and Loctite as specified. Brake components like discs, springs, and retaining rings are also installed/replaced.
Daewoo doosan dx520 lc excavator service repair manualufjjdjkkskemmd
This document provides instructions for disassembling and reassembling the travel motor and gearbox for Doosan excavators models DX480LC and DX520LC. The disassembly process involves removing 16 bolts to separate the end cover, then removing 3 sun gears and 3 planetary gear assemblies. Cleaning and inspection checks for gear and seal damage. Reassembly follows the reverse order, applying threadlock to bolts and torquing components to the specified values. O-rings and seals must be installed correctly to avoid leaks.
Daewoo doosan dx480 lc excavator service repair manualfjjskdmnenemm
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor with gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order and uses Loctite on bolts. The document contains illustrations of each step for servicing the travel motor with integrated reduction gearbox.
Daewoo doosan dx520 lc excavator service repair manualfjjskdmnenemm
This document provides instructions for disassembling and reassembling the travel motor and gearbox for Doosan excavators models DX480LC and DX520LC. The disassembly process involves removing 16 bolts to separate the end cover, then removing 3 sun gears and 3 planetary gear assemblies. Cleaning and inspection checks for gear and seal damage. Reassembly follows the reverse order, applying loctite to bolts and torquing correctly. O-rings and seals must be installed properly with no switches. The document ensures correct reassembly of this important drivetrain component.
Daewoo doosan dx480 lc excavator service repair manualfujsjefjskkem
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor with gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order and uses Loctite on bolts. The document contains illustrations of each step for servicing the travel motor with integrated reduction gearbox.
Daewoo doosan dx480 lc excavator service repair manualufjjdjkkskemmd
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor with gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order and uses Loctite on bolts. The document contains illustrations of each step for servicing the travel motor with integrated reduction gearbox.
Daewoo doosan dx520 lc excavator service repair manualdfujsjefjkskemm
This document provides instructions for disassembling and reassembling the travel motor and gearbox for Doosan excavators DX480LC and DX520LC. The disassembly process involves removing 16 bolts to separate the end cover, then removing 3 sun gears and 3 planetary gear assemblies. Cleaning and inspection checks for gear and seal damage. Reassembly follows the reverse order, applying loctite to bolts and torquing correctly. O-rings and seals must be installed properly with no switches. The document ensures correct reassembly of this important component.
Daewoo doosan dx480 lc excavator service repair manualdfujsjefjkskemm
This document provides maintenance and repair instructions for the travel motor and gearbox on a Doosan excavator models DX480LC and DX520LC. The travel motor with gearbox can be disassembled by removing 16 bolts, 3 sun gears, 3 planetary gear assemblies, and other components. Inspection checks for gear and seal damage. Reassembly follows the reverse order and uses Loctite on bolts. The document contains illustrations of each step for servicing the travel motor with integrated reduction gearbox.
Daewoo doosan dx520 lc excavator service repair manualfujsjefjskkem
This document provides instructions for disassembling and reassembling the travel motor and gearbox for Doosan excavators DX480LC and DX520LC. The disassembly process involves removing 16 bolts to separate the end cover, then removing 3 sun gears and 3 planetary gear assemblies. Cleaning and inspection checks for gear and seal damage. Reassembly follows the reverse order, applying loctite to bolts and torquing correctly. Diagrams illustrate each step for servicing the travel motor with integrated gear reduction.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fujsjejfskekm
This document provides assembly instructions for rear axle components of an excavator model M322C. It describes 37 steps to assemble the final drive carriers, hubs and brakes. Key steps include pressing bearings and seals into place, installing retaining rings, and torquing bolts to specified values. Proper alignment of oil supply holes and achieving the correct rolling torque of 8.2 ± 1.6 N·m are emphasized. A variety of tools are listed to complete the assembly.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fsejfjskefsmem
This document provides assembly instructions for rear axles on an excavator model M322C. It outlines 42 steps to assemble components such as bearings, seals, brake pistons, and gears. Several tools are required, including torque wrenches, seal installers, pullers, and gauges. Proper temperatures and torques are specified at each step to ensure correct assembly. Dimensions are also measured and recorded to verify specifications are met.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fujsjefjkskefsme
This document provides assembly instructions for rear axles on an excavator model M322C. It details 27 steps to assemble bearings and seals in the hub and install the hub on the spindle. Several tools are required, including torque wrenches, seal installers, and pullers. Proper bearing temperatures and torque specifications must be followed to ensure correct assembly.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fhsjejkdm
This document provides assembly instructions for rear axles on an excavator model M322C. It details 27 steps to assemble bearings and seals in the hub and install the hub on the spindle. Several tools are required, including torque wrenches, seal installers, and pullers. Proper bearing temperatures and torque specifications must be followed to ensure correct assembly.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...udjfjkskekmdm
This document provides assembly instructions for rear axles on an excavator model M322C. It details 27 steps to assemble bearings and seals in the hub and install the hub on the spindle. Several tools are required, including torque wrenches, seal installers, and pullers. Proper bearing temperatures and torque specifications must be followed to ensure correct assembly.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fjsekdemmd
This document provides assembly instructions for rear axles on an excavator model M322C. It describes 37 steps to assemble components such as bearings, seals, brake pistons, and hubs. Key steps include pressing components together using specific tools and torques, and verifying proper rolling torque of the hub bearing within a specified range. The instructions include illustrations of each step and specify tools needed to complete the assembly.
Caterpillar cat m322 c wheeled excavator (prefix bdy) service repair manual (...fdhjsekdme
This document provides assembly instructions for rear axles on an excavator model M322C. It describes 37 steps to assemble components such as bearings, seals, brake pistons, and hubs. Key steps include pressing components together using specific tools and torques, and verifying proper rolling torque of the hub bearing within a specified range. The instructions include illustrations of each step and specify tools needed to complete the assembly.
This document provides the installation procedure for a swing motor on excavator models 320D2 and 320D2 L in 30 steps. It details cleaning and preparing the mating surfaces, lifting and attaching the swing motor, connecting multiple hose and harness assemblies using new O-rings, and ensuring the drain valve is closed at the end of installation. Proper torque specifications are provided for installing bolts. Safety notices warn of spring hazards and containing fluids.
Caterpillar cat 320 d2 l excavator (prefix stn) service repair manual (stn000...fusefjjskekemm
This document provides the installation procedure for a swing motor on excavator models 320D2 and 320D2 L in 30 steps. It details cleaning and preparing the mating surfaces, lifting and attaching the swing motor, connecting multiple hose and harness assemblies using new O-rings, and ensuring the drain valve is closed at the end of installation. Proper torque specifications are provided for installing bolts. Safety notices warn of spring hazards and containing fluids.
Caterpillar cat 320 d2 l excavator (prefix stn) service repair manual (stn000...fjskekfoselkkkm
The document provides the installation procedure for a swing motor in 29 steps. It lists the required tools, includes notes on cleanliness and leakage prevention. The procedure involves attaching the motor, connecting hoses and harnesses, filling fluids, testing operation, and installing covers. Proper torque values are specified for bolts.
The document provides the installation procedure for a swing motor in 29 steps. It lists the required tools, includes notes on cleanliness and leakage prevention. The procedure involves attaching the motor, connecting hoses and harnesses, filling fluids, testing operation, and installing covers. Proper torque values are specified for bolts.
Hyundai r210 lc 7 crawler excavator service repair manualdfujdjkskekmmd
The document provides instructions for accessing a complete manual by clicking on a link. It notes that if the link does not work, the PDF document should be downloaded first before clicking the link. It also includes two additional links to a website where other service manuals can be accessed.
Hyundai hl780 9 wheel loader service repair manualdfujdjkskekmmd
This document provides instructions for disassembling and assembling various components of hydraulic pumps and control valves, including:
- Disassembling the main pump by removing components like the control valve, connection plate, distributor plate, and rotary group.
- Inspecting pump components for wear and replacing worn parts like bearings.
- Assembling the main pump by refitting components in reverse order and adjusting tapered roller bearings.
- Disassembling the main control valve by removing spools, valves, and other internal parts.
- Proper precautions for disassembly, reassembly, and inspection of hydraulic components to prevent damage.
- Disassembling remote control
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Understanding Catalytic Converter Theft:
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Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
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Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
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Daewoo doosan dl250 wheel loader service repair manual (serial number 5001 and up)
1. K1023773E Shop Manual
Copyright 2007 Doosan
DOOSAN reserves the right to improve our products in a continuing process to provide the best
possible product to the market place. These improvements can be implemented at any time with no
obligation to change materials on previously sold products. It is recommended that consumers
periodically contact their distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Shop Manual
K1023773E
Serial Number 5001 and Up
DL250
2. Table of Contents
Page I
1Table of Contents
Safety
Wheel Loader Safety........................................................................... SP000865
Specifications
Specification for DL250....................................................................... SP000866
General Maintenance
General Maintenance Procedures ...................................................... SP000097
Standard Torques ................................................................................ SP000813
Drive Train
Transmission and Torque Converter.................................................. SP000867
Transmission Error Codes (ZF).......................................................... SP001056
Front Axle (ZF-MT-L 3085)................................................................. SP000868
Rear Axle (ZF-MT-L 3075) ................................................................. SP000869
Drive Shaft ........................................................................................... SP000870
Brake
Service Brake....................................................................................... SP000871
Brake Supply Valve............................................................................. SP000872
Parking Brake ...................................................................................... SP000873
Brake Pedal Valve............................................................................... SP000874
Accumulator.......................................................................................... SP000875
Steering
Steering ................................................................................................ SP000876
Cushion Valve...................................................................................... SP000328
Emergency Steering ............................................................................ SP000877
3. Table of Contents
Page II
Frame
Articulation Center ............................................................................... SP000878
Counterweight....................................................................................... SP000130
Tank
Oil Tank................................................................................................ SP000879
Fuel Tank............................................................................................. SP000880
Hydraulics
Cylinders............................................................................................... SP001027
Main Pump........................................................................................... SP001035
Main Control Valve.............................................................................. SP000881
Load Isolation System......................................................................... SP000882
Cooling System.................................................................................... SP000883
Pilot System......................................................................................... SP000884
Hydraulic Schematic DL250................................................................ SP000886
Electrical System
Air Conditioner ..................................................................................... SP001211
Electrical System ................................................................................. SP000924
Electrical Schematic DL200/ DL250................................................... SP000925
4. SP000867
Page 69
Transmission and Torque Converter
Disassembly
1. Figure 67, shows complete control unit.
2. Mark installation position of different covers, housing
and cable harness with valve housing.
3. Remove socket head screws.
4. Separate duct plate, 1st gasket, intermediate plate and
2nd gasket from valve housing.
(S) Box spanner (Torx TX-27) - 5873 042 002
5. Remove retaining clip.
Figure 67
Figure 68
Figure 69
Figure 70
5. SP000867Transmission and Torque Converter
Page 70
6. Remove socket head screws.
7. Separate cover from housing and cable harness.
(S) Box spanner (Torx TX-27) - 5873 042 002
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove cable
harness.
10. Remove socket head screws, remove fixing plate and
pressure regulators (3x).
(S) Box spanner (Torx TX-27) - 5873 042 002
11. Remove two socket head screws and locate housing
provisionally, using adjusting screws. (Housing is under
spring preload). Remove remaining socket and screws.
(S) Box spanner (Torx TX-27) - 5873 042 002
(S) Adjusting screws - 5870 204 036
Figure 71
Figure 72
Figure 73
Figure 74
6. SP000867
Page 71
Transmission and Torque Converter
12. Separate housing from valve housing by loosening
adjusting screws uniformly.
(S) Adjusting screws - 5870 204 036
13. Remove components (Figure 76).
14. Remove opposite pressure regulators, housing and
components accordingly (Figure 77).
Figure 75
Figure 76
Figure 77
7. SP000867Transmission and Torque Converter
Page 72
Reassembly
NOTE: Check all components for damage and replace if
necessary. Before installation, check free travel of all
moving parts in housing. Spools can be exchanged
individually. Oil components before reassembly
according to ZF-List of lubricants TE-ML 03.
Insert diaphragms with concave side facing up until
seated.
NOTE: Installation position, see arrows.
1. Figure 79, shows the following components:
2. Install components according to Figure 79.
NOTE: Preload compression spring of follow on sitie
slides and locate spool provisionally using
cylindrical pins Ø 5.0 mm (0.1969 in) (assembly
aid), See Figure 80.
3. Install two adjusting screws.
4. Assemble gasket (1, Figure 81) and housing cover
(Figure 81). Position housing cover uniformly, using
adjusting screws, until seated and remove cylindrical
pins (assembly aid) again (Figure 81).
NOTE: Pay attention to different housing covers.
5. Install recess ∅ 15.0 mm (0.5906 in)
(2, Figure 81), facing spring of pressure
reducing valve.
(S) Adjusting screws - 5870 204 036
Figure 78
Figure 79
Reference
Number
Description
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and
Compression Spring)
Figure 80
Figure 81
8. SP000867
Page 73
Transmission and Torque Converter
6. Fasten housing cover using socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
7. Install pressure regulators and attach using fixing plates
and socket head screws.
NOTE: Install fixing plate, with claw facing down. Pay
attention to radial installation position of
pressure regulators, see Figure 84.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
8. Preassemble opposite side.
A. Figure 85, shows the following components:
Figure 82
Figure 83
Figure 84
Figure 85
Reference
Number
Description
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
3 Vibration Damper (3x
Spool and
Compression Spring)
9. SP000867Transmission and Torque Converter
Page 74
B. Install components according to Figure 85.
C. Preload compression springs of follow on slides
and locate spool provisionally using cylindrical pins
∅ 5.0 mm (0.1969 in) (assembly aid). See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 86) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
NOTE: Pay attention to different housing covers,
install recess Ø 19.0 mm (0.7480 in) (2,
Figure 86), facing main pressure valve.
F. Down, fasten housing cover using socket head
screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
G. Remove cylindrical pins (assembly aid) again.
(S) Adjusting screws - 5870 204 036
(S) Box spanner (Torx TX-27) - 5873 042 002
H. Install pressure regulators and attach using fixing
plates and socket head screws.
NOTE: Install fixing plates, with claw facing down.
I. Pay attention to radial installation position of
pressure regulators, see Figure 87.
NOTE: Torque limit 5.5 N.
(S) Box spanner (Torx TX-27) - 5873 042 002
J. Install cable harness and connect pressure
regulators (6x).
NOTE: Pay attention to installation position of
cable harness, see also markings (Figure
68).
Figure 86
Figure 87
Figure 88
10. SP000867
Page 75
Transmission and Torque Converter
K. Install female connector against shoulder, with
groove facing guide nose of cover.
L. Install gaskets (Figure 89) and fasten cover using
socket head screws.
NOTE: Torque limit 0.56 kg•m (4 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
M. Install female connector using retaining clamp, see
Figure 90.
N. Install opposite cover.
O. Install two adjusting screws and mount gasket I.
NOTE: Pay attention to different gaskets, see
Figure 91 and Figure 94.
(S) Adjusting screws - 5870 204 063
9. Intermediate plate-version with screens:
A. Insert screens (6x) flash -mounted into bore of
intermediate plate, see Figure 92.
NOTE: Pay attention to installation position
screens are facing up (facing duct plate).
Figure 89
Figure 90
Figure 91
Figure 92
11. SP000867Transmission and Torque Converter
Page 76
B. Mount intermediate plate, with screens with
screens facing up.
C. Mount gasket II.
D. Mount duct plate and fasten it uniformly using
socket head screws.
NOTE: Torque limit 1 kg•m (7 ft lb).
(S) Box spanner (Torx TX-27) - 5873 042 002
E. Install new O-rings on plugs (8x) and install them.
NOTE: Torque limit 0.61 kg•m
(4.4 ft lb).
NOTE: The installation of hydraulic control unit is
described in following section, “Mount
Duct Plate and Hydraulic Control Unit” on
page 1-132.
Figure 93
Figure 94
Figure 95
Figure 96
12. SP000867
Page 77
Transmission and Torque Converter
TRANSMISSION DISASSEMBLY
1. Fasten transmission on the assembly car.
(S) Assembly car - 5870 350 000
(S) Strips - 5870 350 063
(S) Support - 5870 350 090
Hydraulic Control Unit (HSG-94) and
Duct plate
1. Remove two socket head screws and install adjusting
screws.
2. Remove remaining socket head screws and valve
housing from duct plate.
(S) Adjusting screws (M6) - 5870 204 063
(S) Box spanner (Torx TX-27) - 5870 042 002
3. Remove both gaskets and intermediate plate.
4. Remove socket head screws and hex. nuts (Figure 99).
Remove duct plate from gearbox housing. Remove
gasket.
(S) Box spanner (Torx TX-27) - 5870 042 004
Figure 97
Figure 98
Figure 99
13. SP000867Transmission and Torque Converter
Page 78
5. Remove converter safety valve out of housing bore.
Engine Connection - Converter
1. Remove lock plate and hex. head screws.
2. Remove disk and pry drive flange off shaft.
3. Remove screw connection.
NOTE: Mark radial installation position of housing
cover.
4. Separate converter, along with cover from the
transmission, using lifting device.
(S) Set of eyebolts - 5870 204 002
Figure 100
Figure 101
Figure 102
Figure 103
14. SP000867
Page 79
Transmission and Torque Converter
5. Remove drive shaft resp. converter out of cover (ball
bearing).
6. Remove retaining ring and ball bearing.
(S) Set of internal pliers - 5870 900 013
7. Remove hex. head screws and diaphragm from
converter.
8. Remove hex. head screws and drive shaft from
diaphragm.
Figure 104
Figure 105
Figure 106
Figure 107
15. SP000867Transmission and Torque Converter
Page 80
9. Remove inductive transmitter (n Engine).
10. Remove hex. head screws and converter bell.
Figure 108
Figure 109
16. SP000867
Page 81
Transmission and Torque Converter
Hydraulic Pump
1. Remove socket head screws.
2. AInstall device (S) on gear teeth run out of stator shaft
and remove (compl.) using two-armed puller carefully
out of housing bores.
(S) Separating device - 5870 300 024
(S) Two-armed puller - 5870 970 004
3. Separate hydraulic pump from stator shaft.
4. Separate control disk from pump.
NOTE: If traces due to running-in should be
encountered in the pump housing or on the
control disk, the complete pump has to be
replaced.
5. Lay on control disk again and secure it using grooved
pins (2x).
6. Remove socket head screws and two hex. head
screws and oil feed housing.
Remove gasket.
(S) Box spanner (Torx, TX-40) - 5873 023 004
Figure 110
Figure 111
Figure 112
Figure 113
17. SP000867Transmission and Torque Converter
Page 82
Converter Back Pressure Valve
1. Preload compression spring and remove lock plate.
2. Remove released components.
3. Loosen hex head screws. Remove cover and gasket.
Remove Output, Input and Clutches
1. Remove lock plate, loosen hex head screws and pry
converter-side output flange off the shaft.
2. Pry shaft seal out of the housing bore.
3. Tilt transmission 180° and remove rear-side output
flange accordingly.
(S) Pry bar - 5870 345 065
4. Remove speed sensor and both inductive transmitters
(Arrows).
Figure 114
Figure 115
Figure 116
Figure 117
18. SP000867
Page 83
Transmission and Torque Converter
5. Remove hex. nuts and both covers (Arrows).
6. Remove screw connection (housing/housing cover)
7. Remove both cylindrical pins (Arrows).
NOTE: The following figures show the common
removal of all clutches.
8. The removal of single clutches without use of special
tool (Handles - 5870 260 010) is difficult due to
installation arrangement.
NOTE: There is also a danger of injuries.
9. Locate all clutches using handles (S) in the housing
cover.
10. Install eyebolts and hang in the lifting device.
(S) Handles (6 pieces needed) - 5870 260 010
(S) Eyebolt 2x (M20) - 0636 804 003
(S) Eyebolt 1x (M16) - 0636 804 001
(S) Puller device - 5870 000 017
(S) Lifting chain - 5870 281 047
11. Separate housing cover along with clutches from
gearbox housing using lifting device.
Figure 118
Figure 119
Figure 120
Figure 121
19. SP000867Transmission and Torque Converter
Page 84
12. Fasten housing cover on the assembly car.
(S) Assembly car - 5870 350 000
(S) Clamping bracket - 5870 350 089
13. Remove socket head screws, output shaft and two oil
collecting plate.
14. Remove tapered roller bearing.
15. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 002 038
(S) Basic set - 5873 002 001
16. Tilt gearbox housing 180°.
17. Figure 125, shows the arrangement of single clutches
and the input in housing cover.
Figure 122
Figure 123
Figure 124
Figure 125
Reference
Number
Description
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
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21. SP000867
Page 85
Transmission and Torque Converter
18. Remove handles (S) (Figure 126).
(S) Handles - 5870 260 010
19. Remove Clutch-K4 a bit using pry bars and remove
Clutch-K1.
20. Remove Clutch-K2.
21. Remove Clutch-K3.
Figure 126
Figure 127
Figure 128
Figure 129
22. SP000867Transmission and Torque Converter
Page 86
22. Remove Clutch - KV and KR using pry bars and
remove Clutch - K4.
(S) Pry bar - 5870 345 065
23. Remove Clutch - KV and Clutch - KR with input
together out of housing cover.
24. Remove outer bearing races out of housing bores.
25. Tilt housing cover 90°.
26. Remove retaining ring and pump shaft from housing
cover.
27. Remove rectangular ring (Arrow) and press ball bearing
from shaft.
Figure 130
Figure 131
IMPORTANT
If contrary to ZF-Recommendation the tapered roller
bearing of clutches and of input and output are not
replaced, the allocation (inner bearing races to
outer bearing races) must at least be maintained.
Mark inner bearing races and outer bearing races
accordingly to each other.
Figure 132
Figure 133
23. SP000867
Page 87
Transmission and Torque Converter
Disassemble Clutch - KV and KR
1. Remove rectangular ring (Arrow).
NOTE: The following figures show the disassembly of
Clutch - KV. The disassembly of Clutch - KR is
similar.
2. Remove tapered roller bearing from shaft.
3. Remove opposite tapered roller bearing.
(S) Grab sleeve - 5873 001 057
(S) Grab sleeve - 5873 001 059
(S) Basic set - 5873 001 000
4. Remove retaining ring.
5. Separate plate carrier from shaft.
(S) Three Leg Puller - 5870 970 003
Figure 134
Figure 135
Figure 136
Figure 137