ZF 3WG-130, 4WG-130, 5WG-130, 3WG-160,4WG-160, 5WG-160 Ergocontrol 2 Repair stage 3 Construction Equipment Repair Instructions

ZF 3WG-130, 4WG-130, 5WG-130, 3WG-160,4WG-160, 5WG-160 Ergocontrol 2 Repair stage 3 Construction Equipment Index:

• 3 WG 130, 4 WG 130, 5 WG 130, 3 WG 160, 4 WG 160, 5 WG 160
  • Copyright
  • Table of Contents
• 1 Preface
  • 1.1 Document overview
• 2 Safety
  • 2.1 Signal words and symbols
  • 2.2 General safety instructions
• 3 Notes on Repairs and Assembly
  • 3.1 General Notes
  • 3.2 Cleaning the ZF product
  • 3.3 Dismantling the ZF product
  • 3.4 Assembling the ZF product
  • 3.5 Cleaning parts
  • 3.6 Reusing parts
  • 3.7 Replacing parts
  • 3.8 Reworking parts
• 4 Technical Data
  • 4.1 Oil
    • 4.1.1 Oil filter
    • 4.1.2 Oil grade
  • 4.2 Transmission type plate
• 5 Settings
• 6 Tightening Torques
• 7 Workshop Equipment
  • 7.1 Special tools
  • 7.2 Standard tools and fixtures
  • 7.3 Operating supplies and auxiliary materials
• 8 Preparatory Activities
  • 8.1 Mounting transmission on assembly truck
  • 8.2 Draining oil
• 9 Dismantling
  • 9.1 Removing the pressure filter
  • 9.2 Removing cover plate (filler neck)
  • 9.3 Removing pressure controller and speed sensors
  • 9.4 Removing the temperature sensors and the breather
  • 9.5 Removing output flanges
  • 9.6 Removing and dismantling shift system
    • 9.6.1 Removing filter bypass valve
    • 9.6.2 Removing control unit (ECA4)
    • 9.6.3 Removing the pressure controllers
    • 9.6.4 Removing and dismantling valve blocks
    • 9.6.5 Removing duct plate
  • 9.7 Removing cover plate (PTO)
  • 9.8 Removing and dismantling engine connection
    • 9.8.1 Removing the converter
    • 9.8.2 Removing torque converter bell housing
  • 9.9 Removing the oil feed housing and pressure oil pump
  • 9.10 Removing pump shaft
  • 9.11 Removing the cover (emergency steering pump)
  • 9.12 Separating the housings
  • 9.13 Removing and dismantling output shaft
  • 9.14 Dismantling housing front part
  • 9.15 Removing and dismantling clutches and input shaft
    • 9.15.1 Removing clutches
    • 9.15.2 Dismantling clutch KV
    • 9.15.3 Dismantling KR clutch
    • 9.15.4 Dismantling clutch K1
    • 9.15.5 Dismantling clutch K2
    • 9.15.6 Dismantling clutch K3
    • 9.15.7 Dismantling clutch K4
    • 9.15.8 Dismantling input shaft
  • 9.16 Dismantling housing rear section
• 10 Assembly
  • 10.1 Assembling housing rear section
  • 10.2 Assembling and installing clutches and input shaft
    • 10.2.1 Assembling clutch KV
    • 10.2.2 Assembling clutch KR
    • 10.2.3 Assembling clutch K1
    • 10.2.4 Assembling clutch K2
    • 10.2.5 Assembling clutch K3
    • 10.2.6 Assembling clutch K4
    • 10.2.7 Assembling input shaft
    • 10.2.8 Installing clutches
  • 10.3 Assembling housing front part
  • 10.4 Assembling and installing output shaft
  • 10.5 Assembling the housings
  • 10.6 Mounting cover (emergency steering pump)
  • 10.7 Mounting the oil feed housing and oil pressure pump
  • 10.8 Assembling and mounting motor connection
    • 10.8.1 Installing torque converter bell housing
    • 10.8.2 Installing the converter
  • 10.9 Installing pump shaft
  • 10.10 Mounting cover plate (PTO)
  • 10.11 Assembling and installing shift system
    • 10.11.1 Installing duct plate
    • 10.11.2 Assembling and mounting valve blocks
    • 10.11.3 Installing the pressure controllers
    • 10.11.4 Installing control unit (EC4A)
    • 10.11.5 Installing filter bypass valve
  • 10.12 Installing output flanges
  • 10.13 Installing the temperature sensors and the breather
  • 10.14 Installing the speed sensors and pressure controller
  • 10.15 Installing cover plate (filler neck)
  • 10.16 Installing the pressure filter
  • 10.17 Adding oil
• 11 Annex
  • 11.1 Formulary and conversion tables
    • 11.1.1 Conversion of length units
    • 11.1.2 Conversion of volume units
    • 11.1.3 Conversion of mass units
    • 11.1.4 Conversion of force units
    • 11.1.5 Conversion of torque units
    • 11.1.6 Conversion of temperature units
  • 11.2 Overview of revisions
• ZF Friedrichshafen AG, www.zf.com

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