ZF Transmission CP190 CP210 CP230 Stage 3 Repair Instructions Manual

[Hyundai]

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ZF Transmission CP190 CP210 CP230 Stage 3 Repair Instructions Manual
Size: 48.42 MB
Format: PDF
Language: English
Brand: ZF
Type of Machine: Transmission
Type of Manual: Repair Instructions Manual
Model: ZF CP190 CP210 CP230 Stage 3 Transmission
Number of Pages: 190 Pages

Contents:
1 Preface

1.1 Document overview​

2 Safety

2.1 Signal words and symbols​

2.2 General safety instructions​

2.3 Product-specific 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​

3.9 Cleanliness specifications for transmissions with hydraulic components​

4 Technical Data

4.1 Oil​

4.2 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 Clamping transmission​

8.2 Draining oil​

9 Dismantling

9.1 Removing the parking brake​

9.2 Removing the pressure filters​

9.3 Removing the control unit​

9.4 Remove and dismantle shift system​

9.5 Remove and dismantle duct plate​

9.6 Removing the speed sensors​

9.7 Removing the cover plates​

9.8 Removing the hydraulic oil pump​

9.9 Removing the engine connection​

9.10 Removing the output flanges​

9.11 Remove hydrostatic unit​

9.12 Removing the oil level indicator and the cover plate​

9.13 Disassembling the front and the rear sections of the housing​

9.14 Removing and dismantling the output shaft​

9.15 Removing and dismantling the power take-off​

9.16 Remove and dismantle clutches, planetary drive and shaft​

9.17 Dismantling the housing rear section​

9.18 Dismantling the housing front section​

10 Assembly

10.1 Assembling the housing front section​

10.2 Assembling the housing rear section​

10.3 Assemble and install planetary drive, shaft and clutches​

10.4 Assembling and installing the power take-off​

10.5 Mounting and installing the output shaft​

10.6 Assembling the housing front and rear section​

10.7 Installing the cover plate​

10.8 Installing the oil level indicator​

10.9 Install hydrostatic unit​

10.10 Installing the output flanges​

10.11 Installing the engine connection​

10.12 Installing the hydraulic oil pump​

10.13 Installing the cover plates​

10.14 Installing the speed sensors​

10.15 Assemble and install duct plate.​

10.16 Assemble and install shift system​

10.17 Installing the control unit​

10.18 Installing the filter heads and the pressure filters​

10.19 Installing the parking brake​

10.20 Adding oil​

11 Annex

11.1 Overview of revisions​