ZF ERGOPOWER (WG161) Transmission Operation & Diagnostics Manual – PDF

Description

ZF ERGOPOWER (WG161) Transmission Operation & Diagnostics Manual – PDF DOWNLOAD

FILE DETAILS:

ZF ERGOPOWER (WG161) Transmission Operation & Diagnostics Manual – PDF DOWNLOAD

Language : English
Pages : 42
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

ZF ERGOPOWER (WG161) Transmission Operation & Diagnostics Manual – PDF DOWNLOAD

Series Code / Model Designation Reference Table 1
General 1
Description 2
General 2
Clutch 5
Operation 5
Hydraulic Operation 5
Clutch Valve 7
Cooling and Lubrication 8
Control System 9
Transmission Control Unit (TCU) 9
Operating Modes 9
Normal Mode 9
Substitute Clutch Control 9
Limp-Home Mode 9
Transmission Shut Down Mode 10
TCU Shut Down Mode 10
Transmission Exceed Codes 10
Self-Test 10
Fault Codes 10
Description 10
Fault Log Mode 11
Access 11
Exit 11
Clear 11
Fault Rectification 12
Hydraulic Control Valve 12
Hydraulic Control Valve Repair 14
Solenoid Replacement 14
Pressure Check 14
Pressure Specifications 14
Speed and Temperature Sensors 16
Speed Sensors 16
Test 17
Temperature Sensors 17
Shift Lever 17
Pedal MONOTROL® 18
ZF Transmission Test and Calibration 18
Transmission Test and Calibration 18
Precautions 18
Stall Test 18
Description 18
Stall Test Procedure 18
Inch Pedal Calibration 19
Description 19
Calibration 19
Brake and Inch Pedal Adjustment 19
Inch Sensor Adjustment 19
Inch Pedal Calibration 20
Preparation 20
Table of Contents
i
TABLE OF CONTENTS (Continued)
Calibration Procedure Using the Calibration Switch 20
Calibration Procedure Using the Testman software 21
Inch Pedal Calibration Fault Codes 21
Clutch Calibration 22
Description 22
Clutch Calibration Procedure 22
Manual Clutch Calibration Procedure 23
Testman Clutch Calibration Procedure 24
Testman 24
Description 24
Connection 24
Truck Configuration 24
Configuration 25
Limitations 25
Capacities and Specifications 26
Electrical Specifications 26
Transmission Control Unit Diagram 27
ZF Transmission Fault Codes 28
Transmission Exceed Codes 28
Testman Fault Codes 29

DESCRIPTION:

ZF ERGOPOWER (WG161) Transmission Operation & Diagnostics Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

S.V 2/04/2025